Power Plant Control and Instrumentation Specification

Anuppur Thermal Power Project, Phase-1, 1000 (+20%) MW
MB POWER (MADHYA PRADESH) LIMITED

Anuppur Thermal Power Project, Phase-1, 1000 (+20%) MW
SPECIFICATION NO. TCE.5657A-H-500-001 FOR EPC SPECIFICATION
VOLUME V SPECIFIC TECHNICAL REQUIREMENTS - INSTRUMENTATION AND CONTROL WORKS
TCE Consulting Engineers Limited 73/1, ST.MARKS ROAD BANGALORE 560 001
MARCH 2009 (Ref. no.: MBPMPL/RfP/EPC/2008-09/144)
MB POWER (MADHYA PRADESH) LIIMIITED MB POWER (MADHYA PRADESH) L M TED

ANUPPUR TPP, PHASE I, 1000 (+ 20%) MW,
MADHYA PRADESH, INDIA
SPECIFICATION NO. TCE.5657A-H-500-001 FOR EPC SPECIFICATION
VOLUME V SPECIFIC TECHNICAL REQUIREMENTS - INSTRUMENTATION AND CONTROL WORKS
TCE Consulting Engineers Limited 73/1, ST.MARKS ROAD BANGALORE 560 001 March 2009

Spec No. TCE.5657A-H-500-001
ANUPPUR PHASE-1 (1000+20%MW) THERMAL POWER PROJECT
SECTION: CONTENTS
CONTENTS
VOLUME - I
SCOPE OF ENQUIRY INSTRUCTIONS TO BIDDERS GENERAL CONDITIONS OF CONTRACT SPECIAL CONDITIONS OF CONTRACT
VOLUME - II
SCOPE OF WORKS,TERMINAL POINTS AND SCHEDULES
VOLUME - III
PART A D1 MECHANICAL WORKS BTG PART B D2 MECHANICAL WORKS BOP
VOLUME - IV
PART A D3 ELECTRICAL WORKS BTG Part B D4 ELECTRICAL WORKS BOP
VOLUME - V
PART A D5 INSTRUMENTATION & CONTROL WORKS BTG PART B D6 INSTRUMENTATION & CONTROL WORKS BOP
VOLUME - VI
D7 CIVIL & STRUCTURAL WORKS
VOLUME - VII
BID PURPOSE DRAWINGS
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Spec No. TCE.5657A-H-500-001
SECTION: CONTENTS
CONTENTS
VOLUME V PART - B SECTION D6 INSTRUMENTATION AND CONTROL WORKS - BOP

SUB SECTION D 6.1 D 6.2 D 6.3 D 6.4 D 6.5 D 6.6 D 6.7 TITLE SYSTEM DESCRIPTION/ PLANT OPERATION PHILOSOPHY SYSTEM/EQUIPMENT/SERVICES TO BE FURNISHED DESIGN, PERFORMANCE AND FUNCTIONAL REQUIREMENTS SPECIFICATION FOR PLC / INSTRUMENTS TO BE SUPPLIED TESTS AND INSPECTION FOR I&C SYSTEM EQUIPMENT OTHER SERVICES PERFORMANCE GUARANTEE LIST OF TABLES SUBSECTION TABLE- 1 TABLE- 2 TABLE- 3 TABLE- 4 TABLE- 5 TABLE- 6 TABLE- 7 TERMINAL POINTS CONTROL SYSTEM HARDWARE / DCS INTERFACING CODES AND STANDARDS DATA TO BE FURNISHED WITH BID LIST OF ESSENTIAL SPARES SIZE, MATERIAL & RATING F FOR IMPULSE PIPES / TUBES & FITTINGS GUIDELINES FOR PROVISION OF INSTRUMENTS AND SPECIFICATIONS TITLE NO. OF SHEETS 5 1 1 1 2 5 23
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Spec No. TCE.5657A-H-500-001
SECTION: CONTENTS
CONTENTS LIST OF TABLES
SUBSECTION TABLE- 8 TABLE- 9 TABLE- 10 TABLE- 11 TABLE- 12 TABLE - 13 TABLE - 14 TABLE - 15 TABLE - 16
TITLE GUIDE LINES FOR SELECTION OF FLOW ELEMENTS GUIDE LINES FOR SELECTION OF CONTROL VALVES MATERIAL AND ACTUATOR TYPE TESTS TO BE PERFORMED FOR DCS/PLC / PROGRAMMABLE CONTROL SYSTEM FACTORY ACCEPTANCE TESTS FOR DCS/PLCs TESTS TO BE PERFORMED FOR INSTRUMENTS FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES) TRAINING TO BE PROVIDED FOR OWNERS PERSONNEL ERECTION, FIELD TESTING AND COMMISSIONING REQUIREMENTS -
NO. OF SHEETS 1 1 4 2 3 5 1 6 1
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Spec No.
TCE.5657A-C-500-002
Volume V SECTION: D 6.1
INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY
SHEET 1 OF 8
SYSTEM DESCRIPTION
1.0 1.1 The instrumentation and control (I&C) system called for in the specification shall be a comprehensive system integrating the functions of plant monitoring, control and protection to facilitate the task of integration, co-ordination and autonomous operation of the plant utilities like coal handling plant, Ash handling plant, DM water plant, Reservoir intake system, Raw water & pre treatment plant and other utility plants. The overall I & C system design shall ensure the following: (a) (b) (c) (d) (e) Maximise safety for the plant personnel and equipment Safe, reliable, efficient and easy operation of the plant under all operating conditions Maximise availability and efficiency of the plant through system redundancy. Consistent control & instrumentation philosophy usage of standard functional modular hardware and software design. Ability to operate under all specified conditions (start-up, normal operation, disturbances and shut down) automatically and/or by remote manual control from relevant control room Malfunction of any component or loss of supply leading to fail-safe condition Provide accurate and reliable information to the plant operators and management. Provide the operators the following facilities: (i) (ii) (iii) Complete information for plant equipment status / abnormal and critical conditions. Alarm notification.
1.2
(f) (g) (h)
1.3
Logging of equipment/component failure duration and data availability for failure analysis. (iv) Historical data storage and retrieval facility for long term monitoring of plant equipment performance. The I&C system shall permit operation and monitoring of the utility plant packages from the utility / local control room (LCR). I&C system shall consist of a functionally distributed microprocessor based system (PLC control systems), with facility for VDU (Video Display Unit) /Keyboard & Large Video Screen based operation, control and monitoring, sequence of events recording and annunciation system, together with, complete with control desk, unit control panel, system cabinets, local panels, sensors, junction boxes, cables, control valves, flow elements, local instruments and erection hardware. The I&C system shall be interfaced with other different auxiliary plant monitoring and analysis systems to provide supervisory and reporting facilities to plant personnel and management.
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1.4
Details of the terminal points between BOP and others are detailed in section D6 TABLE- 1 PLANT OPERATION PHILOSOPHY OPERATION FROM CENTRAL CONTROL ROOM (CCR) All equipment associated with CHS, AHS, DM Plant and their associated auxiliaries and other auxiliary systems shall be operable /monitored from VDU/Keyboard based Operator stations (OS). The OS shall be table top mounted type. When operated from OS, the operator shall be able to call for the various types of displays for all parameters as required on the screen and it shall be possible to carry out all types of operations. LCR operation/ monitoring facility through OS/LVS shall include the following as an additional facility, which will be primarily operated and monitored from respective utility plant located local control room: (a) (b) Complete monitoring of plant common Coal Handling Plant. Complete monitoring of plant common DM water plant & effluent treatment plant etc. Complete monitoring of the Plant Ash handling Plant. Complete monitoring of the reservoir intake water system.. Raw water and pre-treatment system
2.0 2.1 2.1.1
(c) (d) (e) 2.2 2.2.1
LOCAL OPERATION OPERATION FROM LOCAL CONTROL ROOM (CCR)
2.2.1.1 The utility and auxiliary systems viz., Coal handling plant / Ash handling plant / DM Water plant & Effluent treatment plant / etc., will be primarily operated & monitored locally from respective utility plant located local control rooms (LCR). However, facility for monitoring from CCR shall be made available through OPC over Ethernet TCP/IP. shall be provided. Utility plant operation / monitoring will be primarily through VDU/ KB based OS mounted on Control Desk (CD). The OS shall be table top mounted type. When operated from OS, the operator shall be able to call for the various types of displays for all parameters as required on the screen and it shall be possible to carry out all types of operation. 2.2.1.2 Two (2) nos. OS shall be provided for each utility plant local control room. In addition to VDU/KB based OS, one (1) no Large Display screen shall be provided for both CHP & AHP control room.
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2.2.2
Local Operation from Field Local stop push button stations shall be provided near all the drives except for the motorised valves and solenoid valves. Lockable type Local stop push button shall be connected to the MCC/switchgear. Local/remote and auto/manual selection shall be provided in the PLC HMI as soft selection for drives covered in the PLC. For systems provided with relay based local panels, the selector switches shall be provided on the local panel. For the motorised valves, integral starters shall be provided and these shall have local open, close and stop push buttons in addition to local / remote selector. The local / remote selector switches of all integral starters shall be locked and shall have a common key. By unlocking the lock, authorised personnel having the key may operate the motorised valve locally. Local mode selected shall be wired to the PLC for annunciation to operator in the control room.
2.2.2.1 In addition to the Local control room operation / monitoring facility, local start/stop operation from local pushbuttons (LPB) shall be provided for all uni-directional drives as a testing and maintenance facility. The local pushbuttons for various drives shall be hooked up to control system as indicated below: (a) (b) All emergency stop pushbuttons shall be wired directly to MCC / Switch gears. Status of all emergency stop pushbuttons for unidirectional drives (pump/fan etc) shall be monitored into the respective control system.
2.2.2.2 Local / remote operation location selection shall be carried out from local control room through OS. 3.0 3.1 UTILITY PLANT CONTROL PHILOSOPHY PLC based control systems are envisaged for all other unit specific and plant common systems utility plants as detailed below: (a) (b) (c) (d) (e) (f) Plant Common Coal Handling Plant. Plant Common Ash Handling Plant. Plant Common DM water plant & Effluent treatment plant etc. Plant common reservoir intake system with key pad operated. Plant common raw water and pre treatment system with key pad operated. Any other utility plant system/equipment not covered.
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(a) Coal handling plant: The overall operation, control and monitoring of the coal handling plant shall be achieved through a PLC based system provided in the CHP control room. This CHP main PLC shall perform the functions of interlock, protection, individual/sequential control, measurement/monitoring, dynamic status/ parameter updating on graphic pages and annunciation of the coal handling plant. Control room for the CHS system shall be sized considering both phases [I & II]. However remote I/O panels as required shall be provided and the same shall be connected to the main CHS PLC through redundant communication. Control desk as required for the control system components like operating station / engineering station etc shall be provided for phase I. The main PLC shall be provided with remote I/Os that shall be connected to the PLC through redundant fiber optic cables. The remote I/O racks for this main PLC shall be provided as required based on the detailed engineering. The interlocks and protections of all the drives and equipments shall be covered in the CHS PLC with operation and monitoring from the control desk mounted operator station (OS) / Operator cum engineering station (OES) The sequential operation, control and interlocking etc., of the stacker cum reclaimer will be achieved through dedicated Programmable logic controller [PLC] based control system mounted local to the equipment. The PLC shall be interfaced to the CHS PLC through redundant fibre optic cable. The necessary media convertors, patch cable etc for the same shall be in bidders scope. Wagon tippler & side arm charger shall be operated from the wagon tippler control room from a common PLC based control panel, The PLC system will be an independent system for automatic operation of the wagon tippler and single arm charger. It will be complete with all safety devices, protections, controls and interlocks, indications and annunciations implemented in the PLC based system. The PLC shall be interfaced to the CHS PLC through redundant fibre optic cable. The necessary media convertors, patch cable etc for the same shall be in bidders scope.
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(b) Ash handling plant:
A microprocessor based Programmable logic controller shall be provided for the operation and control of the Ash Handling System equipment. The ash transmitters, clinker grinders, conveyors, water pumps, air compressors, etc., shall be operated from VDU/keyboard of the PLC system. All the operation and monitoring functions are to be carried out from the VDU. One local control panel (LCP) shall be provided for bottom ash unloading. This LCP will be provided with conventional operational hardwares such as push bottons, selector switches, indicating lamps. The interlock requirements of bottom ash unloading shall be implemented in common AHS PLC. For this purpose one number remote I/O panel is provided for the interfacing of the signals in the bottom ash area and to the LCP operational hardware. Ash silo unloading system shall be provided with local control panel [wall/column mounted] for its local operation. In addition to this status indication shall be hardwired to the AHS PLC. Control system PLC shall be common for all the units. One number remote I/O panel shall be provided for each unit [for Pneumatic dense phase and bottom ash system] and the same shall be located in the ESP control room of each unit. The unloading of dry fly ash/bottom ash into the trucks shall be independently operated and monitored from their respective local relay based panel. The equipment status shall be indicated on the HMI of the AHS PLC by hardwiring the status signals to the PLC system. The fly ash shall be removed from the ESP, APH & ECO hoppers and transported to the Intermediate fly ash storage silos either under auto mode (timer mode operation or level probe mode operation) or manual mode (one hopper at a time) selectively. Level probes shall be provided for each fly ash hopper to enable operation of the fly ash handling system. The HCS disposal system shall be provided with dedicated PLC based control system. Status signals from this system shall be hardwired to the Ash Handling System PLC for monitoring. The air compressors shall be provided with dedicated PLC / microprocessor based control system. Loading and unloading operations and start of standby on trip of running compressor shall be performed by the ash handling system PLC.
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(c) DM water plant & Effluent treatment plant:
A microprocessor based Programmable logic controller shall be provided for the operation and control of the DM water plant and Effluent treatment plant Systems from the PC based operator stations mounted in the DM plant control room. This DM Plant PLC shall perform the functions of interlock, protection, individual/sequential control, measurement/monitoring, dynamic status/ parameter updating on graphic pages and annunciation of the coal handling plant. The WT plant supply pumps, de-mineralised (DM) plant, DM storage tank, DM water transfer pumps and condensate storage tanks, Neutralising pumps, Filtered water storage tank, Plant Potable Water System, clarified water storage tank, Service Water System and Service water storage tank etc., shall be operated from VDU/keyboard of the PLC system. All the operation and monitoring functions are to be carried out from the VDU.
(d) Reservoir intake water system:
A Programmable Logic Controller (PLC) based local panel with LCD / keypad type operator interface panel shall be provided for the operation and control of the Reservoir Intake water System equipment. It shall be possible to perform all the operation and monitoring functions of the pumps and associated motorised discharge valves from the LCD / keypad of the PLC system. However, the Taprogge air powered intake system and its associated air compressor and the chlorine di-oxide system shall be provided with respective skid mounted local control panels. The taprogge system shall be provided with PLC based local control panel. The local panels for the Taprogge air powered intake system, and chlorine dioxide system shall be provided with operational hardware such as push buttons, switches, indicating lamps, hooters, etc.). Equipment status signals and important alarms from these local panels shall be hardwired to the reservoir intake water PLC system for monitoring from its LCD / keypad HMI. The Reservoir intale water system PLC shall be interfaced to the DM plant PLC through redundant fibre optic cable with required media convertors, patch cables etc. at both ends for monitoring of the same from the DM Plant control room. The same shall be in bidders scope.
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(e) Raw water and pre-treatment system:
Programmable Logic Controller (PLC) based local panel with LCD / keypad type operator interface panel shall be provided for the operation and control of the Raw Water and pretreatment System equipment. It shall be possible to perform all the operation and monitoring functions of the pumps and associated motorised discharge valves from the LCD / keypad of the PLC system. The Plant Raw water System and pre-treatment system comprising raw water supply pumps, Clarified Water System and Filtered Water System and CW make up pumps etc., shall be operated from LCD / keypad HMI of the PLC system. The Raw water and pre-treatment system PLC shall be interfaced to the DM plant PLC through redundant fibre optic cable with required media convertors, patch cables etc. at both ends for monitoring of the same from the DM Plant control room. The same shall be in bidders scope. 3.2 All PLC based utility plant control systems shall be interfaced with DCS through redundant bi-directional OPC link. In general, no plant system/equipment shall have relay based control system. If any considered the same shall be highlighted and it is subject to customers / consultant approval. Details of control system hardware envisaged for the total power plant with interfacing requirements with plant DCS are detailed in Section D 6, TABLE-2. An overview of utility plant Instrumentation and Control system is illustrated in dwg. no TCE.5657A-IC-SK-03. All different PLC based control systems for utility plant/systems and other special monitoring and analysis systems shall be suitably interfaced to Plant DCS for proper functioning. All PLC based utility plant control systems shall be interfaced with DCS through redundant OPC link with Ethernet based TCP-I/P protocol. Communication link shall be Bi-directional for Coal Handling Plant, Ash handling plant control system, Reservoir intake water system & DM Plant /Effluent Treatment Plant, Vibration monitoring system for each package shall be interfaced with respective PLC through redundant interfacing for necessary data exchange. Hand held HART communicator shall be provided for remote calcibration of smart transmitters. A common time synchronisation system is envisaged and the same is provided by the BTG vendor. Provision shall be made available in the utility plant PLCs for the acceptance of the same for synchronisation.
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
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4.0 4.1
CODES AND STANDARDS All equipment, systems, software and services covered under this specification shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. All codes and standards referred in this specification shall be understood to be the latest version on the date of offer made by the Bidder, unless otherwise specified. If such standards are not existing for any equipment or system, the same shall comply with the applicable recommendations of the following professional institutes: (a) (b) (c) (d) (e) (f) (g) (h) (i) National Electricity Manufacturers Association (NEMA) The Institute of Electrical and Electronic Engineers (IEEE). Instrumentation Systems and Automation Society (ISA). American National Standards Institute (ANSI). Deutsche Industries Norman (DIN). International Electrochemical Commission (IEC). International Consultative Committee on Telephone and elegraphy (CCITT). Verin Deutschar Eisecnhuttenleutte (VDE) Indian Standard Institute (ISI).
4.2
Standards not indicated in the specification are acceptable (subject to approval by the Owner / Owners Representative) if they are established to be equal or superior to the standards indicated in the specification. The VENDOR shall furnish English translation of all standards to which the equipment and systems offered conform to. The specific codes and standards applicable are listed in Section D 6, TABLE-3.
4.3
4.4
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INSTRUMENTATION AND CONTROL
SCOPE OF WORK-SYSTEM/EQUIPMENT/SERVICES
Volume V SECTION: D 6.2 SHEET 1 OF 8
1.0
SYSTEM / EQUIPMENT/SERVICES TO BE FURNISHED The Scope includes design, manufacturing, supply, erection, testing and commissioning of the complete Instrumentation and Control System Equipment complete with all hardware, software and accessories and other services including the following, to operate the plant efficiently, reliably and safely as detailed in this section and also under System description/Operation philosophy in Section-D 6.1, Design philosophy in Section D 6.3, relevant technical specification in Section D 6.4 and Testing requirements in Section-D 6.5 with enclosed Tables and drawings. The offer shall comply with the latest applicable codes and standards as prevailing on the date of submission of the bids. i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii. PLC based control system for auxiliary and Utility plants Control Desks and cabinets Field Instruments including pipe mounted items and accessories Final control elements Water Analysis System (SWAS) Large Video Screen Display System [LCD type] Vibration Monitoring system Hand held HART communicator. Supply, laying & termination of complete Instrumentation, Control, Compensating, Special cables, Pre-fabricated cable, Fibre optic cable etc., together with preparation of all cabling related engineering documents like Cable Schedule, Inter-connecting Schedule etc. Auxiliary Power Supply System Maintenance and Erection Tools and Tackles Essential Spares Erection, Field Testing And Commissioning Including Erection Hardware
xiv. Performance Test, Trial Operation And Guarantee Test xv. Engineering Documentation
xvi. Training Of Owners Personnel xvii. Consumables for Operation / Maintenance. xviii. Inspection and testing of I&C system equipment. xix. All the furniture in the Local control room. 2.0 PROGRAMMABLE LOGIC CONTROLLER (PLC) An overview of the required control system is illustrated in Dwg.No.TCE5657A-IC-SKISSUE R0
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03.This system consists of Measurement system; Control System; Interlock, Protection and Sequential Control System; Data Bus System for Control and Communication with the process, interfacing with Plant DCS and software. The requirements of the various features of the control system are detailed further below. 2.1 MEASUREMENT SYSTEMS (MS) Measurement system shall be complete with processor, signal conditioning and monitoring cards and function cards to perform measurement system functions. The system shall also be capable of transmitting the data to Operator Stations (OW)s in the Control. This system is detailed in Measurement system write-up in Section D 6.3 and relevant specification in Section D 6.4. 2.2 CLOSED LOOP CONTROL SYSTEM (CLCS) Closed loop control system shall be complete with processor, signal conditioning and monitoring cards and function cards to perform control system functions. The system shall also be capable of executing commands from OS through key boards.This system is detailed in write-up in Section D 6.3 and relevant specification in Section D 6.4. 2.3 INTERLOCK, PROTECTION AND SEQUENTIAL CONTROL SYSTEM (OPEN LOOP CONTROL SYSTEM) Interlock, protection and sequential control system shall be complete with processor, signal conditioning and monitoring cards and function cards to perform the sequential and combinational logic functions. The system shall also be capable of executing commands from OS through key boards. This system is detailed in write-up in Section D 6.3 and relevant specification in Section D 6.4. 2.4 DATA BUS SYSTEM (DBS) The communication sub system shall be a real time reliable communication network between control processors, MMI (Operator Stations, Printers ) and Engineering station. The main bus shall have Dual redundancy. The bus system requirements are detailed in Section-D 6.4. 2.5 OPERATOR STATION (OS)/ MMI SYSTEM VDUs/key boards of OS, printers and associated hardware form the Operator Station (OS)/MMI. The data communication between VDU/key boards, printers and function cards is through the data bus. The system is detailed in Section-D 6.4. 2.6 ENGINEERING STATION (ES)
ES equipment shall have operator station & printer to perform the functions of software generation and maintenance of PLC system in addition to OS functions. It shall also be used for monitoring the status of all equipment connected to PLC system. The system is detailed in relevant Section-D 6.4.
2.7
SOFTWARE
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Complete software for the microprocessor based PLC system including the system software and application software (to carryout the engineering, monitoring ,operation and maintenance functions) and communication software between various sub systems shall be supplied and implemented as detailed in relevant Section-D 6.4. All software used for the system shall be licensed version only. 2.8 2.8.1 2.8.2 2.8.3 PLC SYSTEM HARDWARE I/O Modules: As required considering the requirements detailed in Section D 6.3 PLC Controllers: As required considering the requirements detailed in Section D 6.3 Operator Stations: (a) (b) (c) 2.8.4 1 nos Operator Stations with single VDU and single Keyboard/ mouse/ trackball for operator / Unit shall be provided for the Coal handling system. 2 nos Operator Stations with single VDU and single Keyboard/ mouse/ trackball for operator shall be provided for Ash handling system. 1 nos Operator Stations with single VDU and single Keyboard/ mouse/ trackball for operator shall be provided for DM water / Effluent treatment system.
Engineering Station: (a) 1 nos Engineering Station (ES) with single VDU and single Keyboard/mouse/trackball for Engineer shall be provided for each utility package PLC [Coal handling system, ash handling system & DM water / Effluent treatment system].
2.9 2.9.1
PLC SYSTEM INTERFACING REQUIREMENT All utility package PLCs like Coal handling system, ash handling system, DM plant / effluent treatment system etc.. shall be interfaced to plant DCS. Interfacing cables required for the applications are included in BTG vendor scope of supply: Communication protocol will be decided during detail engineering stage. It is the Bidders responsibility to offer communication link with protocol suitable for communication between plant DCS & utility package PLCs. Modem for Remote Diagnostic Support complete with all accessories. PLC Make/ Model Qualification: Offered PLC make / model shall have been designed, manufactured and commissioned for at least 2 balance of plants for a capacity of minimum 600 MW size units or higher in last 5 years, with scope of work involving at least automatic controls and sequential controls, which are in successful commercial operation for minimum 2 years at the date of Bid opening. Bidder to furnish the necessary proof for the same in the bid offer PLC BASED CONTROL SYSTEMS FOR UTILITY PLANTS PLC based control system complete with all hardware and software shall be provided for
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2.10 2.11
3.0 3.1
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following packages: The system is detailed in Section D 6.3 / D 6.4 (a) (b) (c) (d) (e) 3.2 3.2.1 4.0 Coal handling plant Ash handling plant DM Water plant & Effluent treatment plant Reservoir intake water system [PLC with LCD key pad operated] Raw water & pre-treatment system [PLC with LCD key pad operated]
PLC Control System Interfacing All PLC based utility plant control systems shall be interfaced with DCS through redundant OPC link with Ethernet based TCP/I-P protocol. Communication link shall be Bi-directional. TIME SYNCHRONISATION EQUIPMENT GPS based time synchronisation equipment for plant I&C system equipment time synchronisation shall be supplied by the BTG vendor. Suitable provision shall be made in the utility package PLCs for the synchronisation of the same. The system is detailed in Sections D 6.4.
5.0
FIELD INSTRUMENTS AND ACCESSORIES All primary elements, field mounted instruments and accessories, racks, field termination cabinets / junction boxes, interconnecting cables, impulse pipes and fittings, etc. shall be supplied. The specification and the guidelines for these items are given in Section D 6, TABLE-7.
6.0
FINAL CONTROL ELEMENTS All final control elements as required are included in Bidders scope. The technical requirements are detailed in Section D 6, TABLE-7
7.0
WATER ANALYSIS SYSTEM Analysers as required for the DM water verification with required sampling system are included in Bidders scope. The system is detailed in Section D 6.4.
8.0
LARGE SCREEN VIDEO DISPLAY SYSTEM 2 nos. Large screen video display system of LCD type shall be supplied for mounting 1 no each in coal handling plant and ash handling plant local control room. The system shall be complete with video screen, workstation for display control and all accessories. Screen size shall be 52 inch. The system is detailed in Sections D 6.4.
9.0
VIBRATION MONITORING SYSTEM
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Vibration monitoring system shall be supplied for all HT and major drives and driven equipment bearings. The system is as detailed in Section D 6.4. 10.0 INSTRUMENTATION AND SPECIAL CABLES Supply, laying & termination of complete Instrumentation, Control, Compensating, Special cables, Pre-fabricated cable, etc., together with preparation of all cabling related engineering documents like Cable Schedule, Inter-connecting Schedule etc. are included in Bidders scope. The requirements are covered in Section D 6, TABLE-7 of this specification. 11.0 AUXILIARY POWER SUPPLY SYSTEM 230 V AC UPS power supply for PLC system shall be provided for Instrumentation and Control system. The details of the above power supply system are covered in Electrical section. 12.0 MAINTENANCE AND ERECTION TOOLS AND TACKLES The Bidder shall include in his offer all special maintenance and erection tools and tackles as required for the system being offered. The details shall be furnished. 13.0 14.0 14.1 ESSENTIAL SPARES Scope of supply includes I&C system essential spares as detailed in Section D 6,TABLE-5. ERECTION, FIELD HARDWARE TESTING AND COMMISSIONING INCLUDING ERECTION
The CONTRACTOR shall erect, test and commission all Instrumentation and Control Equipment for the complete power plant supplied under this contract to the complete satisfaction of the OWNER. CONTRACTORs scope of work will include any additional instruments supplied by other contractors/ OWNER which is required for proper & satisfactory performance of the power plant. Impulse pipes, fittings and air supply and signal piping/tubing shall be supplied for all the instruments under the scope of this specification. The selection of size, material & rating depending upon service conditions is given in Section D 6, Table-6. PERFORMANCE TEST, TRIAL OPERATION AND GUARANTEE TESTS The CONTRACTOR shall conduct integrated test at manufacturer's works (FAT) and inspection, checking and pre-commissioning tests at site as detailed in Section D 6.5 of the specification. The performance and Guarantee test shall be conducted by the OWNER after trial operation as detailed in Section D 6.5 of the specification. The CONTRACTOR shall prove the guarantee of the system and equipment supplied.
14.2
15.0
16.0
ENGINEERING DOCUMENTATION CONTRACTOR shall prepare engineering documents for OWNER / CONSULTANT review and approval. Format for important documents are detailed in TABLE-13.
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17.0 17.1
OTHER SERVICES TRAINING OF OWNERS PERSONNEL The CONTRACTOR shall provide training to OWNERs personnel as specified in Section D 6.6 of the specification.
17.2
PERFORMANCE GURANTEE TEST INSTRUMENTATION The CONTRACTOR shall provide PG test instrumentation as specified in Section D 6.6 of the specification.
18.0 18.1
CONSUMABLES The following consumable shall be supplied / Unit: (a) (b) (c) (d) (e) (f) Fuses DVD R/W CD R/W Insulation Tape Teflon tape 5 Nos. each type. 50 nos 50 nos 50 rolls 50 rolls
Reagents for 12 no.s charges for analysers.
19.0
FURNITURE All the furniture in the Local control Room (s). as required are included in Bidders scope of supply. The requirements are detailed in Section D 6.3 of this specification.
20.0 20.1
INSPECTION AND TESTING FOR I&C SYSTEM EQUIPMENT The Owner or Owners representative reserves the right to inspect and approve the material, equipment and workmanship at all stages of manufacturing of all the main I&C equipment including the PLC. Bidder shall call for inspection / witnessing the conductance of test of the equipment well in advance (minimum 21 days) to the Owner. Owner shall indicate his preference regarding the inspection of the equipment. It is Contarctors responsibility to schedule the inspection & testing of different equipment / systems in a properly phased manner. Inspection and testing requirements for different I&C system equipment are tabulated in Section D 6.5 and Section D 6, TABLE-10 of this specification. Testing requirements not explicitly specified for any equipment but required for establishing the satisfactory performance / functioning of the equipment / system are deemed to be included in the scope of work of Contractor. The following minimum equipment shall be considered for Inspection (witness) at
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20. 3
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manufacturers works (Contractors and sub suppliers) by Owner as specified: (a) (b) (d) (h) 20.4 Integrated PLC testing including testing of communication links. All control valves, dampers etc. Analysers. Transmitters
The Contractor shall conduct site tests for following equipment / systems: (a) Site Acceptance tests including Trial Operation, Performance Guarantee Test & Availability Guarantee Test for PLC systems as detailed in Section D 6.5 of the specification. The CONTRACTOR shall prove the guarantee of the system and equipment supplied. Vibration monitoring System
(b) 21.0 21.1
GENERAL Uniformity of Hardware
21.1.1 To provide smooth and optimal maintenance, easy interchange ability and optimal spare parts management of I&C instruments/equipment, the bidder shall ensure that all the similar equipments shall be of the same make, series and family of hardware 21.1.2 Following equipments shall be of same make, series and family of hardware at minimum: (a) (b) (c) (d) 21.2 Pressure and Temperature Gauges All pressure, Differential pressure, level & flow transmitters of differential pressure type& Temperature transmitter. Programmable Logic Controllers (PLC) Video Display Unit / Keyboard
All the systems in the Bidders scope shall work satisfactorily taking into account all the required interconnections. Measurement and control equipment offered shall be complete in all respects and any equipment / accessories not explicitly indicated in this specification, but considered essential for proper functioning of equipment and process shall be included in the Bidders scope of work and supply. Any I&C equipment required during any stages for the efficient / safe / reliable operation of the plant either during detailed engineering / commissioning / after commissioning shall be installed and commissioned by the Bidder with in the quoted price. Before taking over the plant by the Owner, all the instruments, system and auto control loops shall run satisfactorily for at least one month at varying loads without disturbing any
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21.4
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adjustment. During this period, supervision and maintenance of total instrumentation equipment shall be the scope and responsibility of the Contractors personnel. 21.5 Availability of Spares & Services Spares and services for PLC related equipment/systems shall be available for 15 years from the date of handing over of plant by EPC Contractor. Bidder shall furnish the guarantee for the same in the bid offer. The guarantee shall be re-confirmed by EPC contractor on post contract execution phase from respective equipment / system vendor. The guarantee shall be absolute and shall be a criteria for vendor selection by Contractor.
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INSTRUMENTATION AND CONTROL SYSTEM DESIGN, PERFORMANCE & FUNCTIONAL REQUIREMENTS
SHEET 1 OF 17
1.0
INSTRUMENTATION AND CONTROL SYSTEM PHILOSOPHY MEASUREMENT SYSTEM (MS)
1.1 1.1.1
The measurement system consist of primary sensors, various function modules, processors, VDUs and peripherals. All analogue parameters will be displayed. For all drives, status indication will be displayed. The system requirements are specified in relevant Section-D 6.4. The MS shall have the standard features not limited to the following:Linearisation; Square root extraction; Flow totalising; Compensation for Pressure, temperature & Density; Limit Value Monitoring; Remote field sensor multiplexing etc. CONTROL SYSTEM Design Features (a) (b) (c) (d) (e) No single random fault in the entire automation and control system will cause a load loss, forced outage or unit trip. No two simultaneous faults shall lead to or potentially cause damage to plant Safety related instrumentation and control shall be designed with a fail- safe mode. No single fault shall jeopardise the functioning of the entire system. The control and automation system and the field instruments and actuators as well as its support systems, power supplies and data networks shall be immune to the electromagnetic interference and shall conform to the internationally accepted standards. To meet the operational and safety requirements, the control system hardware and software shall conform to a modular, hierarchical architecture. The system hierarchy shall be at four levels. The closed loop (i.e. modulating) functions and open loop (i.e. sequence or on/off) functions shall form separate elements at each of the hierarchical level.
1.1.2
1.2 1.2.1
(f)
1.3 1.3.1
CLOSED LOOP CONTROL SYSTEM (CLCS)
The CLCS shall control the process variables automatically both under steady state and dynamic conditions with in the limits specified under guarantee clauses over the entire operational range of the equipment/system. The CLCS shall have the following features: (a) Provision of predictive and/or adaptive controls in addition to PID controls as required by the system. (b) Set point adjustments and indication from operating VDU for process variables which need to be changed during load changes, start-up, shutdown, normal or under any other emergency conditions.
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(c)
Fixed set point at the software level/hardware level (only changeable by the maintenance engineer) and indication for those process variables which need not be changed with respect to load or otherwise. Bias adjustment with indication where a single controller is controlling more than one final control element (control valve, control damper, speed drive etc.) to maintain the same process variable. Auto and manual control facility shall be transferable in both directions without bump of the value of the process variable to control the parameter during manual operation. Both Master Auto Manual station and Auto / Manual station for individual control element shall be provided in VDUs. Manual control facility will include operation from Back Up Control Panel also in addition to operation from operator station. Characterisation of final control element to suit the various applications with respect to load or otherwise as dictated by the process. Function generator to provide necessary characterisation or variation of set points with respect to load, speed or any other requirement. Soft Auto /Manual station interlocks to drive the final control elements to a suitable position for safe plant operation in the event of process/equipment abnormal conditions. Blocking/Interlocking function as dictated by process/equipment. Monitoring of loop failures or any hardware failure in the loops. Fail safe operation of final control elements in case of failure of motive power or signal.
(d)
(e)
(f) (g) (h)
(i) (j) (k) 1.4 1.4.1
OPEN LOOP CONTROL SYSTEM (OLCS)
Protection, interlock and sequence controls constitute OLCS. This system shall enable the operator for safe start up and shutdown and carryout normal operation both from control room and local areas. Protection and Interlock shall be provided for all the equipment and system to safeguard the equipment against abnormal conditions which may result in the failure and less utility of the equipment and protect the operating personnel. Controls shall be provided to start/shutdown various systems and/or any equipment with associated auxiliaries and to operate the Unit on line with optimum number of operations and higher safety. The OLCS shall have the following features as a minimum: Features-General Requirements (a) The logic and sequence control shall be Digital distributed microporcessor based and programmable.
1.4.2 1.4.2.1
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(b)
Enable the operator to start/stop various unidirectional motors, to open/close various valves and dampers and carry out inching operation of bypass valves or any other similar equipment both from control room and local areas.
(c)
The system shall be designed based on the philosophy of command to energise a relay or solenoid valve.
(d)
Where there is more than one pump or fan for the same service (say 2 pumps), auto standby features shall be provided to select the standby unit and this standby unit shall start automatically on failure of running pump or on applicable process criteria (say low discharge pressure) with an alarm.
(e) (f)
All the contacts of the sensors used in protection circuit shall be monitored. Triple redundant sensors shall be provided when used in protection circuits for major critical equipment and 2 out of 3 logic shall be derived for further use in protection circuit
1.4.2.2
Features-Interlock Requirements (a) Permissive conditions for a equipment start shall be provided. The permissive conditions within the equipment are bearing temperature normal, winding temperature normal, adequate suction pressure, bearing vibrations normal, bearing lubrication oil pressure normal, switchgear in service, switchgear not in test, no protection trip command persisting (as applicable) etc. (b) The permissive conditions from a process system related equipment are establishment of free path for the flowing medium under all start-up, emergency and shutdown conditions, closure of discharge valve for the starting of first of the identical pumps/fans and then opening the valve after the operating condition is established etc. Selection of standby equipment and starting the equipment automatically on the tripping of running equipment and/or desired process parameter conditions (say loss of discharge pressure or low level in the discharge tank etc.) Isolation of the tripped equipment from the main process. Any other conditions for safe starting and shutting down the equipment.
(c)
(d) (e) 1.4.2.3
Features-Sequence Control Requirements
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Sequence control shall be provided to start and stop the equipment and the associated auxiliaries. The sequence control shall have the following features: (a) Once the start-up or shutdown of an equipment is initiated either manually or automatically from the system, the control of associated auxiliaries shall be automatic with facility for manual operation at each stage (step). (b) (c) Criteria check up for each stage of operation with monitoring and displaying. Bypass facility for each criteria when only the feedback signal/display is incorrect but the actual condition is fulfilled. This activity shall be logged and annunciated in control system (PLC). Adequate time delay between the steps as dictated by the process to establish an operating parameter or healthiness of an equipment. Normally, the auxiliaries of the standby equipment should be running (as applicable) so that the standby equipment is started without loss of time.
(d) (e) 1.4.2.4
Features-Protection Control Requirements The following minimum protection shall be provided for the various equipment/system as applicable to trip the equipment. (a) Any condition which endangers the safety of the plant personnel (b) (c) Any of the permissive conditions becoming abnormal thereby producing a dangerous condition in operating the equipment. The conditions from process such as dry flow conditions, flashing conditions or any other conditions that may create cavitation.
2.0
PLC DESIGN REQUIREMENTS GENERAL
2.1
The Instrumentation and Control System called for in this specification shall consist of a functionally distributed microprocessor based system (PLC) with Vibration Monitoring system, Large Screen Video Display [LCD] system, Diagnostics system, interfacing with various utility plant PLC based control system and various miscellaneous monitoring and control systems all capable of operating along with Local panels, system cabinets, field instrumentation and associated erection hardware. 2.2 PLC System- Specific Design Requirement The microprocessor based distributed control system (PLC) offered by the Tenderer shall offer the following features: (a) Interoperability Ability to work together with third party hardware/software without any customisation required to be carried out. Portability Ability to develop the application for the Plant Information and Management system in personal computer environment and download the same
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to PLC. (c) Scalability Ability to expand the functionality of the system to any size, at minimum cost and without interruption to the continuous operation of the system. Flexibility Ability to provide greater flexibility to the operators in terms of interactive graphics. Also, the system shall support Windows based graphics for intuitive Graphic User Interface (GUI). Upward compatibility Conformance to International standards for communication network and fool proof provision for expandability with investment protection.
(d)
(e)
2.3
SALIENT FEATURES OF PLC
System shall run on the latest Windows NT/2000/XP operating system. The system shall support the following : - Open - Multitasking - Human Interface - Interconnectivity - Networking - Integration System Architecture : -System Architecture should be secure and deterministic. Each processor in the data bus system shall perform dedicated functions and the system shall be capable of determining the system performance at any stage of the system implementation. -The Open side of the system shall run on IEEE 802.3 (TCP/IP on Ethernet) standards and will be used as the information network with connectivity to Desktop PC environment. This shall be Information Domain. The operator station shall directly reside on the Main Bus running on IEEE 802.4 or 802.5 (Token Ring or Token Bus) to facilitate Determinism in the Data transfer. The plant bus and the lower control modules will form the control Domain. In the Client - Server configuration, servers will be residing on the main bus running on IEEE 802.4 (Token Passing) or high speed Ethernet or similar to facilitate determinism in the data transfer. The plant bus and the lower control modules will form the control domain. The operator station will reside on the data bus running on IEEE 802.3 standard. Quantity of the servers shall be suitably selected by considering the performance and response time of the complete system. Networking and Security features :
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: Ability to run third party application : Pre-emptive, with high responsiveness : Comfortable look and feel of GUI-ICON interface : Standard Interfaces like OLE, DDE, DCOM, OPC etc. : Should support standard TCP/IP, IPX/SPX, and NETBUI Protocols by default. : Should provide seamless integration with minimum Glues / Patchworks
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The Node connectivity on the open side shall support Network infrastructure based on TCP/IP protocols. MMI Requirements : Area/Group/loop wise plant control functions. Graphics capabilities. Multi-window capability with Display management tools shall be available as options Flexibility to the operators in terms of interactive graphics Dedicated Alarm view availability while operating through the Process graphic. System MMI should have the capability of the following information. Operator Logs (Should have write access to operator). It should be possible to launch the above information through an operating graphic. eg. calling up a procedure during operation. Operator, Engineer or Manager should be able to view and edit, with appropriate authority, the global database. Engineering Station should be able to carry out all the above functions in addition to System configuration, Station function building, database generation, Graphics editing, Self documenting, System maintenance and Remote diagnostics. Engineering station shall be provided with redundant hard disk. Data Exchange Procedure The Data Exchange between Control Domain and Information Domain shall comply with de-facto standards like DCOM, DDE, OLE and OPC. Any third party system supporting the above Industry standards should be able to interact with the system with minimum Glues or Gateways. Data Exchange between Information and control domain shall have access security levels defined in the security features. Engineering Tools : The tools should facilitate both Online and Offline Engineering of the system Engineering tools to build Graphics and database should be available on a standard desktop Environment viz. Windows NT.
3.0 PLC SYSTEM PERFORMANCE REQUIREMENTS (Under worst loading conditions as defined in Clause 3.1):
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(a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) 3.1
Scanning rate of analog signals Scanning rate of digital signals Scanning rate of pulse signals Loop execution time for CLCS Loop execution time for OLCS Controller output update for CLCS Controller output update for OLCS Updating rate of Analog display Updating rate of Analog display Updating rate of Digital value display
Updating rate of Digital value display
Maximum 1 sec for measurement Maximum. 100 ms Max. 100 ms Maximum 250 ms (For all Loops) Maximum 100 ms (For all Loops) Every 250 ms (For all CLCS Loops) Every 100 ms (For all OLCS Loops) Max. 2 seconds (for measurement) Max. 1 second for OLCS/CLCS Max. 4 seconds (for measurement) Max. 1 second for OLCS/CLCS Max 1-2 seconds on demand Max. 1 sec Max. 60 % Max. 50 % 99.7 %
Time for display in CRT screen Keyboard command execution time Controller Loading Data Bus Loading Overall system availability
Worst Loading Conditions: For distributed control system the worst loading condition shall include the following tasks: (a) All process inputs scanning and processing is in progress and all the data is transmitted over the main data bus every one second.
(b) (c) (d) (e) (f) 3.2
All closed loop controls in operation All open loop controls in operation All output devices are in operation with rated performance/speed. Control/information request is initiated on control VDU. In burst mode operation, 100 digital alarms are generated per second for a period of 10 seconds.
PLC System Reliability / Availability Requirement

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3.2.1
The reliability of the system shall be demonstrated by an analysis of system. Availability during system design and by test upon installation in the plant. The basic system design objective for availability is an annual availability that exceeds 99.7% for certain number of years. Details of the reliability analysis employed by the Bidder during system design and development and used to obtain the required system availability shall be available for Owner/consultant review. These analysis be of two types: (a) (b) Qualitative: Failure modes and effect analysis, common mode failure analysis, single failure analysis and fault failure analysis. Quantitative: Comparative analysis, sensitivity analysis, studies and associated mathematical modules.
3.2.2
3.2.3
PLC system availability shall be computed as following: (a) System Availability During Test Period In % = [100 x (Test Duration - Total Accumulated System Outage Duration )] / Test Duration (b) Total Accumulated System Outage Time is a total duration for which Contractor supplied system / functions are not available. System Outage Duration = (Outage Duration of individual equipment /system / function) x (Weightage Factor) (c) Weightage factor is the relative importance / criticality of the individual equipment / system / function to the total requirement for the PLC system and to be used to determine the amount of total outage time due to partial failures. Total system failure (weightage=1.0) and weightage factors for partial failures shall be as detailed subsequently.
3.2.4 3.2.5
PLC system availability test duration shall be minimum 6 months on a continuous basis. The system shall be considered unavailable (weightage factor=1.0), if any, of the following conditions occur: (a) (b) (c) (d) (e) Failure of the communication system Failure of all Operator Station Loss of MMI capability through failure of control room operator keyboard Malfunction of analog /digital input system in the loss of more than 5% of the total number of inputs Failure of > one controller
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(f) 3.2.6
Total failure of historisation facility/capability
Weightage factor for various partial failures to be considered shall be as follows: (a) (b) (c) (d) (e) (f) (g) Loss of one critical CLCS / OLCS loop Loss of one non-critical CLCS / OLCS loop Loss of one complete DPU (both main and standby controller) Loss of one DPU (redundant in operation) Loss of I/O (For Non-Redundant Modules) > 5% Loss of one OS Loss of data bus (redundant in operation) 0.20 0.10 0.50 0.30 0.20 0.20 0.3
3.2.7
PLC system availability shall be guaranteed by the Contractor. Availability guarantee test shall be conducted as specified in this specification. Contractor to prove the guaranteed system availability of 99.7%.
REDUNDANCY AND AVAILABILITY REQUIREMENTS
4.0
4.1
Measurement system (MS), Closed Loop Control System (CLCS) and Open Loop Control System (OLCS) shall all be configured with redundancy at processor modules, communication modules, data bus and power supply modules. Redundant sensors shall be provided for all control applications. For all important and critical controls (CLCS) triple redundant sensors shall be provided. This will include sensors provided for compensation also. Similarly for critical protection logic requirements triple redundant sensors for 2 out of 3 logic shall be provided to avoid spurious tripping. For all other control application dual redundant sensors shall be provided. Critical closed loop controls are detailed in Clause 18.0 of this specification.
SPARE PHILOSOPHY FOR PLC I/O CHANNELS:
4.2 4.3
5.0
(a) (b) (c) (d)

6.0
Spare I/O Channels: All types of I/O modules shall be provided with 10 % spare channels. Spare channels shall be wired and shall be distributed among the control processors. 10% hot spare I/O modules (installed) shall be provided. 10% spare slots for I/O modules distributed among the control processors. 10% spare rack space shall be provided and distributed among the control processors.
GROUPING OF CONTROLLERS
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6.1
The grouping of control loops in controllers shall be done based on the input / output (I/O) handling capacity of the individual controllers such that the system availability in the event of loss of one controller is not less than 50% (ie. Whenever there is more than one similar equipment, necessarily the two shall be implemented in different controllers) and fulfilling the following specific requirements: (a) I/O channel & module requirements considering spare channel requirement (b) Controller Loading considering the specified loop execution time (spare processing capacity shall be minimum 40%)
6.2 6.3
Control loop grouping philosophy to be followed in minimum are detailed in Clause 19.0 of this specification. The controller spare processing capacity shall be demonstrated during Factory Acceptance Test by loading all the spares as specified, including the spare slots mounted with modules. The system availability for PLC shall be 99.7 %. Contractor to submit the procedure for the availability test to be approved by Purchaser/Consultant and this shall be demonstrated during warranty period.
GENERAL GUIDELINES FOR FIELD INSTRUMENTATION
6.4
7.0
8.0
The various field instruments shall confirm to the specifications as per Table-7. The selection of a particular type of instrument for a specific application shall confirm to established engineering practices in a Power Plant and is subject to approval by Owner / Consultant during detailed Engineering. SELECTION OF RANGES FOR INSTRUMENTS The ranges of the instruments shall be selected based on the following philosophy indicated below: For pressure and draft measurements, the maximum operating pressure will be within 70 to 80% of the maximum scale range. All pump suction measurement and steam pressure measurements in extraction steam and in heaters will cover the negative pressure range also and all draft gauges will cover the negative pressure as well as the positive pressure as the case may be. For temperature measurement, the maximum operating temperature will be within 80 to 90% of the maximum scale range. For pressure switches and temperature switches, the set points shall fall within 40% to 70% of the scale range selected. For level measurement, the maximum of the range will cover the overflow point or six inches from the top of the vessel and the minimum of the range will be six inches above the bottom of the vessel. Also, the gauge glasses will be stacked with overlap to cover permissive, alarm and trip levels. For flow measurement, the maximum range shall be fixed at about 10 to 15% above the
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8.1 8.2
8.3 8.4 8.5
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maximum operating flow. 8.7

9.0
For electro-chemical measurements (conductivity, pH, dissolved O2, Silica etc.), the maximum range will be around 10 to 15% higher than the recommended alarm settings.
PG TEST POINTS
9.1 9.2
Pressure, temperature and flow test points shall be provided in line with latest performance test code requirements. In addition, pressure and temperature test points shall be provided for the following services: (a) At the discharge of all pumps and fans (b) (c) (d) At the inlet and outlet of the heat exchangers for the fluid media involved Adequate number at the Combustor at different zones At the inlet and outlet of each control valve
9.3 9.4
10.0
Pressure test points shall be complete with root valves and shall terminate with a nipple. Temperature test points shall be provided with thermowell..
SIZE OF TAPPING POINT STUB, NO. AND SIZE OF ROOT VALVES FOR DIFFERENT TYPE OF MEASUREMENTS
These shall be as follows Sl Quantity of No. root valves -------------Size of stub and root valve -------------Service Condition -----------
A. Pressure and differential pressure measurement (i) (ii) 2 1 25 NB 15 NB >=62 bar OR 425 degree C < 62 bar AND425 degree C.
B. Level measurement a) (i) (ii) Level Gauge & Switch 2 1 25 NB 25 NB >=62 bar OR425 degree C < 62 bar AND425 degree C.
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b) (i) (ii) c) (i) (ii)
Level transmitter (displacement type) 2 1 40 NB 40 NB >=62 bar OR425 degree C < 62 bar AND425 degree C.
Stand pipe for level measuring instrument 2 1 80 NB 80 NB >=62 bar OR425 degree C < 62 bar AND425 degree C.
C. Flow measurement i) ii) 2 1 25 NB 25 NB >=62 bar OR425 degree C < 62 bar AND425 degree C.
D. Sampling system measurement (steam & water service) i) ii)

11.0
2 1
25 NB 25 NB
>=62 bar OR425 degree C < 62 bar AND425 degree C.
CONTROL ROOM LAYOUT
11.1
Local control room shall be made independently for Coal handling system, ash handling system, Reservoir intake water system, raw water and pre-treatment plant and DM water / Effluent treatment plant independent. Each package shall have its own separate area/ desk for control & monitoring. The Local control room to house the following equipment: (a) (b) (c) (d) Control Desk Large Screen Video Display Unit [LCD] The system cabinets, marshalling cabinets Uninterrupted power supply system (UPS) in UPS room.
11.2
11.3 11.4
Control room floor shall be provided with anti static matting. Ambient condition in the control room shall be as follows: (i) (ii) Temperature: 23.0 +/- 2 deg. C Relative humidity: 55%+/- 5%.
11.5
The control room shall be designed with diffused illumination uniformly over the entire
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area except where the large screen video displays are placed. At this area variable lighting shall be envisaged such that displays shall be visible brightly against the area lighting. 11.6 11.6.1 Following furniture shall be provided for the central control room and utility plant local control rooms: For Central control room (a) Cushioned revolving, independently adjustable seat and back chairs to be located at each Local control room for all OS and ES/OS. (b) (c) (d)
12.0
Any other equipment to be located in control room shall be provided with metallic tables. Metallic half consoles for mounting operator station video monitors. In addition to the above furniture as required shall be provided for the Instrument lab.
SPECIFIC DESIGN REQUIREMENTS VALVE ACTUATOR / PLC / MCC INTERFACE
12.1 A Sl. no.
Drives less than 200 kW - Unidirectional Service Feedbacks from switchgear to PLC Motor running Motor stopped MCC disturbed Local emergency stop operated Motor current Commands from PLC to switchgear 6 7 Command to start motor Command to stop motor Local push button station to switchgear 8 Local emergency stop Direct to switchgear. Lockable type emergency stop push buttons to be provided. DO DO Output interposing relays to be mounted in independent relay cabinets of the PLC. DI AI Signal Type Remarks
1 2 3 4 5
DI DI DI
It includes THERMAL O/L OPTD / CONT. SUPP. FAIL / MCC ISOLATED Applicable for rating 50 kW and above.
LT drives bidirectional (integral starters)

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Sl. no.
Service Feedbacks from valve actuator to PLC
Signal Type
Remarks
1 2 3 4 5
Limit switch opened Limit switch closed Opened torque switch not operated Closed torque switch not operated Position feedback Signals from Integral starter panel to PLC
DI DI DI DI AI Applicable for inching valves.
DI 6 7 Integral starter panel disturbed Local mode selected Commands from PLC to integral starter 8 9 C Sl. no. Command to open Command to close Solenoids Service Feedbacks from valve limit switches to PLC 1 2 Limit switch opened Limit switch closed Commands from PLC to switchgear 3 Command to open / close DO DI DI Signal Type DO DO DI
It includes THERMAL O/L OPTD / CONT. SUPP. FAIL / MCC ISOLATED
Output interposing relays shall be mounted in independent relay cabinets of the PLC.
Remarks
Output interposing relays will be mounted in independent relay

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cabinets of the PLC; Command shall be to energize or deenegize decided based on fail safe condition; For solenoids with dual coils, two independent outputs shall be provided for open and close.
D Sl. no.
DRIVES ABOVE 200 kW (3.3 kV and 11kV) UNIDIRECTIONAL Service Feedbacks from switchgear to PLC 1 2 3 Motor running Motor stopped Motor tripped on fault DI 4 Breaker ready to close DI DI DI It includes DIFFERENTIAL PROTN OPTD, COMPOSITE MOTOR PROTN OPTD, S/C PROTN OPTD. It includes BREAKER IN SERVICE, TRIP CIRCUIT HEALTHY, MASTER TRIP RELAY RESET and SPRING CHARGED. Signal Type Remarks
5 6 7 8 9
Breaker in remote Control circuit fault Local emergency stop operated Motor current Motor kW Commands from PLC to switchgear
DI DI DI AI AI
10 11
Command to start motor Command to stop motor Local push button station to switchgear
DO DO
Output interposing relays will be mounted in independent relay cabinets of the PLC.
12
Local emergency stop
Direct to switchgear .
Lockable type emergency stop push buttons to be provided.
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SHEET 16 OF 17
12.2 12.3
Both open / close torque switches and Limit switches shall be individually wired to PLC. For all HT drives alarm and trip signals for bearing and winding temperatures shall be considered through soft LVM from temperature element signal only. No temperature transmitters are required for these signals. All Critical control valves shall be provided with anti-cavitation trim. Control valves / dampers shall be supplied with all accessories including non-contact type position transmitters and E/P Positioners. Combination of I/P + Pneumatic positioner is not acceptable. All inching valves shall be supplied with position transmitters integral with the valve positioner. All transmitters shall be SMART type with integral local LCD indication and HART protocol. All Temperature sensors shall be Duplex type and field mounted temperature transmitter shall be provided for all temperature measurement applications. Direct wiring of RTD or T/C to PLC is not preferred. Switches (pressure, temperature, level & flow etc.) shall be provided only for critical equipment trip. Wherever possible, transmitters shall be provided with required redundancies for all other purposes. Similar make and model shall be provided for same type of I&C system equipment. This shall specifically apply for field transmitters, PLC, control valves etc. Interrogation voltage for the Digital inputs shall be of 24VDC. All motorised isolation and inching service valves and dampers shall be provided with integral starters. Where multiple functions like monitoring /control/alarm etc. are sought to be performed based on a parameter value, in minimum dual sensor shall type be provided. All outdoor field equipment shall be provided with epoxy painting. All outdoor field instrument / panel /cabinet shall have IP-65 protection. Canopy for the same shall be provided. All panel / cabinet / desk shall have following colour scheme: (a) Exterior: RAL 7035 with texture finish. (b) Interior: Brilliant white with glossy finish.
12.4
12.5 12.6
12.7
12.8 12.9 12.10 12.11 12.12 12.13 12.14
12.15 12.16
Uniform KKS tag numbering philosophy through out the plant shall be used. All local cabinets / utility plant control panels with bottom cable entry shall be provided with suitable pedestals for easy cabling. The panels shall be designed for ease of operation of operating hardware and monitoring the indicators.
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SHEET 17 OF 17
12.17
All local panel indicating lamp/indicating type Push button should be of cluster LED type only. All local panels shall be of double door type instead of double leaf type to avoid ingress of dust in dust prone areas. All motorised bypass valves shall be inching type and shall be provided with position transmitters of non-contact type. Spring-loaded terminals shall be used for termination of instrumentation cables at field JBs, FTCs and local panels. Fused terminals shall be used in marshalling cabinets at Control room for all analog signals. Instrumentation cables shall be laid in separate cable trays. Cable number tags and markings will be provided at every 30 meters along the entire length of cable. Instrumentation cable trays will be run on the top in the cable gallery. Cable routing to the control system from field instruments and devices shall be through junction boxes. Cable glanding to be made at all ends like field instruments, junction boxes inlet and outlet, control panels or instrument panels. Cladding of cabling is not acceptable. All instrument marshalling / system / local control panels shall be provided with gland plates [preferably of 4 quadrant] at the bottom for glanding the cables.
12.18 12.19 12.20 12.21 12.22 12.23 12.24
12.25
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TCE.5657A-C-500-002

INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM - TECHNICAL SPECIFICATION
1.0
PROGRAMMABLE LOGIC CONTROLLER (PLC) MEASUREMENT AND CONTROL SYSTEM
1.1 1.1.1
CONTROL PROCESSOR Processor will be minimum 32 bit with floating point arithmetic capability. It will have adequate capacity of volatile memory to store dynamic plant data, control programmes and self- diagnostic routines. Also it will have adequate capacity of nonvolatile memory to store programmes, standard software to perform control data acquisition and diagnostic functions. Battery back up (if applicable) for duration not less than 50 hours shall be provided. Memory expandability of 150% of offered capacity shall be provided.
1.1.2
Processor shall have the following functional capabilities as a minimum: a) Mathematical Functions : To meet the functional requirement of the control system and provision to add more algorithms by the purchaser. b) Logic Functions : For performing Boolean operations and time delay requirements c) Control Techniques: Shall include Multivariable, feed forward, feedback, cascade, auto tracking, ratio and bias, dynamic dead band, proportional, integral, derivative and their combinations, auto inching, auto limits, blocks, run- ups, run downs, over rides, analogue hold and any other techniques as may be necessary. d) Point Status and Quality feed back
1.2 1.2.1
1.2.2
INPUT/OUTPUT MODULES Digital Input Modules shall have the following features: (a) Signal isolation (optical) (b) Fuse protection (c) Contact bounce protection (d) Field cable monitoring (e) Short circuit protection (f) Configurable as status input, latched input (g) Alarming of abnormal state (h) The interrogation voltage for digital inputs shall be 24 V DC Digital output Modules shall have the following features: (a) Individually fused (b) Individual contact suppression (c) Configurable as momentary, latched or pulse-width modulated outputs (d) Individually definable default state (e) Output read back verification (f) Short circuit protection (g) Interposing relays shall be provided for all DOs. Relya boards are not acceptable.
Analog Input Modules shall have the following features:
1.2.3
Analog inputs can be 4-20 mA DC, (a) Signal isolation (Galvanic/ Opto-coupler) (b) Fuse protection and fuse failure detection (c) Transmitter power supply at 24 V DC (d) Input filtering for noise level
ISSUE R0 TCE FORM NO. 120R2
Spec No.
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(e) (f) (g) (h) (i) (j) (k) (l) 1.2.4
Cold junction compensation for thermocouples Transmitter monitoring for parity, wire break and limit values Monitoring of A/D conversion Conversion to engineering units Test for normal or extended range Detection of open circuit for thermocouples Detection of open circuit for thermocouples Alarm limit testing for high, high-high , low, and low-low substituted values
Analog Output Modules shall have the following features: (a) Analog outputs shall be 4-20 mA DC (b) Direct or reverse operation (c) Loop check back of output (d) Default options upon failure Design Features/Requirements of Process Controllers
1.2.5 1.2.5.1
Microprocessor based multiloop controllers with input/output ports/cards shall be used with configuration and control software. All open/close control loops shall be easily configurable using user-friendly software. Controllers shall be able to operate in either manual, auto, cascade mode. Mode changeover in either direction shall be bumpless. The controller shall also have facility for slow and fast ramping of set point and output. The controller should be capable of implementing complex and advanced control strategies through the use of exhaustive set of control algorithm/software blocks. These shall include PID, adaptive, feed forward, dead time, lead-lag compensation, high-low signal selection, curve fitting, real time computational capability etc. In addition the controller shall be able to perform batching, sequencing, interlocks and logic functions. Failure of one loop shall not result in failure of other loops. The distributed processing unit shall be provided with redundant floating power supply. The power supply modules, which are vital to the systems continuous operation, shall have the means to receive power from two (2) independent power sources. Suitable battery back up shall be provided for protection of volatile memory (for 72 hours). The system shall have 1:1 redundancy with respect to the processor modules, power supply modules, communication modules and network interface. The system shall be designed in such a manner that in the event of failure of the primary controller, the entire configuration of the failed controller shall be instantaneously and automatically transferred to the back-up controller without operators intervention. Mode changeover in either direction shall be bumpless. Simultaneously, a message should appear on the video-monitors of the Operator's/Engineer's work station indicating the failure.
OPERATOR STATIONS (OS)
1.2.5.2
1.2.5.3
1.2.5.4
1.3 1.3.1
OS shall provide man machine interface for monitoring and operating the plant equipment with the help of various graphics and displays and also generate various
Spec No.
TCE.5657A-C-500-002

1.3.1.1
logs/reports for effective plant operation. OS shall be Freely assignable and have the following features as a minimum: Plant Control Displays: Control displays shall facilitate normal plant operation. These displays shall be organised in the form of plant overview display, group displays, individual input/output point displays and logical function displays. It shall be possible to perform both open loop and closed loop control from these displays. The parameters like set point, measured value, controller output, control deviation, deviation limits, controller tuning parameters, sequence status and criteria, waiting and monitoring time, position of final control element shall be monitored. Auto/manual mode change, set point/ bias/output change, automatic/step-by-step, manual sequence control, criteria bypass, sequencing and intermediate step operation shall be provided. A display page shall have maximum 8 loops.
Plant Schematics : Facility for overlaying displays with other displays on mimics, performing control actions through touch panels in mimic diagram (graphics) shall be provided. Minimum 300 mimic diagrams shall be provided. Display call up time and updating of dynamic information will be as per clause 1.2. above ISA standard graphic symbols library for generating mimics shall be provided. No. of lines per display page shall be 48. Minimum 24 dedicated display push buttons shall be provided. Alarm Notification/Actions :
1.3.1.2
1.3.1.3 1.3.1.4
3 levels of process alarm prioritising facility shall be provided. The alarm messages shall be printed on dedicated printer on occurrence of fault or on demand strictly in chronological order. Display of alarm messages on VDU shall be in the order of occurrence. Alarm display shall be provided for the following functions : Equipment malfunctions Control deviations of process variables indicating High, High-High, Low and Low-Low limits Automatic inhibition for "Bad" and "Out of service" points from limit checking The alarm display shall contain the latest 20 alarms, with the previous alarms (back log) stored in memory as an additional page. Storage for minimum 10 pages shall be provided. Alarm Summaries shall be provided for existing alarms, bad-inputs, points out of scan, C&I faults, Lock-out alarms. Alarm summary in the order of priority and chronological order within priority shall be possible.
1.3.1.5
Spec No.
TCE.5657A-C-500-002

1.3.2
Individual Point Data:
The display of analog/digital inputs shall contain the following data (i) PID number (ii) Point description (iii) Current value/status (iv) Sensor/transmitter/ instrument tag number (v) Scan status (under scan/out of scan) (vi) Data quality (type status) (vii) Scan frequency (viii) Current alarm status (ix) Alarm limits. The display of analog/digital outputs shall contain the following data : PID number (ii) Point description (iii) Current value/status (iv) Drive/device tag number (v) Update status (active/blocked) (vi) Up date frequency. 1.3.3
Trend Plot features:
Configuration of up to 8 pens per trend plot for real time and historical trending should be provided. Real time trending and historical trending of 1 sec. shall be provided. Bidder to state the maximum number of configurable trend groups and max. no. of historical points supported by the system. 1.3.4
X-Y Plots:
Facility to plot up to four variables on vertical axis against one variable on horizontal axis shall be provided. Minimum configurable scan rate is 1 sec. Contractor to state the no. of X-Y plot variables configurable/group display page. 1.3.5
Logs/Reports:
Event activated logs/reports consisting of pre and post trip log with 100 points sampled at 10 secs intervals with 5 minutes history of all relevant analog points; On demand logs consisting of analysis logs with 120 points in 10 groups; Unit 'Snap-shot' report of 100 analog and 25 digital points shall be provided; Time activated report consisting of daily report of fuel consumption, fuel storage availability status, daily power generation, daily power consumption shall be provided. Shift report consisting of approx. 50 predefined key parameters at the end of the shift and accumulated values of certain parameters like power generation, fuel consumption, auxiliary power consumption, etc. over the shift and status of maximum 25 nos. of major equipment shall be provided. Periodic log of 300 parameters, which are grouped in 25 groups of 12 points each collected at the end of each hour, shall be printed at the end of each shift. 1.3.6
Equipment Operating History
1.4
Facility to accumulate run time from initial commissioning and last overhauls of the equipment. ENGINEERING STATIONS (ES)
Spec No.
TCE.5657A-C-500-002

ES shall have all the features of OS and in addition shall have the following capabilities as a minimum: To generate control software through logic diagrams with out any programming knowledge; To generate graphic display and control displays, facility to change/enter all the attributes of analog and digital I/O points, calculated and Boolean variables and constants like scan rate, process range, To test, configure/reconfigure process interface modules/cards, CLCS tuning, To accumulate I&C faults to analyse downtimes and time to repair, To run offline system diagnostic programmes, On- line fault detection through diagnostics Other maintenance Engineer's functions.
1.5 1.5.1
DATA BUS SYSTEM
The data bus system comprises the following: (i) Main data bus for communication between various distributed processing units (DPU), OS and ES. (ii) Communication controller (iii) Cubicle bus local to the DPU's. The communication controller, main data bus and the cubicle bus shall be configured in redundant mode with bump less auto switching feature.
1.5.2
Data Bus System shall have the following features: Coaxial or fibre optic data bus in redundant hot stand by mode Minimum transmission rate of 10 Mbps. Communication protocol shall be token passing/master less as per IEEE 802.3 / 802.4. Provision for 25% expandability On-line addition/removal of distributed processing units 50% spare bus loading capacity considering the 25% expandability requirements Direct connectivity with Ethernet operating at 100 Mbps
CENTRAL PROCESSING UNIT FOR MAN MACHINE INTERFACE (CPU)
1.6
The CPU shall be 32 bit RISC based processor, suitable for real time Process applications and supports man machine interface equipment like VDU's, printers, key boards, bulk data storage unit and communication control and monitoring system. 1.7
COLOUR GRAPHICS VIDEO DISPLAY UNIT
21" colour TFT monitor with mouse / track ball facility shall be provided. Resolution shall be 1280 x 1024 pixels minimum. Number of characters per line shall be minimum 80 and number of lines per display page shall be minimum 48. Total number of characters shall be minimum 256 graphic characters + ASCII. Minimum
Spec No.
TCE.5657A-C-500-002

Sixteen (16) colours shall be provided. Anti-reflection feature shall be provided. Main memory capacity shall be 8 MB with minimum 160GB Hard disc capacity and shall have a DVD / CD RW drive. The system shall support Seven (7) types of audible alarms (3 Process related, 2 no system related and 2 keyboard related). The VDUs shall be table top mounted type. The VDU's shall be fully assignable and functionally interchangeable. All VDU's shall have dedicated keyboard. 1.8 1.8.1
KEYBOARD
Keyboard for OS Flat Membrane type Keyboard shall be provided for operator interface with process for plant control and display functions to access plant data in conjunction with Operator station VDUs. The keyboard shall have a minimum of 80 configurable keys for assigning most frequently used displays. A minimum of Sixty-four (64) of those keys shall have two independently lit LED's used for event-specific alarm annunciation.
1.8.2
Keyboard for ES : Qwerty type Keyboard shall be provided to enable the maintenance engineer to develop graphic displays, control system software and system configuration for the PLC. It shall be possible to perform OS functions from VDU of ES. Assignable function keys shall be provided for execution of command, program etc. Pass- word protection facility shall be provided to set ES in engineer or operator mode. BULK MEMORY UNIT (BMU) The BMU shall have the following features: Two discs in hard stand by mode Fixed disk drives with one controller per drive Disk capacity to meet functional requirements of the control system with a minimum formatted disk capacity of 250 GB. Data transfer rate shall be 1.5 MB/second Average access time shall be less than 40 milliseconds. Error checking and Error recovery feature
CD ROM DRIVE & CD WRITER The features shall include:
1.9 1.9.1
1.10
1.12
Capacity shall be minimum of 2 GB CD ROM drive shall be provided for loading the system software. Writable CD with formatted capacity of 640MB Data transfer rate shall be minimum 5 MB per minute and seek time shall be 22 milli seconds or better. Facility shall be provided for direct transfer of bulk data from BMU to CD drive unit SOFTWARE: The software supplied shall meet the following requirements. The Real Time operating System (RTOS) supplied shall be proven, able to support all the equipment/peripherals and execute all the tasks as stipulated in this specification. The background executive shall enable software development
Spec No.
TCE.5657A-C-500-002

2.0 2.1
2.2 2.3
in time sharing mode by two or more programmes simultaneously and shall run/Test any program without making it into an online program. The data acquisition, processing and alarm monitoring/ reporting software resident in each DPU shall enable processing of raw process data including Engineering unit conversion and process alarm time checking. The control software resident in each DPUs shall enable the execution of both modulating and sequential control without interrupts to ensure security of controls software for performing mathematical function routines/algorithms and logic functions for control loops as specified. The generation of control software shall be based on logic blocks and ladder diagrams and no programming knowledge shall be necessary. Utilities like report and display generation, data base management, file handling unit, communication, online system back up, on line diagnostics, screen editor, soft ware development, on line debugger and down loader, man machine interface software, log generator, data transfer from magnetic tape to disk and vice versa, test and maintenance program, anti virus vaccine/detection utility, full scale water property routines conforming to ASME 1967 steam table and any other utility soft ware to meet the functional requirements of the intended control system shall be supplied. All software used for PLC shall be licensed version only. CONTROL SYSTEM The microprocessor based Hot-redundant PLC system shall perform protection logic, interlock and sequential control functions such as binary logic operation, set/rest operation, timers, counters, logic blocks, math functions, Boolean functions & timer functions. PLC shall complete with processor, I/O cards, memory modules, racks, mounting accessories. The scan time for digital inputs shall not be more than 60msec and execution 120msec. The system shall be loaded to maximum 60% under worst loading conditions. The system shall be redundant in processor, power supply and communication interfaces. The system shall have self diagnosis features. The operation, monitoring and programming shall be performed from the CRT station. The system shall have facility for connecting to DCS using hot redundant bi-directional OPC communication link. The redundant UPS power supply shall be provided for the PLC system. PLC shall specifically meet the following requirements: (a) (b) PLC shall have extensive self-diagnostic capability. Self diagnostics shall include both module level diagnostics as well as channel level diagnostics PLC shall have redundant processors/controllers. This shall mean the fulfilment of both the following requirements: (i) (ii) (c) Automatic synchronisation of primary processor/controller of PLC with secondary processor/controller Bumpless switchover to secondary processor/controller of PLC when the primary fails.
Automatic program and data equalisation in the event of any on-line program
Spec No.
TCE.5657A-C-500-002

/ edit executed in the primary processor/controller of PLC. (d) (e) 3.0 3.1 Automatic Forcing Bit update in the secondary processor/controller of PLC when any Forcing is applied in the primary processor/controller of PLC. Communication speed shall be minimum 2 MBPS.
WATER ANALYSIS SYSTEM
The water chemical sampling system shall be designed to monitor the chemistry of the water cycle to ensure the desired quality. Information from the analyser shall be used to control the high pressure and low pressure dosing system. Long term monitoring and trending of essential elements shall be carried out, to provide an indication of the general condition of the mechanical plant. The sample points, their location, type of chemical analysis to be carried out for each sample, measurement ranges etc., shall be subject to the approval of the Owner. The tenderer shall provide a composite system including sample probes, sample piping, safety valves, ball valves, relief valves, grab sample collection facility, pressure, temperature, level, flow indications, coolers, on line analysers etc. The system shall include the following: Sample conditioning panel with all accessories-Typical scheme for sampling is illustrated in dwg. No TCE.5103A-IC-SK-03. Analyser panel housing cells, analysers, monitors etc. The sample conditioning and analyser panels shall be physically separated from each other. Analyser panel shall be located in a separate air-conditioned room. Sample conditioning panel shall be walk in corridor type/open rack type. All panels shall be designed for ready access of components for easy maintenance. The layout and general arrangement of these panels shall be subject to Owners approval. All sample lines shall be annealed seamless 304 stainless steel of 12 mm O.D. All sample lines shall be sloped towards the sampling panel. pH Measurement Solid state/micro processor based system with system accuracy of 0.02 pH, auto temperature compensation, auto zero check, manual zero and span calibration, integral indicator, automatic ultrasonic cleaner, isopotential adjustment having flow type cells. Housing for electrode and analyser shall be IP65. Output shall be isolated 4-20 mA DC linear signal. Accessories shall include preamplifier, screened junction box for electrode. Online reading shall be provided at Main Plant Control room
3.2
3.2.1
3.2.2 3.2.3
3.3
3.4
Spec No.
TCE.5657A-C-500-002

3.5
Conductivity Measurement Solid state/micro-processor based system with an accuracy of +1 FSD, auto temperature compensation, auto calibration, zero check and integral indicator having gate valve insertion type (withdrawable) cell for hotwell conductivity measurements and flow line (screwed) type cell for other services. Housing for cell and analyser shall be weather and water proof. Output shall be isolated 4-20 mA DC linear signal. Online reading shall be provided at Main Plant Control room
3.6
Dissolved Oxygen Measurement Solid state/micro-processor based system with an accuracy of +1 ppb, having features like auto temperature compensation, auto zero & span calibration and integral indicator. Fault diagnosis data shall include faults in analogue/digital circuits, faults in calibrated values, power supply failure and sample failure. Housing for cell and analyser shall be IP54 or equal. Output shall be isolated 4-20 mA DC linear signal. Online reading shall be provided at Main Plant Control room.
3.7
Silica Analyser Solid State/micro-processor based system with an accuracy of +2 ppb, response time better than 12 min for 90% change, six number of sample streams having features like auto zero & span calibration, ambient temperature compensation and integral indicator. Self diagnostic features shall include alarm for no reagent, calibration fault and silica concentration low/high. Analyser housing shall be weather and water proof. Output shall be isolated 4-20 mA DC linear signal.
3.8
Online reading shall be provided at Main Plant Control room Hydrazine Analyser Polaro graphic type, Solid state/micro-processor based system with an accuracy of +5% FSD, repeatability of +2% FSD, response time of 90% of any change indicated in 6 min having features like auto zero & span calibration, ambient temperature compensation, and integral indicator etc. Fault diagnosis data shall include faults in analog/digital circuits, faults in calibrated valves, power supply failure and sample failure. Analyser housing shall be weather and water proof. Output shall be isolated 4-20 mA DC linear signal.
3.9
Online reading shall be provided at Main Plant Control room Sodium Analyser : The Analyser shall be continuous flow through sample , single stream with accuracy + / - 10 and response time less than 2 minutes for 90% of full scale readings. The range shall be 0-20 /0-200 ppb. The analyser shall have features like auto zero &
Spec No.
TCE.5657A-C-500-002

span calibration, ambient temperature compensation, and integral indicator etc. Fault diagnosis data shall include faults in analog/digital circuits, faults in calibrated valves, power supply failure and sample failure. Analyser housing shall be weather and water proof. Output shall be isolated 4-20 mA DC linear signal. Online reading shall be provided at Main Plant Control room. 4.0
4.1 VIBRATION MONITORING SYSTEM GENERAL
4.1.1 4.1.2
The vibration monitoring system shall provide monitoring on continuous on-line basis. The system to be provided shall include all necessary hardware, software, firmware and interfaces, all special and field signal cabling required for implementing a fully functional system. Bidders offered system shall include but not limited to the details specified in subsequent paragraphs.
Vibration monitoring system shall be independent for each package.
4.1.3
4.2.2
The vibration monitoring system shall be complete with eddy current type proximity vibration sensors, signal conditioning cards, amplifiers, special cables, vibration monitor (if required) etc. together with all necessary equipment and accessories. Vibration sensors shall be provided for measurement in both X (horizontal) and Y (vertical) axis at 900 angle to each other for each bearing. For bearings of high speed machines (= / >1500 rpm) accelerometer type sensor and for low speed machines (<1500 rpm) velocity type sensor shall be provided. Necessary, one or two stage integrators for obtaining vibration measurement in terms of displacement shall be provided in the system. Vibration pickup shall meet the following requirements: (a) (b) (c) Pick-up sensitivity-Minimum 25 mv / mm / second Enclosure protection- IP 65 Pick ups suitable to function in temperature range of (-)10 0 To (+) 200 0 C.
4.2.3 4.2.4
4.2.5
4.2.6
Vibration monitoring system shall provide the vibration measurement in the form of 420 mA DC signal to be directly connected by hardwired cable to applicable control system [PLC] for monitoring. Limit value generation (soft) for alarm and protection applications for the auxiliaries and their drive equipment shall be carried out in applicable control system (PLC).
INSTRUMENTATION AND SPECIAL CABLES
5.0 5.1
Specification of instrumentation and special cables application guidelines are listed in Section D 6, Table-8. CONTRACTOR shall supply as per these specifications and
Spec No.
TCE.5657A-C-500-002

deviations if any are subject to approval by OWNER / CONSULTANT.

6.0 QUALITY ASSURANCE
6.1
Bidder shall furnish a detailed Quality Assurance / Quality Control Plan (QA/QC) for each Instrument/System covered under this specification for OWNER/ Consultant review and approval.

Spec No.
TCE.5657A-C-500-002
INSTRUMENTATION AND CONTROL TEST AND INSPECTION FOR DCS/ PROGRAMMABLE SYSTEM
SHEET 1 OF 4
1.0
TESTS AND INSPECTION FOR INSTRUMENTS
1.1
After Manufacturing, all instruments shall be tested and calibrated at Factory. CONTRACTOR shall be responsible in obtaining test certificates related to calibration of all the Instruments and submit for Owner/Engineers approval. CONTRACTOR shall allow despatch of these instruments only after passing applicable Factory Acceptance test and approved by Owner/Engineer. The details of the tests to be carried out for the different instruments / field equipments/ Systems shall be as indicated in the Section D, TABLE-10 and any other tests as required by the Standards and Codes.
TESTS AND INSPECTION FOR PLC
2.0
2.1
Tests for PLC system will include the following: (a) Factory Acceptance Test (FAT): To be carried out at PLC system CONTRACTORs / Sub-Vendors works and witnessed by Owner/Engineer, successful completion of which will be the basis for Authorisation for Shipment to Site. FAT shall be preceded by a pre-FAT inspection/test by Vendor. Site Test (SAT): Involves tests for site commissioning, guarantee tests for system performance & availability to be conducted in the presence of Owner.
(b)
2.2 2.2.1
Factory Acceptance Test (FAT) FAT shall be a complete integrated test of the PLC system and carried out at CONTRACTORs / Sub-Vendors works on completion of manufacturing of the system. The test shall be performed with the completely assembled system and performing all the functions, it is expected to perform while in actual service. The various tests to be performed for PLC system equipment / total system together with the guideline for Factory acceptance test (FAT) procedure are detailed in Section D 6, TABLE-11. The CONTRACTOR shall submit a detailed "Factory Acceptance Test Procedure" in line with the above specified guidelines for Owner / Consultant approval. FAT shall be preceded by a Pre- FAT Inspection/ Test to be carried out by Contractor/ Vendor. Pre-FAT inspection / test shall be carried out as per approved FAT procedure detailed above and shall submit Pre- FAT Inspection/ Test report for Owner/Consultants review and approval. Owner/ Consultant shall witness the actual FAT on the basis of successful completion of Pre- FAT Inspection/ Test. Site Test (SAT) Tests to be conducted at site will involve the following: (a) Site Pre-commissioning Tests comprising the following to be conducted by Contractor at site:
2.2.2
2.3 2.3.1
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(i) (ii) (b) (c) (d)

3.0
Calibration of monitoring and control equipment Integrated loop test wiring, Simulation input from site
Trial Operation of the PLC system functioning. Performance Guarantee Test for I&C systems Availability Guarantee Test for PLC system
TRIAL OPERATION OF THE PLC SYSTEM FOR EACH PACKAGE
3.1
Trial operation test of PLC system shall be conducted on completion of installation as per specification requirements, checking and satisfactory pre-commissioning tests detailed at 2.3.1 (a) above. Test shall be conducted at site by Contractors personnel in the presence of the Owner / Consultant. Test shall be a Total Integration Test of the whole PLC System including the testing of communication links. Test duration shall be of 14 days out of which 72 hours shall be continuous operation performing all the specified functions. The trial operation shall be considered successful provided that each item of equipment can operate continuously at the specified characteristics for the period of trial operations. During this period, any modifications / repairs as required shall be carried out. If the total interruption period (outage time) is more than 4 hours, the trial operation duration shall be extended by the period of interruption. Total interruption period (system outage time) shall be calculated as detailed in 5.4 below.
PERFORMANCE GUARANTEE TEST FOR I&C SYSTEM
3.2 3.3 3.4 3.5
3.6
4.0
4.1
After successful trial operation, the OWNER shall conduct performance guarantee test for a period of 14 days in the presence of CONTRACTORs commissioning engineer. During the test, the system shall run with 100% availability. Contractor shall also furnish the guaranteed process parameters and the acceptable deviations before conducting the performance test. Following tests to be performed during the PG test: Redundancy checks for processor, communication, power supply and 1/O modules. This check shall be conducted in a sequence as mutually decided between the Client and the contractor. During each redundancy check, the plant operation shall not be disturbed and the control loops shall continue in auto mode. The trending of control parameters shall be in service during these checks and the over shoot / under shoot of the controlled parameters shall be less than 1%. These
ISSUE R0
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SHEET 3 OF 4
checks shall be logged (removal and relocation of modules/cables) in the system in addition to being made available to the operator in operator station. 4.2.2 4.2.3 Response time for each type of update as per the specification shall be checked on line by suitably recording each activity. Guaranteed parameters shall be checked and established as per Schedule of Performance Guarantees furnished by the contractor. The stability tests for the control loops shall be checked for other load conditions viz. 75%, 50% and 25% and the variation in the process parameters shall be within the limits specified. Checking of the time activated and on demand reports. Functional inter-changeability of the Operator Stations and printers shall be checked. Time synchronisation with master clock shall be tested. Specified serial links shall be established and proven. The calculations / documents earlier furnished for establishing the specified system availability, shall be demonstrated with due consideration for the running plant. The specified MIS functions, Performance Calculations etc., shall be checked.
PG Test Methodology
4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 4.2.9 4.3 4.3.1
If the performance of the system deviates from the specification requirements, the contractor shall be given a maximum period of 3 days depending on the gravity of the defect as mutually agreed, to carryout the modification without disturbing the plant operation. Contractor shall declare the system fit for checking after completing the modification / rectification. The specific test shall be repeated for proper functioning. Contractor shall be given maximum of three attempts each not exceeding 3 days for any subsequent defects found. After 3 tests for each activity, if the system still deviates from the specified requirements, the warranty period may be extended depending on the gravity of the defect, during which period, the contractor shall rectify / modify the system to meet the specified requirements. During the test, any modules / equipment fails, the contractor immediately within four hours shall replace the faulty module / equipment and the test shall be repeated after extended continuous running of 96 hrs. The total duration for the site acceptance tests i.e site pre-commissioning tests and Trial operation test together shall not exceed 30 days including the repetition of tests and duration for replacement / rectification.
4.3.2
4.3.3
4.3.4
4.3.5
ISSUE R0
TCE FORM NO. 120R2

Spec No.
TCE.5657A-C-500-002
SHEET 4 OF 4
4.3.6 4.4 4.4.1
During all the above tests, Contractor shall ensure that the disturbance to the process is minimum. PG Test Result Interpretation The failure of any one of the hard or soft copy device shall not be taken as nonavailability of the system. However, the mean time to repair shall not exceed that specified by the CONTRACTOR. Any other failure shall be considered as system reliability / availability failure as defined in Section D 6.3. The PG test shall be repeated if the test results deviate from the guaranteed values. All the special equipment, tools and tackles required for the successful completion of the PG test shall be provided by CONTRACTOR as part of the total scope of services. Ready stock of all types of modules / PC boards shall be available as part of the total scope of services for immediate replacement during the period. The PLC System PG test shall be carried out to Owners satisfaction. The last 5% of the total supply payment will be released only after successful completion of PLC system PG test.
AVALABILITY GUARANTEE TEST FOR PLC SYSTEM
4.4.2
4.5
5.0
5.1
The test shall demonstrate the specified guaranteed PLC system availability of 99.7% for a continuous period of 6 months as specified in Section D 6.3 or as agreed for the project. The test period shall be a continuous period of 6 months. PLC system availability shall be computed as specified in Section D 6.3. During the test period, the Owners engineer shall keep the log of total outage period in a pre-determined format mutually agreed between Owner and Contractor. Equipment repair shall be carried out by Contractors engineer by using the spare and as per trouble shooting procedure furnished by PLC System Vendor. The Contractor shall depute their representative/ engineer for the total duration of Availability Guarantee Test covering 24 hrs. of the day. If the accrued downtime exceeds 0.3% (considering guaranteed availability of 99.7%) of the test duration of 6 months, then a new 6 months test run shall start from the time the system is fully available again. The PLC System Availability Guarantee Test shall be carried out to Owners satisfaction. The last 5% of the total supply payment will be released only after successful completion of PLC system Availability Guarantee Test.
5.2 5.3 5.4
5.5 5.6
5.7
ISSUE R0
TCE FORM NO. 120R2
Spec No.
TCE.5657A-C-500-002

INSTRUMENTATION AND CONTROL OTHER SERVICES
1.0 1.1
TRAINING OF OWNER'S PERSONNEL The CONTRACTOR shall at no extra to the OWNER, undertake to train engineers selected and deputed by the OWNER. These engineers shall be given special training in shop, laboratory and drawing office of the CONTRACTOR, where the Instrumentation and Control Equipment will be designed, and manufactured and in any other power plant where similar type of equipment designed, manufactured and supplied by him is under installation, test, operation or maintenance, to enable the engineers to become fully familiar with the equipment offered. The type of training with number of personnel to be trained and the quantum of training to be provided are detailed in TABLE- 14. The CONTRACTOR's personnel at site, shall continuously and intensively instruct and train adequate number of the OWNER's operating and maintenance personnel at site during erection and commissioning of the equipment to enable them to take over the proper operation and maintenance of the equipment after commissioning. The CONTRACTOR shall include in his bid, the charges for providing training to purchaser's personnel as above which will include lodging & boarding charges, local transport at place of training etc. CONTRACTOR shall include in his bid a detailed description of the proposed training for the OWNER's personnel. INSTRUMENTS FOR PERFORMANCE TESTING All instruments required for performance testing to prove the guaranteed performance of the Instrumentation and Control Equipment as specified in Section-D 6.5, shall be loaned to the OWNER by the CONTRACTOR for the duration of the Performance Test. These test instruments shall have test certificates, from reputed test house, valid for the duration of the performance test.
1.2 1.3
1.4
1.5
2.0
Spec No.
TCE.5657A-C-500-002

INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM PERFORMANCE GUARANTEE
1.0
MEASUREMENT SYSTEM (MS)
1.1
2.0 2.1
Accuracy of each instrument shall be as specified in Section-D 5.3 & D-5.4 of specification.
PLC SYSTEM CLOSED LOOP CONTROL SYSTEM (CLCS)
2.1.1 2.1.2
The control system shall be capable of regulating the control devices to achieve the performance guarantees specified below. Control range for the guaranteed limits specified in para 2.1.3 shall be from 15% of full load to turbine control VWO condition. These limits shall be applicable for firing of either fuel namely, coal or fuel oil or in any combination. These limits shall also be applicable for various modes of operations of co-ordinated master control specified in the control system.
INTERLOCK, PROTECTION AND SEQUENTIAL CONTROL SYSTEM
2.2
The BIDDER shall guarantee the proper functioning of interlock, protection and sequential control system as specified in Section-D 6.3 and D 6.4 of specification. 2.3
DATA BUS SYSTEM (DBS)
The BIDDER shall guarantee that the data bus system shall not be overloaded (above 50%) even under peak data transfer load. The response time as specified in Section-D 6.3 of specification shall also be guaranteed. 2.4
HUMAN-MACHINE INTERFACING SYSTEM
The BIDDER shall guarantee the proper functioning of HMI system & Control Engineers interfacing equipment as specified in Section-D 6.3 & D 6.4 of specification.
3.0 PLC BASED CONTROL SYSTEM(S)
The BIDDER shall guarantee the proper functioning of all PLC based control system including all sub-systems namely, PLC Controller, HMI system, Interfacings, etc. as specified in Section-D 5.3 & D 5.4 of specification.
4.0 SOFTWARE PACKAGES
The BIDDER shall guarantee the proper implementation and functioning of all Software packages required for different control systems namely, PLC type control system etc. included in the scope.
5.0 AUXILIARY POWER SUPPLY SYSTEM (APSS)
Spec No.
TCE.5657A-C-500-002

The BIDDER shall guarantee the proper functioning of auxiliary power supply system as specified in Section-D 6.2 of specification.
6.0 LOCAL INSTRUMENTS /PANEL MOUNTED HARDWARES/ FINAL CONTROL ELEMENTS
All analysers, indicators and switches like pressure switches, level switches, control switches, selector switches, relays, panel mounted items like digital display unit, etc. and final control elements like control valves / control dampers, etc., shall be guaranteed for proper functioning within an accuracy as specified.
7.0 LARGE VIDEO SCREEN / VDU MONITORS
All equipment shall be guaranteed for proper functioning as specified in Section-D 6.4 of specification.
8.0 WATER ANALYSIS SYSTEM
The BIDDER shall guarantee the proper functioning of water analysis system as specified in Section-D 6.4 of specification.
9.0 VIBRATION MONITORING SYSTEM
The BIDDER shall guarantee the proper functioning of the Vibration monitoring system as specified in Section-D 6.4 of specification.
10.0 COMMUNICATION LINKS
Bidder shall note and confirm to the successful implementation of all the specified communication links among different Control & Monitoring systems like PLC Controls under the scope of this specification. All the links shall be redundant and Bidirectional and shall be implemented through Fibre Optic cables and run in two physically separate conduits.
11.0 TOTAL SYSTEM AVAILABILITY
11.1 11.2
12.0
The BIDDER shall guarantee the availability of PLC Based Control systems for minimum 99.7% on an annual basis and demonstrating the same. The method of calculating the total system availability shall be as specified in SectionD 6.5 of specification.
PERFORMANCE
The BIDDER shall guarantee that the goods furnished by him shall be in full accordance with the requirements of the enquiry specifications.
13.0 QUALITY
Spec No.
TCE.5657A-C-500-002

13.1
The BIDDER warrants that the goods are new and of high quality and that the goods will be free of defects in design, materials or workmanship. Bidder shall warranty the same for a period of twelve (12) months from the date of taking over of the plant. Bidder shall guarantee the specified requirements for microprocessor based systems supplied by him.
13.2
Spec No.
TCE.5657A-C-500-002

INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM - TABLE 1 TERMINAL POINTS
Design / Engineering
BOP BOP
Volume V SECTION: D6 SHEET 1 OF 5
Sl. no.
1.0 1.1 1.2
Package / Activity
Coal handling system All field devices & instruments PLC system for CHS (With 1nos. Of operator station & 1no. Of Engineering station) Remote I/Os at main CHP substation, wagon tippler substation, bunker floor PMCC room and air compressors. Redundant fiber optic cables between PLC and remote I/O Control desk in CHP control room and wagon tippler control room. Local control panel / DB local control panel for magnetic separator, metal detector, apron feeder, belt weigher, sump pump, bunker level indicators, travelling tripper, dust extraction / dust suppression / ventilation fan. Equipment mounted PLC based control systems for wagon tippler & side arm charger and stacker / reclaimer Redundant communication link between a) PLCs of stacker reclaimers and CHP main PLC b) PLC wagon tippler, side arm charger and main CHP PLC Bunker level indicator signals to DCS - cabling to DCS Cabling for master clock signal from master clock to PLC system UPS for complete I&C system Communication link between DCS and PLC system Redundant fiber optic cables from CHP main PLC to DCS corresponding, to OPC link, including media converters, LIUs and patch cords at both ends of the link. I&C cabling for entire CHS package including JBs, cable trays, etc.
Supply
BOP BOP
Erection
BOP BOP
Commissioning
BOP BOP
1.3
BOP
BOP
BOP
BOP
1.4 1.5
BOP BOP
BOP BOP
BOP BOP
BOP BOP
1.6
BOP
BOP
BOP
BOP
1.7
BOP
BOP
BOP
BOP
1.8
BOP
BOP
BOP
BOP
1.9 1.10 1.11 1.12
BTG BTG BOP BTG
BTG BTG BOP BTG
BTG BTG BOP BTG
BTG BTG BOP BTG
1.13
BTG
BTG
BTG
BTG
1.14
BOP
BOP
BOP
BOP
Spec No.
TCE.5657A-C-500-002

BOP
Sl. no.
1.15
Package / Activity
Cabling between CHS MCC to PLC DM Water plant & Effluent treatment plant Complete filed instrumentation and final control elements Installation hardware for instrumentation equipment PLC System with 1 nos. operator station and 1 no. of engineering station based local control panel Programming station for the PLC station Control desk DM control room Complete I&C cabling including JB's, Cable trays, etc. for the DM plant UPS for DM water plant & Effluent treatment plant PLC based I&C system Cabling for master clock signal from master clock system to PLC Cabling between DM Plant MCC to PLC RESERVOIR INTAKE WATER SYSTEM Complete filed instrumentation and final control elements Installation hardware for instrumentation equipment PLC based local control panel LCD keypad operated Complete I&C cabling including JB's, Cable trays, etc. Redundant fiber optic cables from Reservoir intake water system PLC to DM water system PLC, corresponding to OPC link including media converter, LIUs and patch cords at both ends of the link UPS for Reservoir intake water PLC based I&C system Cabling between Reservoir intake MCC to PLC
Supply
BOP
Erection
BOP
Commissioning
BOP
2.0 2.1 2.2 2.3 2.4 2.5 2.6
BOP BOP BOP BOP BOP BOP
2.7
BOP
BOP
BOP
BOP
2.8 2.9
BTG BTG
BTG BTG
BTG BTG
BTG BTG
3.0 3.1 3.2 3.3 3.4
BOP BOP BOP BOP
BOP BOP BOP BOP
BOP BOP BOP BOP
BOP BOP BOP BOP
3.5
BOP
BOP
BOP
BOP
3.6 3.7
BOP BOP
BOP BOP
BOP BOP
BOP BOP
Spec No.
TCE.5657A-C-500-002

Sl. no.
Package / Activity
Raw water & pre-treatment system Complete filed instrumentation and final control elements Installation hardware for instrumentation equipment PLC based local control panel LCD keypad operated Complete I&C cabling including JB's, Cable trays, etc. Redundant fiber optic cables from Reservoir intake water system PLC to DM water system PLC, corresponding to OPC link including media converter, LIUs and patch cords at both ends of the link UPS for Reservoir intake water PLC based I&C system Cabling between Raw water MCC to PLC Circulating water / auxiliary cooling water Field instruments and associated instrument installation hardware except CW header Field instruments and associated instrument installation hardware for CW header DCS operator station and I/O modules in CW / ACW pump house I&C cabling where both ends are BTG equipment (eg. Field instruments) I&C cabling where at least one end of cable connects to BTG equipment (MCC, hardwired annunciation system and CW header instruments) Cabling for master clock signal from master clock system to PLC
Supply
Erection
Commissioning
4.0 4.1 4.2 4.3 4.4
BOP BOP BOP BOP
BOP BOP BOP BOP
BOP BOP BOP BOP
BOP BOP BOP BOP
4.5
BOP
BOP
BOP
BOP
4.6 4.7
BOP BOP
BOP BOP
BOP BOP
BOP BOP
5.0
5.1
BTG
BTG
BTG
BTG
5.2
BTG
BTG
BTG
BTG
5.3
BTG
BTG
BTG
BTG
5.4
BTG
BTG
BTG
BTG
5.5
BTG
BTG
BTG
BTG
5.6
BTG
BTG
BTG
BTG
6.0
Ash handling system
Spec No.
TCE.5657A-C-500-002

BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP
Sl. no.
6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10
Package / Activity
All field devices & instruments along with Installation hardware AHS PLC (With 1 nos. Of operator station & 1no. Of Engineering station) Slurry system PLC LCPs for Bottom ash handling system LCPs of bottom ash handling system Local control panel for Silo unloading system Local control panel for Coarse ash handling system Remote I/O as required Control desk in AHS control room Redundant serial link between ash water & slurry PLC to AHS PLC Bus cabling between remote I/Os and ash handling system PLC UPS for PLC based I&C systems Complete I&C cabling including JBs, cable trays, etc. Communication link between DCS and PLC system Redundant fiber optic cables from AHS PLC to DCS corresponding, to OPC link, including media converters, LIUs and patch cords at both ends of the link. Cabling for master clock signal from master clock system to PLC PLC / microprocessor based control system for air compressor Communication link between air compressor PLC and AHS PLC system
Supply
Erection
Commissioning
6.11 6.12 6.13 6.14
BOP BOP BOP BTG
BOP BOP BOP BTG
BOP BOP BOP BTG
BOP BOP BOP BTG
6.15
BTG
BTG
BTG
BTG
6.16
BTG
BTG
BTG
BTG
6.17
BOP
BOP
BOP
BOP
6.18
BOP
BOP
BOP
BOP
7.0
GENERAL
Spec No.
TCE.5657A-C-500-002

Sl. no.
Package / Activity
Cable link between the slave clocks and the PLC system across the plant [BTG & BOP PLC's] including master and slave clock Redundant fiber optic cables from BOP / BTG PLC's to DCS corresponding, to OPC link, including media converters, LIUs and patch cords at both ends of the link. Hardwired signal exchange from BOP to BTG DCS cabling I&C cabling where at least one end of cable connects to BTG equipment (MCC, etc)
Supply
Erection
Commissioning
7.1
BTG
BTG
BTG
BTG
7.2
BTG
BTG
BTG
BTG
7.3 7.4
BTG BTG
BTG BTG
BTG BTG
BTG BTG
Spec No.
TCE.5657A-C-500-002

INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TABLE 2
Sl. No. 1 2 3 4 5 6
System / Equipment Reservoir intake Water Intake System Raw Water & PreTreatment Plant Coal Handling Plant Ash Handling Plant DM Water /Effluent Treatment Plant Other Utility Plants
Control System Hardware PLC Based Control System PLC Based Control System PLC Based Control System PLC Based Control System PLC Based Control System PLC Based Control System
Interfacing with Plant DCS Note 1 Note 1 Note 1 Note 1 Note 1 Note1
Remarks
Plant common Plant common Plant common Plant common Plant common Plant common
NOTES: 1 Communication link between Plant common DCS & PLC control is redundant bi- directional OPC communication link with TCP-I/P protocol.
Spec No.
TCE.5657A-C-500-002

TABLE-3: CODES AND STANDARDS Instrumentation Symbols and identification. Binary Logic Diagrams for Process Operation Graphic symbols for DCS, shared display inst. logic & Comp. System Environmental Conditions Control Valve Sizing Control Valve Procedure Capacity Test Uniform Face Two Face Dimensions for Flanged Globe Style CV Bodies Diagrams, Charts, Tables Industrial Process Control Valves Graphical Symbols for Diagrams, Binary Logic Elements Operating Conditions for Industrial Process Meas. & Control Equipment. Electromagnetic Compatibility for Industrial Process Measurement Preparation of Function Chart for Control System Industrial Measurement & Control Terms & definition Vibration, Axial Position & Bearing Temperature Monitoring Systems Plain End Steel Tubes, Welded & Seamless General Table Dimensions & Masses / Length Measurement of Fluid Flow by Means of Orifice Plates & Nozzles Pipe Threads Quality Control Standard for Control Valves Seat Leakage Thermocouples Measurement & Control, Electrical sensors, Elec. Position sensors & Sig. Converters for IS two wire DC systems. Industrial Platinum. RTD Measurement of Fluid Flow by Meter Run Temperature Measurement Degree of Protection by Enclosure Electrical Apparatus for Explosive Gas Standards for Cables Process control security requirements ISA S 5.1 ISA S 5.2 ISA S 5.3 ISA S 71.04 ISA S 75.01 ISA S 75.02 ISA S 75.03 IEC 113 IEC 534 IEC 617-12 IEC 654 IEC 801 IEC 848 IEC 902 API 670 ISO 4200 ISO 5167 ANSI B 2.1 ANSI FCI 70.02 ANSI B 16.104 ISA MC 96.1 / ASTM E 230-03 DIN 19243 DIN 43760/ IEC 751 ISO 5167 ANSI MC 96.1 / IEC 751 IEC 529 IEC IEC IEC 62443
Spec No.
TCE.5657A-C-500-002

TABLE-4: I&C DATA TO BE FURNISHED WITH THE BID The following documents shall be furnished along with Bid for utility packages.
SL. NO 1.0 DATA TO BE FURNISHED Reference list with capacity of plant, year of commissioning & control system implemented along with minimum two (2) nos. users certificate for the PLC system configuration offered.
2.0 3.0 4.0 5.0 6.0
Control philosophy / operation philosophy / Design philosophy / Redundancy philosophy for utility control system. Grouping philosophy of control loops in controllers PLC configuration drawing / system architecture drawings including MMI. Local control room layout Flow diagram / P&ID (Process and Instrumentation drawings) indicating primary and secondary Instruments and the destination/functionality of the signals for main Plant. Clause wise confirmation / deviation list with respect to I & C requirements specified in sections. Duly signed schedule of performance guarantees. System Architecture highlighting the applicable standards for control and information domain; networking and security features; graphic capabilities data exchange procedure, engineering tool, system capability such as graphic displays, trending, archiving, history, logs, reports, etc. List of software. Confirmation certificate for the latest version of software and hardware offered. Codes and applicable standards followed for the project. List of closed loop controls included. List of open loop controls included. Evidence that the offered PLC system is upgradable and evolutionary in both hardware and software Letter confirming support of spares for 15 years for the PLC system supplied.
7.0 8.0 9.0
10.0 11.0 12.0 13.0 14.0 15.0 16.0
ISSUE R0
TCE FORM NO. 120R2
Spec No.
TCE.5657A-C-500-002

INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TABLE 5 TABLE- 5: ESSENTIAL SPARES
SL. NO.
ITEM/DESCRIPTION
Field Instruments (Gauges, Switches, transmitters, radar type level instruments), Solenoid Valves
QUANTITY / UNIT
1.0
10% for each type and range but minimum 2 nos.
2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7
PLC CONTROL SYSTEM (Each) Power Supply modules/Cards Network Cards Communication Interface Cards All other electronic modules I/O Cards (Each Type) Controller card Interposing Relay
Panels, local panels, system /marshalling cabinets for Main Plant
5% for each type and range but minimum 1 no 5% for each type and range but minimum 1 no 5% for each type and range but minimum 1 no 5% for each type and range but minimum 1 no 5% for each type and range but minimum 2 nos each 2 nos. 10% of total quantity
3.0 3.1 3.2 3.3
Fuses of each type and rating MCB of each type and rating Male/female parts of pre-fabricated cables
Control valves and Pneumatic Block valves (for each valve): For main Plant Plug and steam assembly
50 nos 10 nos 6 nos. of each type
4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7
1 no. of each type 1 no. of each type 1 no. of each type 1 no. of each type 1 no. of each type 2 no. of each size 1 no. or 10% of total qty. whichever is higher.
seat ring packing and gaskets pilot relay actuator diaphragm O-rings Control valves (Electrical operated- if supplied) Interfacing modules Solenoid Valve Solenoid Valve Coil
5.0 5.1
Minimum 01 no. or 10% of each rating of total quantity whichever is higher.

ISSUE R0
TCE FORM NO. 120R2
Spec No.
TCE.5657A-C-500-002

INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM TABLE 5 TABLE- 5: ESSENTIAL SPARES
SL. NO.
ITEM/DESCRIPTION
QUANTITY / UNIT
6.0 6.1
Vibration Monitoring System Vibration pickups with cable 1 no. or 10% of total quantity whichever is higher for each type and range.
7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7
Analyser Electronic cards Conductivity cells/ pH cells & electrodes Chemical Reagents Resin Column Sampling system Accessories Pressure Control valve, Minimum 1 no or 10% of total quantity whichever is higher for each type Minimum 1 no or 10% of total quantity whichever is higher for each type 1no for each type and range 1no for each type and range Suitable for 6 charges/usages 2 nos
Thermometer, Temperature switch, Pressure indicator, Solenoid valve, Rotameter, Flow switch. NOTE: SPARES requirement for any equipment/system not specified above, the Contractor shall supply the spares for the supplied system/sub-system/instruments as per the manufacturers recommendation.
ISSUE R0
TCE FORM NO. 120R2
Spec No.
TCE.5657A-C-500-002
A SIZE, MATERIAL & RATING FOR IMPULSE PIPE/TUBE AND FITTINGS SIZE PIPE (REF. SL.NO. 2) ANSI RATING ANSI RATING
IN SH.NO. 1)
SERVICE TUBE
SL . N O.
IMPULSE TUBE MATERIAL (REF. L.NO. 1) IN SH.NO. 1)
IMPULSE PIPE MATERIAL
IMPULSE LINE FITTING MATERIAL
INSTRUMEN TS VALVES MATERIAL
1. SS 316 3000 LBS
WATER SYSTEM ASTM-A-106Gr-B (CARBON STEEL)
SCH.80 21.34 mm OD
12.7 mm 00X1.65 MM THK
ASTM-105Gr-II
ASTM-A-62 BRONZE BODY 150 LBS
TABLE-7: SIZE, MATERIAL & RATING FOR IMPULSE PIPES / TUBES & FITTINGS
Volume V
SECTION: D6
SHEET 1 OF 5
ISSUE R0
TCE FORM NO. 120R2
Spec No.
TCE.5657A-C-500-002
2. 12.7 MM ODx1.65 mm THK (GALVANISED ) 12.7 MM ODx1.65 mm THK SS 316 IS 1239 HEAVY CLASS (BLACK) SS 316
INSTRUME NT AIR SYSTEM 3000 LBS
IS 1239 HEAVY CLASS ASTM-A105-Gr-II
ASTM-B-62Gr-II 150 LBS
SCH.40 21.3 mm (PIPE THOUGH OUT) ASTM-A105-Gr-II 3000 LBS
B. SIZE, MATERIAL & RATING FOR IMPULSE PIPES / TUBES & FITTINGS
3.
SERVICE AIR SYSTEM
SCH.40 21.3 mm OD
ASTM-A105-Gr-II 150 LBS
Volume V
SECTION: D6
SHEET 2 OF 5
ISSUE R0
TCE FORM NO. 120R2
Spec No.
TCE.5657A-C-500-002
A SIZE, MATERIAL & RATING FOR IMPULSE PIPE/TUBE AND FITTINGS SIZE MATERIAL MATERIAL PIPE TUBE (REF. SL.NO. 1 IN SH.NO. 1) IN SH.NO. 1) SCH. 40 21.3 mm 0D SS 316 3000 LBS. 12.7 mm 0DX1.65 mm THK ASTM-A-312TP-316 (STAINLESS STEEL) ASTM-A182-Gr-IF6a ASTM-A-182Gr-F6a 150 LBS ANSI RATING (REF. SL.NO. 2 ANSI RATING IMPULSE TUBE IMPULSE PIPE IMPULSE LINE FITTING MATERIAL INSTRUMEN TS VALVES MATERIAL
S L. N O .
SERVIC E
4.
MAKE UP WATER SYSTE M 21.3 MM 0Dx2.77 MM THK * (PIPE THROUG HOUT) SS 316 ASTM-A-312TP-316 (STAINLESS STEEL)
C. SIZE, MATERIAL & RATING FOR IMPULSE PIPES / TUBES & FITTINGS
NOTES: 1.0 IMPULSE PIPE THICKNESS SHALL BE SELECTED AS PER ANSI B 36.10 BASED ON THE SCHEDULE INDICATED AGAINST EACH SERVICE.
5.
SAMPLI NG SYSTE M
AS APPLICABLE TO SERVICE UNDER SL.NO. 1 TO 12.
Volume V
SECTION: D6
SHEET 3 OF 5
ISSUE R0
TCE FORM NO. 120R2
Spec No.
TCE.5657A-C-500-002

2.0 WHEREVER IMPULSE TUBES ARE PROVIDED, ALL THE FITTINGS REQUIRED FOR THESE SHALL BE SS 316. IMPULSE LINE/TUBE FITTINGS & ACCESSORIES 1.0 NIPPLE SHALL BE PROVIDED FOR ROOT VALVE SIZE MORE THAN INCH AND NIPPLE SIZE SHALL BE SAME AS THE ROOT VALVE SIZE. REDUCER/ADAPTER SHALL BE PROVIDED TO SUIT INSTRUMENT CONNECTION, WHERE NIPPLE, ROOT VALVE SIZE IS MORE THAN INCH. BULK HEAD FITTING SOCKET WELDED TYPE TO BE PROVIDED AT INSTRUMENT RACK/ ENCLOSURE. ALL INSTRUMENT IMPULSE TUBE SIZE SHOULD BE SS. IMPULSE TUBE SHALL BE TIG WELDED FROM ROOT VALVE TO INSTRUMENTS. ANCHOR FASTENERS SHALL BE PROVIDED FOR INSTALLATION OF STANDPIPE WHENEVER REQUIRED.PURGE LINE SHALL BE CONNECTED NEAR ROOT VALVE ONLY. PURGE ROTAMETER, BACKPRESSURE REGULATOR, AIR FILTER REGULATOR FOR PURGE AIR SHALL BE LOCATED NEAR INSTRUMENT. 3.0 3.1 FITTINGS : ALL FITTINGS EXCEPT THE LAST FITTING CONNECTING TO THE INSTRUMENT SHALL BE SOCKET WELDED. THE SIZE OF THE FITTINGS SHALL BE SAME AS THE IMPULSE LINE SIZE. THE FITTING CONNECTING TO THE INSTRUMENT SHALL HAVE A SIZE AND THREAD TO SUIT THE INSTRUMENT CONNECTION. DRAIN DRAIN SHALL BE PROVIDED FOR ALL WATER AND NONINFLAMMABLE / NON-CORROSIVE FLUIDS ONLY. DRAIN VALVE TWO NUMBERS OF GLOBE DRAIN VALVES SHALL BE FOR O PROCESS CONDITIONS OF 425 C OR 62 BAR AND HIGHER. ONE NUMBER GLOBE DRAIN VALVE SHALL BE PROVIDED FOR O PROCESS CONDITIONS OF LESS THAN 425 C AND 62 BAR THE VALVE SIZE SHALL BE SAME AS IMPULSE PIPING/TUBING SIZE. FUNNEL WITH DRAIN HEADER
1.0
3.2
4.0 4.1
5.0 5.1 5.2 5.3
6.0
ISSUE R0
TCE FORM NO. 120R2
Spec No.
TCE.5657A-C-500-002

6.1
THIS SHALL BE PROVIDED IN THE RACKS FOR BLOWING/DRAINING OUT THE PROCESS FLUID IN THE IMPULSE TUBINGS. THE DRAIN HEADER OF THE RACK SHALL BE CONNECTED TO THE NEAREST FLOOR LEVEL OR PLANT DRAIN.
6.2 6.3
THE SIZE OF THE DRAIN HEADER SHALL BE 1. WHEN INSTRUMENTS ARE MOUNTED LOCAL TO THE TAPPING POINT AND ARE NOT MOUNTED IN THE RACK, OR PANEL OR ENCLOSURE. THE DRAINS SHALL BE CONNECTED TO THE NEAREST FLOOR LEVEL OR PLANT DRAIN. INSTRUMENT TYPE OF THE VALVE SHALL BE NEEDLE VALVE WITH BUILT IN DRAIN VALVE. SIZING OF THE VALVE SHALL BE . RIGHT/LEFT THREADED FITTINGS : THIS SHALL BE PROVIDED FOR INSTALLATION/REMOVAL OF INSTRUMENTS WITHOUT DISTURBING THE TUBING/PIPING. A SUITABLE ADAPTER SHALL BE PROVIDED TO INSTALL THE INSTRUMENTS ON RIGHT-LEFT THREADED FITTING A VENT LINE WITH A ISOLATION VALVE SHALL BE PROVIDED IN THE INSTRUMENT RACK FOR AIR AND COMPRESIBLE FLUIDS OR OTHERWISE IF THE INSTALLATION CALL FOR EG., FOR LIQUID SERVICE WHERE THE TRANSMITTER IS LOCATED AT A HIGHER ELEVATION THAN THE TAPPING POINT.
7.0 7.1
7.2 8.0 8.1
9.0
10.0
ISSUE R0
TCE FORM NO. 120R2

Spec No.
TCE.5657A-C-500-002
Volume V SECTION: D6
SHEET 1 OF 23
TABLE 7: GUIDELINES FOR PROVISION OF INSTRUMENTS AND SPECIFICATIONS 1.0 GENERAL GUIDELINES FOR PROVISION OF INSTRUMENTS / TAP POINTS Instrumentation and control system shall be supplied in accordance with the various sections of the specification. 1.1 Pressure indicators shall be provided for (a) (b) (c) (d) 1.2 Suction and discharge lines of pumps, including on header section, if two or more pumps are employed for the same service. Suction and discharge lines of fans, including on header section if 2 or more fans are employed for the same service. All input and output lines of process equipment. Inlets and outlets of heat exchangers and desuper-heaters.
Pressure Switches shall be provided (a) On all process lines / Equipment where parameter abnormality/status including pre trips alarms to be communicated to the operator in control room. For all permissive conditions governed by safety operation of the equipment. e.g. pr. adequate, conditions. For all interlock conditions which governs starting of standby equipment or subsequent equipment for safety operation of the system. Inlet and outlet of filters/strainers.
(b) (c) . (d) 1.3
Differential Pressure Switches (Indicating type) shall be provided (a) (b) Across filters/strainers for remote monitoring Across condenser for remote monitoring and interlocks
1.4
Pressure Transmitter shall be provided For all control applications and as demand by the process. It shall be noted that for all critical control applications, 03(Three) transmitters shall be provided. All Drive/equipment protection trip due to pressure shall be derived from LVM of transmitter signal and not through switches.
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1.5
Differential Pressure Transmitter shall be provided For all the requirements of Diff. pressure, flow, level measurement All Drive/equipment protection trip shall be derived from LVM of transmitter signal and not through switches.
1.6
Temperature indicators (Thermometers) shall be provided (a) (b) (c) (d ) (e ) On all process lines where local indication is warranted by the system either for monitoring or testing. On the inlet/outlet equipment such as desuper-heaters, Heat Exchangers & Coolers for both the fluid media. Differential temperature indicator shall be provided across BFP suction and discharge service Capillary type temperature indicators shall be used in vibration prone areas. Thermowell shall be provided for all temperature indicators.
1.7
Temperature Elements :. Thermowells shall be provided for mounting of all temperature elements. (a) (b) All thermocouples and RTDs as required for implementation of control & monitoring shall be supplied The elements shall be duplex type with integral thermowell (except for metal thermocouples). K-type for temperature upto 600deg.C and R-type for temperature above 600 Deg.C. For metal thermocouples suitable pads with clamps etc. shall be provided. All temperature elements shall be supplied with associated junction box Compensating cable shall be provided with all thermocouples (i) From T/C to field junction box and to system cabinets. Six nos. ( 2 nos. per phase) Resistance temperature detectors (RTDs) shall be provided for all 6.6 kV motors, for winding temperature monitoring. Each element shall be 3 wire type, duplex with thermowell assembly. RTDs shall be terminated in the external terminal box, for connection to DCS system. 1 no. duplex k-type thermocouple shall be provided for each bearing of HT equipment. For all alarm and Trip application, a LVM of temperature element shall be used. Temperature switches are not acceptable.
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(h)
5 to 15 meter long thermocouple (MTM type) shall be provided in high surrounding temperature zone (e. g. combustor, FBHE, Sealpot etc) areas. The termination of the thermocouples shall be at low temperature area.
1.8
Level gauges shall be provided on all tanks and the maximum length of one gauge glass shall not exceed 1 metre. The gauge glasses shall be stacked to cover the complete height of the tanks including over flow level. There shall be an overlap of minimum 150 mm, when more than one level gauge is required. Suitable platforms shall be provided for purpose of taking measurements and during maintenance. Level switches : The instrument shall be provided : (a) (b) On all equipments (storage vessel) where parameter status has to be communicated to the operator in the control room. All permissive, and interlock conditions governed by the safety operation of the equipment. .
1.9
The instrument shall be external float type with SW connection with isolation facility for surface mounted tanks and top mounted with steel pipe for all sumps. Steel pipes will be provided with adequate supports. Necessary mounting clearance with approach platforms shall be provided. 1.10 Level Transmitters (a) Level transmitters shall be provided on process equipments where continuous remote monitoring and/or control of level is envisaged. The instrument will be displacement type for all high pressure and vacuum applications involving two phase media and range of measurement or control is within 32 inches. (b) The instrument will be differential pressure type for other applications for ranges exceeding 32 inches. Continuous level measurement shall be provided for CW forebay, Clarifier water tank, Condensate Storage tank, ACW over head tank etc. 1.11 Flow Glasses shall be provided at the outlet of the pipe lines and shall be employed under the following conditions: (a) Coolant from the equipment (coolers).
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(b) (c) 1.12 1.13 1.14
The instrument shall be rotary type with glass mounted for indication. Upto 6 inch on-line flow glasses shall be supplied and above 6 inch bypass type flow glasses shall be provided.
Speed Measurement shall be provided, where variable speed drives are to be controlled from remote . Flow elements shall be provided as detailed in Table-9. Pneumatically operated control valves shall be provided for all control application. If the process demands any other control, then control valves shall be provided for those applications also. Where a single control valve can not meet the turned down ratio as dictated by the process, control valves with split range application shall be provided. All bypass valves of control valves shall be motor operated valves suitable for inching operation provided with position transmitters. All integrated bypass valves shall be motor operated. Pressure test points & drains shall be provided across each control valve . Solenoid valves shall be provided for all pneumatic control valves hooked up with process interlock requirements and where direct tripping is involved. Direct operated solenoid valves shall not be used for the process lines size more than 1. For line sizes more than 1 pneumatic block vales shall be used. The number of ways for solenoid valve shall be provided as indicated below:(a) On line two (2) way solenoid valves shall be provided, where process line of less than 2 inch with low pressure(below 10 Kg/cm2 ) & temperature application is involved. Three (3) way solenoid valve shall be provided commonly, where the low pressure(below 10Kg/cm2) is admitted or exhausted from a diaphragm valve or single acting cylinder. E.g.: Pneumatic operated spray water block valve. Four (4) way solenoid valve shall be provided for operating double acting cylinders. If applicable. E.g.: Pneumatically operated on-off type dampers. Dual coil Solenoid valves shall be supplied for equipment trips and single coil for balance.
1.15 1.16
(b)
(c ) (d) 1.17
Position Transmitters shall be provided for all control valves and including valves, control dampers where modulating/inching operation is required. Position transmitters shall be non-contact proximity type only. Electro-Pneumatic Converters shall be provided for all pneumatically operated control valves, power cylinders etc., for converting controller output of 4-20 mA to 3-15 PSI for interfacing with pneumatic actuators.
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1.19
Air Filter Regulators along with gauges shall be provided in each of the (a) (b) (c ) Air supply line to valve positioners /power cylinders Air supply line to electric to pneumatic converters Air supply line to pneumatic interlocked block valves
1.20
Interposing relay (To be mounted in IPR panel located at local control room) for interface to the following: LTMCC Relays with contact rating of 0.2Amps (two relays per drive) Integral Starter(for all valves; two relays per valve) - Relays with contact rating of 0.2Amps. HTMCC (two relays per drive) Relays with contact rating of 2amps. Solenoid valve (two relays per valve) - Relays with contact rating of 2Amps. Hardwired signal exchange as required.
1.21
Analytical Instruments (a) (b) Withdrawal Type Conductivity Analyser shall be provided at condenser hotwell along with necessary mounting arrangements/ accessories as required. For other analytical measurements, the sampling tap points as called in Table-11 of the specification, shall be provided.
1.22
Vibration Measurements: Complete vibration measurement system (microprocessor based) for all bearings on both X-Y directions, shall be provided. The vibration sensors in horizontal and vertical direction and vibration monitors shall be provided for all HT equipment. Vibration monitors shall be located in the central control room. The vibration signals shall be made available at applicable controls system [PLC] for monitoring and protection purpose. Vibration pads shall be provided on all HT equipment for mounting the vibration sensors. Junction Box (JB) /Field Termination cabinets (FTC)
1.23
1.23.1 Junction Boxes shall be provided for a) b) c) d) Shall be Double door type and not of double leaf type with cable entry from bottom. Termination of all sensors located equipment wise. Termination of Duplex thermocouples/RTDS. Termination of limit switch, torque switch, position transmitter and
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e) f) g)
control demand, independently for each valve. Additional field JB shall be provided where there is a length limitation for the signal cable from sensor. 10% spare terminals shall be provided in each JB. Only spring-loaded terminals shall be used.
1.23.2 Field Termination cabinets : Areawise termination of cables from JBs. FTC shall be double door type and not double leaf type with cable entry from bottom. 20% spare terminals shall be provided in each FTC. Only spring-loaded terminals shall be used for termination. 1.24 Instrumentation & control cables and Prefabricated Cables termination guidelines (i) (ii) (iii) To connect field instruments to field junction boxes/Local Panels. For switches, both the SPDT contacts of switches shall be wired upto the J.B. To connect limit switches, torque switches and position transmitters to their respective field junction boxes. Compensating cable shall be supplied for connection between the element and the respective junction boxes / system cabinets as per guidelines. Prefabricated cable for connecting between system cabinets, marshalling cabinet to system cabinet, system cabinet to Relay Rack, etc. Cabling between interposing relay cabinet to the marshalling cabinet located in MCC room. Heat Resistant Instrumentation cable (PTFE) with armouring shall be used near Combustor, Turbine and other hot zone area.
(iv)
(v) (vi)
1.25
Auxiliary Power Supply System (APSS) The power supply system shall confirm to the requirements indicated in Electrical specification. The power requirements of the systems shall be estimated and the power supply requirement shall worked out. Based on the requirement, the power supply scheme along with distribution board shall be designed and provided. All power supply in the system cabinets shall be redundant and have auto-change over facility or diode auctioning.
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For AC Power distribution, the redundant power supply change over scheme shall only be provided in distribution board and not at the equipment end. Power supply to all the other panels like Vibration Monitoring panel, PLC system shall be redundant with bumpless changeover. 1.26 Instrument Air Supply System Instrument air requirement shall be worked out for the complete plant. Based on the estimation, compressors along with distribution shall be designed and provided. 1.27 Impulse pipes/tubes & fittings (a) Impulse pipes, fittings and air supply and signal piping/tubing shall be supplied for all the instruments under the scope of this specification. The general specification is given in Table-7. Instrument isolation valves (needle type SS) before manifold on the impulse line in addition to the root valves for all Instruments. Globe valves are to be used for all clarified water tapings. Gunmetal valves are not allowed for any instrumentation applications. All instrumentation Isolation valve should have drain facility.
(b)
(c ) (d) 1.28
Selection of Ranges for Instruments The ranges of the instruments shall be selected based on the following philosophy indicated below: (a) For pressure and vacuum measurements, the maximum operating pressure will be within 70 to 80% of the maximum scale range. All pump suction measurement will cover the negative pressure range also and all vacuum measurements will cover the negative pressure as well as the positive pressure as the case may be. (b) (c) (d) For temperature measurement, the maximum operating temperature will be within 80 to 90% of the maximum scale range. For pressure switches and temperature switches, the set points shall fall within 40% to 70% of the scale range selected. For level measurement, the maximum of the range will cover the overflow point or six inches below the top of the vessel and the minimum of the range will be six inches above the bottom of the vessel. Also, the gauge glasses will be stacked with overlap to cover permissive, alarm and trip levels.
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(e)
For flow measurement, the maximum range shall be fixed at about 10 to 15% above the maximum operating flow.
1.29
Pull cord, belt sway and zero speed switches A canopy made of 5mm M.S. plate shall be provided over the lever of each pull cord switch and for each belt sway switch so that spilled over coal lumps do not trip the belt by actuating the lever. Enclosure shall be provided for pull cord and belt sway switches. The degree of protection for all protection switches shall be IP-65. All switches shall have 2 NO & 2 NC potential free contacts. Pull-Cord Switches Pull Cord (manually reset type) emergency stop switches shall be located along both the sides of entire length of all conveyors. The spacing shall be at an interval of not exceeding 30 meters. Adequate length of PVC coated wire rope and all accessories shall be furnished. From either end of conveyor pull cord switches should not be more than 15m. Also a local trip indication (Cluster of LEDs) shall be provided with each pull cord switch. Pull cord switch shall have C.I. body with additional enclosure to prevent ingress of dust. Belt-Sway Switches Belt Sway limit switches (auto reset type) shall be furnished in pairs at periodic intervals of minimum 30m to limit belt sway to permissible extent. For any conveyor, however, minimum two pairs of switches shall be provided. These switches shall be placed not more than 15 m from either end of conveyor. Belt sway switch shall have C.I. body with additional enclosure to prevent ingress of dust. Non contact type zero speed switches Each conveyor shall be provided with a zero speed switch (auto reset type) at the tail end for sequential operation of the system. In case of belt speed falling below the tolerable limit, the same switch shall stop the conveyor. The speed setting should be adjustable. Necessary provision to be kept in control circuit to by-pass the switch during starting. Pull cord switch / Belt sway switch identification system The system shall identify the one or more operated pull cord / belt sway switch location and monitor the condition of the cable connecting the switches in series for open and shorted conditions. The system shall comprise sensor modules installed in the field switches and indicator / transmitter module to identify switch operated / cable healthy condition. The
1.30
1.31
1.32
1.33
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system output shall be connected to the PLC for identifying the operated switch location / cable condition to the operator on the VDU. The system shall be provided to cover all the conveyors from the mines to the bunker.
1.29 PG Test Points (a) Pressure, temperature [with thermowell] and flow test points shall be provided in line with performance test code requirements. In addition, pressure and temperature test points shall be provided for the following services: i) ii) iii) (b) (c) 1.30 At the discharge of all pumps and fans At the inlet and outlet of the heat exchangers for the fluid media involved At the inlet and outlet of each control valve
Pressure test points shall be complete with root valves and shall terminate with a nipple. Temperature test points shall be provided with thermowell along with a cap and chain.
Instruments for Performance Testing All instruments required for performance testing to prove the guaranteed performance of the Instrumentation and Control Equipment shall be in Contractors Scope. These test instruments shall have test certificates from reputed test house, valid for the duration of the performance test. Stand pipes required for hotwell, deaerator, heaters, GSC, drain pot, etc. shall be provided by Bidder.
1.31
CABLE TRAY GROUPING Separate cable tray shall be provided for instrumentation cables extension cables, flames scanner cables, MMI cables etc. instrumentation cables shall run through the top most cable tray Minimum distance of 500mm to 1000mm must be maintained between the instrumentation cable tray and the high heat zones where the temperature is 200 deg.C and above. All the control room cabinets , field JBs etc. shall have bottom cable entry.
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High heat resistant instrumentation cables (PTFE) with armouring Shall be used in and around the combustor, main Turbine & other hot zone areas in the plant.
2.0 2.1
SPECIFICATIONS FOR INSTRUMENTS TO BE SUPPLIED ARE AS FOLLOWS. Pressure Indicators Direct reading, pipe mounted Pressure gauges of aluminium casing (epoxy coated) with 4and1/2 inch phenolic dial (white dial with black numerals), 316 SS Bourbon tube, AISI 304movements and micrometer type adjustable aluminium pointer an accuracy of +0.5% of span including accessories like siphons for steam services, snubbers for pump discharge applications and chemical diaphragm for corrosive and oil services and name plate, etc. Material of accessories will be SS. IP65 or equivalent degree of protection for enclosure. Over range protection will be 50% above maximum pressure. Armoured capillary of 15 M shall be provided as required.
2.2
Pressure Switches Non indicating type, field mounted Pressure Switches of aluminium casing (epoxy coated), and 316 SS element and accuracy of +1% of span, including accessories like siphons for steam services, snubbers for pump discharge applications and chemical diaphragm for corrosive and oil services, name plate & mounting brackets. Material of accessories will be SS. Auto reset micro switch with internal adjustment For set values with 2 SPDT contacts rated for 0.2 A at 220 V DC. IP 65 or equivalent degree of protection for enclosure. Over range protection 50% above maximum pressure. Scale for setting shall be provided.
2.3
Pressure Transmitters (Smart) Micro-processor based indicating type (LCD display), rack mounted with accuracy of +0.2% of span, external zero and span adjustment, self diagnostics, temperature sensor for compensation. Power supply 24 V DC; output signal of 420 mA DC. IP 65 or equivalent degree of protection. Aluminium housing with epoxy coating, 316 SS sensing element. Accessories like snubbers for pump discharge applications and chemical diaphragm with 15 m PVC covered SS armoured capillary for corrosive and oil services, etc. Material for accessories will be SS. HART protocol output shall be available in each transmitter. Calibration facility shall be provided via HART communicator .
2.4
Differential Pressure Indicators
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Direct reading type, pipe mounted, bellows or diaphragm operated differential pressure indicators; aluminium casing (epoxy coated) with six (6) inch dial (white dial with black numerals), with micrometer type pointer, 316 SS pressure element; an accuracy of +0.5% of span including accessories like snubbers for pump discharge application, chemical diaphragm with 15 m PVC covered SS armoured capillary for each limb for corrosive and oil services and 5 way manifold & name plate, mounting brackets, etc. Material of accessories will be SS. IP 65 or equivalent degree of protection. Over range protection will be 50% above maximum pressure. 2.5 Differential Pressure Switches Bellows or diaphragm operated indicating field mounted type; aluminum casing (epoxy coated); 316 SS pressure element nylon movement; an accuracy of +1% of span within adjustable contact including accessories like snubbers for pump discharge applications, chemical diaphragm with 15 m capillary for each limb for all corrosive and oil services and 5 way manifold, name plate & mounting brackets, etc. Material of accessories will be SS. Auto reset micro switch with tamper proof external adjustable set values with 2 SPDT contacts rated for 0.2 A at 220 V DC. IP 65 or equivalent degree of protection over range protection 50% above maximum pressure. Repeatability shall be + 0.5% FSR. 2.6 Differential Pressure Transmitters (Smart) Micro-processor based indicating type (LCD display), rack mounted with accuracy of +0.2% of span, external zero and span adjustment. Self diagnostics, temperature sensor for compensation. Power supply 24 V DC; output signal of 420 mA DC. IP 65 or equivalent degree of protection. Aluminium housing with epoxy coating, haste alloy sensing element. Accessories like snubbers for pump discharge applications, chemical diaphragm with 10 m PVC covered SS armoured capillary for each limb for corrosive and oil services and 5 way manifold & name plate, etc. Material for accessories will be SS. Accuracy : +0.25% of FSR or better. Repeatability : +0.05% of FSR or better. Linearity :+0.1% of FSR or better. Hystersis: +0.1% of FSR or better. Remote communication with field communicator/ control system. HART protocol shall be available in each transmitter. Calibration facility shall be provided via HART communicator. 2.7 Thermometers Indicating type, field mounted, filled system with ten (10) metres SS capillary with SS armour and six (6) inch dial (white dial with black numerals with micrometer pointer) housed in aluminium casing (epoxy coated) with an accuracy of +1% of span, response time of 2-4 seconds, auto temperature calibration, linear calibration over the range and SS bulb with 316 SS thermowell having a process connection of M33 x 2 thread or 150 RF flanged. Material of accessories (name plates, mounting brackets, etc.) will be SS. IP 65 or equivalent degree of
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protection for enclosure. Thermowell with Hex head bar stock assembly. The thermowell construction shall meet the ANSI 19.3-1994 (latest) requirements. 2.8 Thermowells Pipe/equipment mounted temperature test wells of 316 SS with a process connection of M33x2 thread or 150 RF flanged. Accessories like name plate, plug with chain, etc. shall be provided. Material of accessories will be SS. Thermowell shall be hex head of barstock assembly. In case flanged wells are required for any specific application, the same shall be supplied as required. The thermowell construction shall meet the ANSI 19.3-1994 (latest) requirements. The thermowells shall be hardfaced/sterlited to avoid erosion for boiler area applications. 2.9 Thermocouple Assembly Duplex type with accuracy of +0.5% of span, response time of 2 to 6 sec, Spring loaded mineral insulated thermocouple assembly with 316 SS thermowell housed aluminium casing (epoxy coated) having a process connection of M33 x 2 thread or 150 RF flanged. Material of accessories (name plate, etc.) will be SS. IP 65 or equivalent degree of protection for enclosure. Thermowell with hex head (with screwed cover & SS chain) bar stock assembly with ungrounded junction. For metal temperature measurement, thermocouple pads weldable to MS pipes shall be provided with 15 m thermocouple extension wires. Element size shall be 18 AWG. Insulation resistance at 540oC shall not be less than 5 M ohms. Temperature devices provided with thermowell shall be calibrated with the associated thermowell as an assembly. The thermowell construction shall meet the ANSI 19.3-1994 (latest) requirements. All pent house thermocouples shall be supplied with 15mts flexible extension length. All bed thermocouples shall have solid tungsten carbide or SS440 protecting sheath. Thermocouple termination head shall be 300 mm above the pipe insulation to avoid cable damage in hot zones. 2.10 Resistance Temperature Detectors (RTD) Duplex PT-100 type with accuracy of +0.5% of span, response time 1-2 seconds; Spring loaded mineral insulated three (3) wire RTD assembly with 316 SS Thermowell housed in aluminium casing (epoxy coated) having a process connection of M33 x 2 thread or 150 RF flanged. IP 65 or equivalent degree of protection for enclosure. Material of accessories (name plate, etc.) will be SS. Thermowell with hex head with screwed cover & SS chain, barstock assembly. Element lead size will be 18 AWG. The insulation resistance at 540oC shall not be less than 5M ohms. Repeatability over full range shall be better than 0.02%. RTDs shall be ungrounded. RTD shall be supplied as an assembly complete with thermowell meeting ANSI 19.3-1994 (latest) requirements.
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2.11
Level Gauges Tubular type level gauges for low pressure upto 7 kg/cm2 & reflex type for high pressure water & steam services & vacuum services with automatic ball check valves, illuminator (240 AC), pyrex / borosilicate glass, mica shield, brass guard rods & brass holders. Material of accessories (name plate, etc.) will be SS. Tubular glass OD will be 5/8. Vent & drain valves shall be provided. Connection shall be screwed or flanged (ANSI class 150 RF). Enclosure shall be IP 65.
2.12
Level Switches External float operated level switches for tanks and vessels and top mounted level switches and underground tanks. The top mounted level switches shall be supplied with steel tubes to suit Purchasers requirement. Micro switch with 2 SPDT contacts rated for 0.2 A, 220 V DC. Material of float & float chord will be 316 SS & cage material shall be fabricated steel and the material of accessories will be SS. IP 65 or equivalent degree of protection for enclosure. Accessories like name plate, drain valve for external case type level switches, mating flange, gaskets (asbestos), fasteners, bolts & nuts, etc. shall be supplied. Conductivity type electronic Probe type level switches shall be supplied for Drain pots and for sump level. The required pressure vessel assembly for mounting probes are included in the scope.
2.13
Displacement type Level Transmitter Displacement type level transmitters of float length of 14 inches or 32 inches with an accuracy of +0.5% of span, 4-20 mA DC output (2 wire system), +24 V DC supply, isolated and ungrounded electrical circuits, zero adjustment (100% of sensing element) for control application and measurement purposes for all services of Condensate and drains, particularly where two phases of steam and water are present. IP 65 or equivalent degree of protection for enclosure. Displacer /float material of 316SS. The material of accessories will be SS.
2.14
Flow Glasses Online flow glasses for pipe size up to 6" with a rotary wheel (not a flapper type) suitable for installation on vertical or horizontal pipe lines, material Pyrex tempered glass. Body material will be carbon steel, rotor & wetted parts will be bronze. The material of accessories will be SS. IP 65 or equivalent degree of protection for enclosure. Upto 50 NB size, connection shall be screwed & above 50 mm NB size it shall be flanged - ANSI, 150 RF. Accessories like name plate, mating flanges with gaskets (neoprene), bolts & nuts, etc. shall be supplied. Enclosure shall be IP65.
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2.15
Flow Elements SS 316 flow nozzles for all steam and feed water services with D and D/2 pressure tappings; 316SS flow orifice plate assembly for all water services with flange tap connections; B ratio of 0.5 & 0.7. Element material of SS 316. The material of accessories will be SS. Refer to Table-7 for provision of flow elements. All the flow elements shall have 3 pairs of differential pressure tappings complete with root valves. Orifice plate shall not be less than 3 mm thick for nominal pipe diameter upto 300 mm & not less than 6 mm thick for pipe diameter > 300 mm. The flow elements shall be supplied as assemblies with High/low pressure tappings, root valves as required. Performance Guarantee flow elements shall be provided separately. Butt welded edges shall be prepared as per ANSI 16.25 & flanged connections shall be as per ANSI 16.5 standards. Orifice assembly complete with nipples & valves to be supplied by Bidder shall be one metre long with ANSI class 150 RF SS flanges at the ends including gaskets, bolts & nuts. Isolating valves shall have SW end connection. Accessories like name plate, gaskets, bolts & nuts, reservoirs (condensing chambers), 6 nos. shut off valves per assembly, nipple, welding adapters, etc. shall supplied.
2.16
SAMPLING RACKS Enclosed panel style; indoor located; construction material of steel/channel. IBR certification for tube & fittings to be provided for pressure greater than 3.5 kg/cm2 and corresponding saturation temperature.
2.17
SAMPLE COOLER Indoor located, coil in coil type sample coolers with counter flow operation shall be provided. Material of the inner tube shall be inconel 600/316 SS and material of outer tube shall be AISI 316SS. IBR certification shall be provided. Guidelines for provision of steam and water system analysers is enclosed in Table-11.
2.18
CONTROL DESK Indoor located, desk type control desk with 3 mm thick sheet metal of cold rolled steel; shall be provided to place CRTs, key boards etc. The Processor shall be housed in the bottom section of control desk. Sliding drawers shall be provided above the Processor compartment and below the desk portion all along the control desk for storing operation log books. Indoor located, free standing panel type unit control panel shall be mosaic grid type. The Profile of control desk with the layout arrangement shall be subjected to OWNER/ENGINEER approval.
2.19
Bunker level Indicator
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Radar type level transmitters top mounted with LCD indicator shall be provided. IP-65 protection; +24 V DC supply; 4-20mA output with HART protocol; Accuracy 1%; Resolution 0.04; Repeatability 0.04; Linearity 0.01%; Beam angle <20; Accessories like integral cable between sensor and transmitter unit with connectors on both side, gasket and cable gland, digital panel meter, name plate & metal tag; the material of accessories will be SS. Switch 2 nos. of SPDT contacts (1 NO and 1 NC) rated for 0.2 A, 220 V DC.
2.20 Pressure and Differential Pressure Transmitter Racks Open type transmitter racks with canopy to mount all pressure, differential pressure and flow transmitters with vibration dampener (Keldur); air supply lines and header will be provided with bulk head fittings to receive impulse lines; Also provided with blow down/drain header. The material of accessories will be SS. Drains shall be connected upto suitable drain header.. Transmitter rack with continuous purging arrangement shall be provided in boiler area. Air filter regulator and purge rotameter shall be used at boiler side. 2.21 Junction Boxes (JB) and Field termination cabinets(FTC) Wall/column mounted junction boxes having 32 (2x16) terminals and cable entry only at the bottom and sealed with fire proof compound; Screwed terminal type; IP 65 or equivalent degree of protection for enclosure. Separate terminal blocks shall be used for analog and digital signal signals. Separate JBs for different voltage levels shall be supplied. Removable gland plate shall be supplied. JB shall have single lockable door with gasket, able to open side ways, with common keys. Painting inside will be glossy white & outside - IS-5 shade 631. Shield bus for screw connection shall be provided. Terminal size shall be suitable for 0.5 mm2 to 2.5 mm2 wire. Terminal blocks shall be vertical. JB shall have provision to add 10% additional terminals. Accessories like metal tag (SS), clamps, fixtures, bolts (SS), nuts (SS), gaskets (neoprene), lock & key, fire proof compound for sealing, etc. shall be supplied. The grouping of instruments in JBs is subject to Purchasers approval. All the field Junction boxes shall have double doors. All JBs shall be provided with individual canopies to avoid ingress of water. Minimum 5 nos. FTCs in Boiler, 4 nos. FTCs in TG side, 02 Nos. of FTCs at MCC shall be provided. All should be of bottom cable entry type .JB material shall be acrylic fiber.FTC material shall be 3 mm sheet steel. 2.22 Interposing Relays (IPR) Electro magnetic type IPRs with plug-in type connections, suitable for channel/rail mounting in cabinets; coil rating 24V D.C; 2 set of silver plated charge over contacts rated for 0.2A 220 V DC. Free wheeling diode across relay coil (copper) and self reset type status indicator flag (electronic) shall be provided. All relays shall be mounted in IPR cabinet & relay base (silver plated)
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internally wired to the external cabling termination block in IPR cabinet. Wiring connection shall be screwed & termination shall be suitable for 0.5 mm2 to 2.5 mm2 size wiring. Facility to simulate relay operation manually shall be provided. Relays of different contact interrogation voltages shall be separated by a barrier in IPR cabinet. Accessories like name plate (SS) with tag & service inscription, relay base mounting rail/channel, nuts & bolts, etc. shall be supplied. Three nos. change over contacts shall be wired to external TB with screwed terminations only. Status/amps shall be provided. 2.23 System Cabinets These cabinets shall house signal conditioning cards, input/output cards, processor cards & associated power supply units. Indoor located, free standing vertical type system cabinets with IP-42 enclosure and with 2 mm thick sheet metal of cold rolled steel; double doors with neoprene gaskets; antivibration pads of 15 mm thick; blower & louvers in each cabinet with brass mesh; fire proof compound (50 mm thickness) for sealing cable entry (bottom); fire detector for each cabinet. Beacon lamp shall be provided in each cabinet to indicate the cabinet having fault condition. The racks in system cabinets shall have provision along with plug in sockets/back plane to house at least 20% additional cards, to accommodate for engineering flexibility or future expansion. The colour of the cabinets shall be indicated at detailed engineering stage. Doors shall have concealed type of hinges and swing of 100 degrees. Alternatively system cabinets with lift off type doors can be offered. The doors shall be provided both at the front and rear. In addition to Beacon Lamp provided for each cabinet to monitor fault, a fault lamp shall be provided on the first or last (based on the control room layout to be decided during detailed engineering) cabinet, on the side to help the operator. Power supply distribution shall be provided on per cabinet basis with all associated MCBs, protections, etc. The system cabinets, racks in system cabinets, slots in the racks & the terminals shall have identification numbers. A stainless steel metal tag (plate) shall be fixed to the inside of the door & the layout of the racks, slots & details of the card type/service shall be inscribed on this metal tag. Each cabinet shall be provided with one each 3 pin receptacles for 240 V, 1P 50 C/S and receptacles for +24V DC. Cabinet shall be delivered totally wired. All electronics shall be mounted & wiring connections at these hardware shall be terminated by vendor. Quantity shall be as required. Prefab cable connectors shall be used for connecting signals between system cabinets. The cabinet shall have space provision to mount at least 20% additional cards to provide for future expansion. Smoke detector shall be mounted in each system panel and shall be connected to the plant Fire detection and Alarm system. 2.24 Marshalling Cabinets Indoor located, free standing vertical type marshalling cabinets with IP-42 enclosure and with 2 mm thick sheet metal of cold rolled steel; double leaf type with neoprene gaskets; antivibration pads of 15 mm thick; fluorescent lighting;
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Spec No.
TCE.5657A-C-500-002
SHEET 17 OF 23
blower & louver in each cabinet with brass mesh; fire detection for each cabinet; fire proof compound (50 mm thick) for sealing cable entry (bottom, front, rear). The colour of the cabinets shall be indicated at detailed engineering stage. The type of terminal shall be WAGO make only. The type of terminals for terminations from cabinets/panels shall match with the pre fabricated cables and pins supplied. The terminals for field cables shall be arranged in a logical order of equipment/system wise and shall be worked out by vendor, subject to approval by Purchaser/ Consultant. Door shall have concealed type o hinges and swing of 180 & lockable. The doors shall be provided both on the front and rear. Channels, bolts & nuts shall be zinc plated and passivated. Two coats of premier paint and black colour paint shall be applied. Fluorescent lamp of 40W shall be provided and shall be operated by the door switches as well as by manual switches. The marshalling cabinets, the terminal blocks, the terminals and the electronic hardware if any, shall have identification numbers. Each cabinet shall be provided with one each 3 pin receptacles for 240 V, 1P, 50 c/s and receptacles for +24V DC. A system cabinet and associated cabinets shall be supplied on a skid to avoid outside interconnecting cables. Cabinet shall be delivered totally wired. Interconnection schedule (ICS) between marshalling cabinets, FTCs and JBs shall be prepared by Contractor and the format of ICS will be decided during detailed engineering stage. Fused Terminals are to be used in the marshalling cabinets for analog signals to protect the DCS cards from short circuit/grounding 2.25 Local Panels Indoor/Outdoor located, free standing vertical type local panels with 3 mm thick sheet material of cold rolled steel; antivibration pads of 15 mm thick; fluorescent lighting; Double doors with neoprene gaskets at every 1.5 m; blower & louvers in each section with brass mesh; fire proof compound (50 mm thick) for sealing cable entry (bottom); fire detector for each section; space heater with thermostatic control for each section (strip type). IP 65 degree of protection for enclosure. Removable cover plates with locking facility shall be provided along the bottom of the front desk continuously to facilitate maintenance work. The length of each cover plate shall not exceed 1 m. Fluorescent lamp of 40 W shall be provided from one end of the panel to the other end at continuous length and shall be operated by the door switches as well as by manual switches. Name plates shall be provided for all instruments/inserts with Tag. No. & short description of service engraved. These shall be phenolic overlays (1.6 mm thick), black background with white lettering & shall be fixed to the panel by stainless steel screws (counter sunk). Each section of the panels shall be provided with one each 3 pin receptacles for 240V, 1P 50 c/s & 110 V, 1P, 50 c/s. Panel shall be delivered totally wired. All instruments, inserts and annunciation windows shall be mounted & wiring connections at these hardwares shall be terminated at site by vendor. Quantity shall be as required. 2.26 Vibration Monitoring System
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Spec No.
TCE.5657A-C-500-002
SHEET 18 OF 23
Vibration pickup with sensitivity of minimum 15 mv/mm/ second, degree of protection IP65. Vibration pickups shall be provided for X and Y directions; velocity pickup for low speed; accelero-meter pickup for high speed. Microprocessor based control room mounted vibration monitors (dual channel) shall be provided. The vibration system shall provide isolated one (1) 4-20 mA DC output and 2 nos. SPDT alarm contacts for high and v.high conditions. In addition, the vibration system shall perform vibration analysis like signature analysis, Fourier analysis etc in as available in Bentley latest system for analysing & diagnosis of machine faults. 2.27 230 VAC DISTRIBUTION CABINETS The function of the 230V AC distribution is sub distribution of 230V AC power supply from UPS to all the utilities viz., operator station/Engineering station & other peripherals located at Control room, any other requirement at Field. All the other voltages such as 24VDC shall be derived from UPS system. Redundant feeders shall be provided. The cabinets will be free standing vertical cabinets, designed for indoor location. Material of construction will be 2mm thick CRCA. Fluorescent lighting, fire detector and space heater will be provided for each cabinet. Isolating switches and HRC cartridge fuses will be provided for individual feeder isolation. Ammeter and voltmeter will be provided for incoming feeders to the distribution boards. 24V DC supply tolerance shall be +25% and 20%. 230 V AC to 24 V DC distribution system shall be designed with the complete redundancy and the scheme is subjected to approval of OWNER/ENGINEER. 2.28 24V DC DISTRIBUTION BOARD The input to this board shall be from 230V AC UPS system. The function of the 24V DC distribution board is sub distribution of 24V DC power to all the utilities viz., DCS system cabinets, and all other 24V DC requirements. Redundant feeders shall be provided through diode auctioning using diodes of high peak inverse voltage. The cabinets will be free standing, vertical cabinets designed for indoor location. Material of construction will be 2mm thick CRCA. Fluorescent lighting, fire detector and space heater will be provided for each cabinet. Isolating switches and HRC cartridges fuses will be provided for individual feeder isolation. Ammeter and voltmeter will be provided for the incoming feeders to the distribution boards. 230 V AC to 24 V DC distribution system shall be designed with the complete redundancy and the scheme is subjected to approval of OWNER/ENGINEER. 2.29 CONTROL VALVES Multistage, anticavitation, Balanced, modulating, globe type, cage guided, single ported, diaphragm type of actuator with hand wheel, Pneumatic positioners, air filter regulator, air lock device, solenoid valve, limit switches and position
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TCE FORM 329 R3

Spec No.
TCE.5657A-C-500-002
SHEET 19 OF 23
transmitters completely tubed with junction box. E/P converters suitable for accepting 4-20mADC signal. Pneumatic (copper) tubing complete with accessories, fittings, positioners shall be provided with input/output/bypass gauges. Local position indicator & LVDT type position transmitter with 2 wire, 420mA DC output. All limit switches/position transmitters, E/P converter signals etc., shall be wired out to external block of actuator and respective junction boxes. Control valves shall be sized to have an opening of 15% at minimum flow condition and 85% at maximum flow condition. Noise level shall not exceed 85 dB at a distance of about 1.5 M from the valve. In case of predicted noise level above 85dBA, suitable low noise trim shall be provided. Leakage class for double seated valve shall not exceed 0.05%, and single seated valve shall not exceed 0.01%. Either extended type bonnet or cooling fin type bonnet shall be provided for o service above 200 C and for other service the bonnet type shall be standard. The end connections shall be socket welded for sizes below 50 NB and butt welded for sizes 50 NB and above. Flanged connection shall be provided for DM water services, with suitable rubber lined interfaces. Water seal shall be provided for valves that could be subjected to below atmospheric conditions. Generally stem and guide material(trim) shall be SS 316 sterlited, and plug and seat material will be 17-4 PH SS, except for specific applications like DM water, HP bypass services. Refer to Table-6 for selection of control valve body material and actuator type. The noise abatement shall be obtained by valve body and trim design and not by use of silencer. The trims supplied shall be suitable for quick changing. Actuator housing shall be of pressed steel construction. In Vibration prone areas, positioners shall be located away from the control valve/damper and location shall be approved by OWNER/ENGINEER. Position transmitter shall be non-contact type. The control valve design shall be suitable for the required fail-safe conditions, of process / equipment. The valves shall be supplied and commissioned as per the fail-safe philosophy required for the process. Wherever the required turndown is not possible with a standard single valve, specially designed trims shall be customised and used. Pressure regulators upstream of control valves would not be envisaged. All final Control elements (Control valves & control dampers) shall be with pneumatic or electric actuators. All actuators would be sized so that the final control elements operate properly even when the upstream pressure exceeds 110% of maximum value. Pneumatic actuators would be provided with air failure lock and remote release, limit switches, adjustable minimum and maximum stops,
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TCE FORM 329 R3

Spec No.
TCE.5657A-C-500-002
SHEET 20 OF 23
load position indicators, positioners, non-contact type electronic position transmitters and solenoid valves in accordance with the system requirements. 2.30 Instrumentation & Control Cables Individual pair shielded & overall shield twisted pair copper cables shall be used for analog signals & only overall shielded cables shall be used for digital signals. All these cables shall be armoured. All the insulation including overall sheath will be FRLS quality. The wire size shall be 0.5 mm2. Ferruling indicating terminal numbers on termination side shall be followed. Colour coding shall be as per standard. FRLS 1.5 sq.mm copper control cable would be used for cabling between MCC and control system. 2.31 Thermocouple Extension Cable 600 V twisted pair (20 twist/metre), 1.5 mm2 dia. thermocouple extension wires, PVC insulated, aluminium nylar tape shielded/PVC jacketed/ armoured & overall PVC jacketed/FRLS. Features such as colour coding, thermo electric characteristics, etc. shall be as per ANSI STD-MC.96-1, 1975. Alternatively thermocouple extension wires with 600 V twisted pair 0.5 mm2 PTFE insulated copper braiding & PTFE outer jacket will be considered for turbine area. 2.32 Wiring, Termination and Accessories
2.32.1 Instrument wires : Wires carrying 4-20 mA DC or any other low voltage or current signals. Used for panel internal wiring, tinned copper conductor of 0.5 sq.mm cross section with seven strand and twisted pair with 20 twists/metre. Insulation material shall be PVC, heat resistant with flame retarding properties with thickness not more than 0.5 mm and voltage grade will be 1100V. 2.32.2 Control Wires : Wires used for power supply like 110V AC, 240V AC, 220V DC, + 24V etc. Used for panel internal wiring, tinned copper conductor of 1.5 sq.mm cross section with seven strands. Insulation material shall be PVC, heat resistant with flame retarding properties, voltage grade will be 1100V. 2.32.3 Prefabricated cable : Used for interconnection between system/marshalling cabinets. Used for panel external wiring, tinned copper conductor of 0.5 sq.mm cross section with seven strands twisted pair with 20 twists/metre. Insulation material shall be PVC, heat resistant with flame retarding properties with thickness not more than 0.5mm. Voltage grade will be 600V. Each prefabricated cable shall have a minimum of 5 cores as spares and these should not be connected to end connectors. 2.32.4 Terminal Block (TB) Screwed type for marshalling panels and spring loaded terminals for FTC and JBs shall have following features :
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Spec No.
TCE.5657A-C-500-002
SHEET 21 OF 23
600 grade, vertically mounted, size of 0.5 sq.mm to 1.5 sq.mm for instrument wires and 1.5 sq.mm to 2.5 sq.mm for control wires. Clearance between TBs will be 150 mm and between TB and bottom plate will be 250 mm, flame resistant, non-hygroscopic, decarbonised. Insulation between adjacent terminals or between terminals & frame work and will be 2 kV RMS for 1 minute - Power supply and signal TB shall be separate. Signals shall be grouped in TBs in the same order as that in junction box so as to provide neat cable layout and wiring. High voltage and low voltage signals shall be provided on separate TBs which are mounted separately. WAGO make spring loaded terminals shall be used for termination of the instrumentation cables at Field JB, Field Termination cabinet (FTC) and any other field termination cabinets. 2.32.5 Termination Details Maximum of 2 wires shall be terminated per terminal. Wiring raceways, strapes shall be flame retardant. All wiring shall be ferruled. Wires carrying power and signal wires shall be routed in separate raceways. Accessories like MCB, cable support fuses, etc. shall be supplied. Cable entries shall be cemented with fire proof compound. 2.33 Air Filter Regulator (AFR) Constant bleed type AFR with an accuracy of +0.1%, inlet pressure range of 5-8 kg cm2 and suitable spring ranges (AFR) for use with positioners in control valves, control damper, E/P converters and shut off valves, transmitter purging lines etc; Filtering particles above five microns having phosphor bronze filter element. Material of accessories will be SS. Built in blow down valve shall be provided. AFR shall have automatic drain feature. All accessories shall be supplied. Degree of protection shall be IP65 2.34 Electro-Pneumatic Converters (E/P) Two wire type E/P converters with an accuracy of +0.25% accepting 4-20 mA dc signals from control system and converting to 0.2 to 1 kg/cm2 air pressure to operate valve positioners of all final control elements; Housed in cast aluminium casing (with polyurethane paint); IP65 degree of protection for enclosure. Material of accessories shall be SS. Direct/reverse acting, 4SCFM capacity etc. 2.35 Position Transmitters 24VDC operated Non contact LVDT type with 4-20 mA DC 2 wire system with an accuracy of 1%; range adjustment and zero adjustment to be provided; IP65 degree of protection for casing. The output shall be linear. All accessories shall be SS. 2.36 Solenoid Valves
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TCE FORM 329 R3

Spec No.
TCE.5657A-C-500-002
SHEET 22 OF 23
Direct operated solenoid valves, pilot operated for higher sizes with shut of class (leakage) VI, body material of bronze, plunger material of 316 SS rated for continuous duty. IP 65 class for enclosure. Insulation class of 'F' for the solenoid. Body ratings shall suit the pressure and temperature conditions. Solenoid valve shall be rated either for 220V DC or 24 V DC only. 2.37 Pneumatic block valves Balanced, on-off, plug type, single ported, gate valve. Body material shall be ASTM A 216 GR WCB with end connection socket welded for sizes 50 NB and below & butt welded for sizes above 50 NB and flow direction will be horizontal. Bonnet: Std. type of material ASTM A 216 GR WCB & packing material GRAFOIL. Trim : Cage guided, metal seated with flow characteristic of quick opening with stem, plug, seat and guide material of SS 316. Actuator : Diaphragm (Nitrile) type with handwheel & travel indicator and adjustable stop. It shall be sized for shut off differential pressure. Accessories like air filter regulator, solenoid valve, limit switch with Nema4 & enclosure, etc. shall be supplied. Actuators & accessories requiring tubing shall be mounted and tubed. 2.38 Control Damper Drives Pneumatic actuator type, located in flue gas/air area with damper shaft bearings mounted externally. Bearings are grease lubricated. Blades(SS) shall be linked together. Accessories like position transmitters (2 wire) with 4-20mA DC output. Position indicator, position locks, limit/torque switches, etc. shall be supplied. Positioners with all required accessories, required for the positioning of control damper drives shall be provided. Spare cams for accommodating any change in characteristic to achieve better process control during commissioning shall be supplied as required. In vibration prone areas , positioners should be located away from the control damper and the location finalisation subject to OWNER / ENGINEER approval. Non-contact type positioner transmitter shall be supplied. 2.40 MAGNETIC FLOWMETER : Inline type with indicating top mounted transmitter with flange connection. Accuracy: 0.5% of flow rate or volume flow. Repeatability 0.1% of flow rate/volume flow. Transmitter shall be smart with LCD display and superimposed HART on 4-20mA DC output. Data storage shall be in EEPROM. Shall have diagnostic capabilities. Touch control facility on the indicator for checking the rate/volume and diagnostic messages.
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TCE FORM 329 R3

Spec No.
TCE.5657A-C-500-002
SHEET 23 OF 23
Material: Case-Al.alloy with corrosion resistant, flow tube and extension pipeStainless steel (SS 304) and Lining-fluro carbon. The flow rate shall be available in DCS/PLC and flow integration shall be implemented in DCS/PLC to indicate volume flow. 2.41 ANUBAR ( IMPACT HEAD TYPE): Element shall be tubular, insert type with minimum four impact ports facing upstream direction, located precisely for measurement of average flow velocity. The material of the sensor shall be SS 316. Accuracy shall be +/ - 1% of the actual value or better. Repeatability shall be + /- 0.1 of actual value or better. Online retracting facility and flushing arrangement shall be provided. The sensor shall be supplied with complete mounting hardware and support plugs and valve manifolds ( NPT) for DP transmitter connection. The specification of DP transmitter is specified elsewhere. 3.0 General Wherever indicating type transmitters are provided, local gauges need not be provided. Dedicated distribution boards shall be provide for solenoid valves with adequate number of spare terminals to loop the interposing relay contact to the respective feeders. All the switches shall be provided with 2nos. changeover contacts and both shall be wired to JB. All instruments provided on piping/equipment on HFO/LDO/Lube oil/Control oil services and in Fuel oil pump house shall be explosion proof. Explosion proof certificates to be furnished by Vendor. All JBs, Local panels and similar equipment shall not have top and side entry to avoid dust entry. Instrument accessories shall include fittings for welding. Welding procedure is subject to Purchasers approval, prior to welding. All VFDs shall be located in air-conditioned environment. All instruments located in outline area shall be provided with canopy. For all Local panels required transformers shall be included to provide the required power supplies.
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TCE FORM 329 R3
Spec No.
TCE.5657A-C-500-002
INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 1 OF 1 SYSTEM TABLE 8 TABLE-8: GUIDE LINES FOR SELECTION OF FLOW ELEMENTS
SL. NO
TYPE OF FLOW ELEMENT
ORIFICE PLATE
FLUID MEDIUM WHERE USED WATER ( FEED WATER, CONDEN SATE, DM WATER)
PRESSURE, TEMPERATUR E OF FLUID SUITABLE PR. <=30 Kg/Cm2 AND TEMP. <=100 C
PIPE SIZES SUITABLE FOR FE
APPLICATION
TYPE OF CONNECTION
FOR ALL SIZES EXCEPT VERY LARGE DIA. PIPE
i)
CEP DISCHARGE FLOW ii) CONDENSATE AT DEAERATOR INLET iii) MAKE-UP FLOW TO HOTWELL iv) DM WATER FLOW TO CST
BW BW
FLANGED FLANGED
ORIFICE PLATE
WATER
PR.>+30 Kg/Cm2 TEMP .>100 C
ALL PIPE SIZES
i)SH/ RH SPRAY WATER FLOW ii) HP/LP BYPASS SPRAY SOOT BLOWING STEAM FLOW i) BFP SUCTION FLOW (FOR ONE EACH BFP) ii) FW FLOW
BW
ORIFICE PLATE FLOW NOZZLE
STEAM
FOR ANY CONDITION PR. >=30 Kg/cm2 OR TEMP >100 C
< 3 INCH
BW
WATER
FOR ALL PIPE SIZES EXCEPT VERY LARGE DIA PIPE
BW
BW i) HP BYPASS STEAM FLOW ii) AUX. STEAM FLOW BW BW
FLOW NOZZLE
STEAM
PR..>30Kg/cm 2 OR TEMP >100 C
ORIFICE
WATER (CW)
PR. <=30 Kg/cm2 & TEMP <=100 C PR.<=30 Kg/cm2 AND TEMP.<=100C
FOR ALL PIPES
CONDENSER COOLING WATER TO ASH COOLERS
FLANGE
AIR FOIL/ VENTURY
AIR
ALL DUCT SIZES
i) PRIMARY AIR ii) SECONDARY AIR FLOW
BW BW
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TCE FORM NO. 120R2
Spec No.
TCE.5657A-C-500-002
INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 1 OF 1 SYSTEM TABLE 9 TABLE 9: GUIDE LINES FOR SELECTION OF CONTROL VALVES MATERIAL AND ACTUATOR TYPE
SL. NO.
DESCRIPTION
PR. Kg/Cm2
TEMP. MAX C
PRES S STD
BODY MTL.
ACTUAT OR TYPE
1. 2. 3. 4. 5.
WATER SERVICES CONDESATE WATER SERVICES DM WATER SERVICES AIR SERVICES LUBE/CONTROL OIL/FUEL OIL SERVICES ANY OTHER SERVICES AS REQUIRED CONTROL DAMPERS/VALVES FOR AIR AND FLUE GAS SERVICES
WC6 WCB SS316 WCB WCB
P P P P P
6.
7.
WCB
* MATERIAL IS SUBJECT TO PURCHASERS APPROVAL DURING DETAIL ENGINEERING.
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TCE FORM NO. 120R2
Spec No.
TCE.5657A-C-500-002
INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 1 OF 4 SYSTEM TABLE 10 TABLE-10: TESTS TO BE PERFORMED FOR PLC / PROGRAMMABLE CONTROL SYSTEM
PROGRAMMABLE CONTROL SYSTEM - PLC
1.0
Measurement and Control systems / PLC Functional test (simulated) for the complete system (Refer Note-1&2) System performance & tests for monitoring functions (Refer Note-2) Surge withstand capability test as per ANSI C37.9A/ IEEE 4721 BE MMA 219, Damp heat cycling test as per is 2106, part 1I- 1962 or equivalent, Dielectric strength test (high pot tests as per NEMA ICSI. part ICS-109) ANSI C39.51/UL 508, Radio frequency interference test as per SAMA PMC 33.1, Immunity to noise test as per IEEE SWC test 587, Burn in test & temperature rise test for 120 hrs, Continuity test & short circuit test for current limiters, Under voltage and over voltage test (Refer Note-2), Simulation test for all control loops (Refer Notes-1 & 2), Factory Acceptance Test as per Section D2, Table 13.( Refer Note-2) Notes :1. Bidder shall furnish in his proposal the test facility and details of the simulation test available in their factory including their previous experience. 2. All these tests shall be witnessed by OWNER or his representative.
2.0
Data bus system :Functional test for the complete system (Both hardware & software) simulating worst condition, Noise test-surge withstand capability test as per IEEE, Quality assurance and tests shall be as per latest BS-5750 and ESS-1980 or equivalent, Factory acceptance test as per Section D 2, Table 13.
3.0
Central Processing Unit for Man Machine Interface Main memory test of 12 hours duration to demonstrate the capability of memory Read-Write function under worst pattern at various voltage levels Main memory parity detection test of 12 hours duration to demonstrate that parity detection feature performs properly to the purchaser's satisfaction Logic tests for 12 hours duration to demonstrate the hardware commands, interrupt structures and hardware failure detection Count down registers and pulse counter test of 8 hours duration to demonstrate the accuracy of all time count down registers Bulk memory Data transfer test of 36 hours duration to demonstrate possible combinations of transfer from/to bulk memory including checks for illegal writing, reading and wrong transfer indications Voltage and speed variation checks Bulk memory parity detection test of 12 hours duration to demonstrate the proper
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TCE FORM NO. 120R2
Spec No.
TCE.5657A-C-500-002
INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 2 OF 4 SYSTEM TABLE 10 TABLE-10: TESTS TO BE PERFORMED FOR PLC / PROGRAMMABLE CONTROL SYSTEM functioning of parity detection feature Functional test for complete system (Both hardware and software) simulating worst conditions Noise test - surge withstand capability test as per IEEE, Quality Assurance as governed by BS 5750 or equivalent. Design, construction, components, materials, finishes and testing of electronic equipment as per EES - 1980 (General specification of electronic equipment) or equivalent Factory Acceptance Test as per Table 13
4.0
Colour Graphic Video Display Unit (CRT) Functional tests Test for capabilities of CRT including error detection for the complete system (Both Hardware & Software) simulating worst conditions Noise test Surge withstanding capacity as per IEEE or equivalent Quality assurance as governed by BS 5750 or equivalent Design, construction, components, finishes and testing of electronic equipment as per EES-1980 (General specification of electronic equipment) or equivalent Factory Acceptance Test as per Table 13
5.0
Keyboard :Test for satisfactory operation of keyboard controls, push buttons and all associated functions Quality assurance as governed By BS5750 or equivalent for functional test for the complete system simulating worst conditions Design, construction, components Materials finishes and testing of electronic equipment as per EES-1980 (General specification for electronic equipment) or equivalent Factory Acceptance Test as per Table 13.
6.0
Printers : Noise level test for the printer Test of interlock performance and error detection feature, Quality assurance as governed by BS 5750 or equivalent, Design, construction components materials, finishes and testing of electronic equipment as per EES1980 (General specification of electronic equipment) or equivalent Functional tests for the complete system (Both hardware and software) simulating worst conditions. Factory Acceptance Test as Table 13
7.0
Floppy/Tape Drive Unit/Bulk Memory Unit/CD drive Unit
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TCE FORM NO. 120R2
Spec No.
TCE.5657A-C-500-002
INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 3 OF 4 SYSTEM TABLE 10 TABLE-10: TESTS TO BE PERFORMED FOR PLC / PROGRAMMABLE CONTROL SYSTEM Noise test Surge withstand capability as per IEEE or equivalent Quality assurance as governed by BS 5750 or equivalent, Design, construction, components, materials, finishes and testing of electronic equipment as per EES1980 (General specification of electronic equipment) or equivalent Functional tests for the complete system (Both software and hardware) simulating worst conditions Test of Control unit and drive for all features, Date checking features. Factory Acceptance Test as per Table 13
8.0
Local Panels Verification of degree of protection / Electrical tests as detailed under Wiring, Terminations & Accessories/Type tests & routine tests as per relevant Indian standards. Marshalling Cabinets Verification of degree of protection / Electrical tests as detailed under Wiring, Terminations & Accessories/Type tests & routine tests as per relevant Indian standards. System cabinets Verification of degree of protection / Electrical tests as detailed under Wiring, Terminations & Accessories/Type tests & routine tests as per relevant Indian standards. Wiring Termination and Accessories Routine test Conductor resistance test (*) / High voltage test (*)/Impulse dielectric test/Insulation test/Humidity test/Temperature rise tests on power circuits/Short time current tests on power circuits. Type test Annealing test (*) / Test for insulation and sheath (*)/Flame retardance test (a) Oxygen index, (b) Flammability/Test for acid gas generation/Test for water absorption (*)/Wet dielectric test. Note (*) As per IS-1554
9.0
10.0
11.0 11.1
11.2
11.3
Test for terminal blocks Test for moulding for flame resistant, Non-hygroscopic and Decarbonised / Insulation test between terminals / Insulation between terminal block and frame Tests For Auxiliary Plant Monitoring Systems Vibration Monitoring & Analysis System (a) (b) Simulated Functional test (Note-1) Tests for Server, VDU, Printer, Keyboard
12.0 12.1
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Spec No.
TCE.5657A-C-500-002
INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 4 OF 4 SYSTEM TABLE 10 TABLE-10: TESTS TO BE PERFORMED FOR PLC / PROGRAMMABLE CONTROL SYSTEM Note-1: Test to be witnessed by Owner or Owners representative.
12.2
Flame Monitoring & Analysis System
(a) (b)
Simulated Functional test (Note-1) Tests for Server, VDU, Printer, Keyboard
Note-1: Test to be witnessed by Owner or Owners representative. 12.3 PADO System (a) (b) Simulated Functional test (Note-1) Tests for Server, VDU, Printer, Keyboard
Note-1: Test to be witnessed by Owner or Owners representative. 12.4 CMMS System (a) (b) Simulated Functional test (Note-1) Tests for Server, VDU, Printer, Keyboard
Note-1: Test to be witnessed by Owner or Owners representative. 12.5 MIS System (a) (b) Simulated Functional test (Note-1) Tests for Server, VDU, Printer, Keyboard
Note-1: Test to be witnessed by Owner or Owners representative.
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TCE FORM NO. 120R2
Spec No.
TCE.5657A-C-500-002

TABLE 11: FACTORY ACCEPTANCE TESTS FOR PLCs

1 2 3 4 5 6
GENERAL
FACTORY ACCEPTENCE TEST (FAT) :REF NOTE-1 FACTORY ACCEPTENCE TEST (FAT) PROCEDURE:REF.NOTE -2
7 8 9 10 11 12 13 14 15 16 17 18 TOTAL SYSTEM CONFIGARATION DRAWINGS 19 FAT PROCEDURE CONSITING OF : 20 (i) TEST EQUIPMENT 21 (ii) TEST ENVIRONMENT 22 (iii) TEST CONFIGURATION 23 (iv) TEST PROCEDURE 24 (v) TEST SCHEDULE 25 (vi) TEST VENUE 26 (vii) TEST REPORTS- SPECIMEN COPIES 27 FUNCTION DESIGN SPECIFICATION FOR EACH EQIPMENT / SYSTEM 28 29 30 GENERAL APPEARENCE CHECK & BILL OF MATEIRALS CHECK 31 CONSTRUCTION CHECK AS PER OVER ALL GENERAL ARRANGEMENT DRAWINGS 32 DIMENSTIONAL CHECK 33 LABELLING , TERMINAL ARRANGEMENT AND EQUIPMENT IDENTIFICATION CHECK 34 POWER SUPPLY VOLTAGE LEVEL CHECK & POWER 'LEDs -ON CHECK 35 COOLING FAN OPERATION CHECK 36 GROUNDING NETWORK CHECK 1. THE INTENT OF THE FAT IS TO DEMONSTRATE AND ENSURE THAT THE I&C SYSTEM MEETS ALL THE FUNCTIONAL REQUIREMENTS AS INTENDED IN THE SPECIFICATION / CONTRACT. A COMPLETED INTEGRATED TEST OF THE SYSTEM SHALL BE CARRIED OUT AT VENDOR'S WORKS IN THE PRESENCE OF PURCHASER/CONSULTANT, The SHIPMENT OF I&C EQUIPMENT TO SITE WILL BE EFFECTED ONLY AFTER THE FAT HAS BEEN CONDUCTED AND THE RESULTS ARE ACCEPTED BY PURCHASER/CONSULTANT BY THE PURCHASER/CONSULTANT. 2. FAT PROCEDURE SHALL BE PREPARED BY VENDOR AND TO BE SUBMITTED FOR PURCHESER'S/ CONSULTANT'S APPROVAL WELL IN ADVANCE PRIOR TO THE COMMENCEMENT OF FAT
PPRELIMINARY
TEST DOCUMENTS
TEST REQUIRMENTS
TEST SHALL BE PERFORMED WITH THE COMPLETELY ASSEMBLED SYSTEM AND ALSO WITH COMPLETELY ASSEMBLED SYSTEM OF AUTOMATION EQPT,MMI,SOE AND PERIPHERALS I&C SOFTWARE AND PERFORMING ALL FUNCTIONS EXPECTED OUT WHILE IN ACTUAL SERVICE AND WITH STSTEM CONFIGURATION AS FINALISED. PROCESS INPUT/OUTPUT CONDITIONS AND OTHER LOAD ON THE SYSTEM ARE TO BE STIMULATED EITHER BY HARDWARE/SOFTWARE. ALL SYSTEM SOFTWARE & APPLICATION SOFTWARE TO BE LOADED AND OPERATIONAL ON THE SYSTEM PRIOR TO FAT REFER RELEVANT SECTIONS.
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TABLE 11: FACTORY ACCEPTANCE TESTS FOR PLCs

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 POWER SUPPLY UNDER VOLTAGE AND OVER VOLTAGE CHECK ( 10%) PROCESSOR & MAIN DATA BUS NETWORK REDUNDANCY CHECK COMMUNICATION COUPLER IF APPLICABLE REDUNDANCY CHECK COMMUNICATION MODULE OF THE CONTROLLER TO NETWORK REDUNDANCY CHECK POWER SUPPLY REDUNDANCY CHECK HARDWARE ON-LINE MAINTAINABILITY CHECK ,
SYSTEM
CLOSED LOOP CONTROL SIMULATION CHECK OPEN LOOP CONTROL SIMULATION CHECK CONTROL LOOP RESPONSE CHECK BUMPLESS AUTO MANUAL TRANSFER CHECK CRT GRAPHIC OVERVIEW CHECK CRT- TREND CHECK CRT- REAL TIME TREND CHECK CRT- MIMICS CHECK CRT- CHECK FOR OPERATING CONTROL DIRECTLY FROM MIMICS CRT- FUNCTION KEYS CHECK CRT- ANALOG CONTROL DISPLAY CHECK CRT- SEQUENCE CONTROL DISPLAY CHECK CRT- OPERATOR GUIDENCE MESSAGE CHECK CRT/ BACKPANEL OPERATION PRIORITY CHECK CRT- ALARM MANAGEMENT FUNCTION CHECK CRT LOGGING FUNCTION CHECK CRT / RESPONSE / UPDATING CHECK KEYBOARD LOCK FUNCTION CHECK CRT INTERCHANGEBILITY & ASSIGNABILITY CHECK PRINTER ASSIGNABILITY & BACK-UP FUNCTION CHECK FLOPPY DISK/ STD / OPTICAL DISK UNIT STORAGE & RETRIEVAL CHECK CRT ASSIGNABILITY CHECK FOR HARD COPIER FUNCTION PLANT PERFORMANCE CALCULATION CHECK COMMUNICATION INTERFACE TO OTHERS SYSTEM SIMULATION CHECK SER INTERFACE DATA DUMP FUNCTION CHECK DATA BUS DISTANCE BUILDING CHECK (REFER NOTE- 3)
CONTROLLER ENGINEER NOTES MAINTENANCE
35 GRAPHIC DISPLAY BUILDING FUNCTION CHECK 36 CLOSED LOOP CONTROL SYSTEM MODIFICATION CHECK 37 OPEN LOOP CONTROL SYSTEM MODIFICATION CHECK 38 ALARM DISPLAY PRIORITISATION CHECK 39 SYSTEM SECURITY CHECK 40 SYSTEM ALARM CHECK 41 SYSTEM DIAGNOSTIC FUNCTION CHECK 42 POINT DETAIL CONFIGURATION CHECK 43 CONTROL LOOP TUNING CHECK 44 SYSTEM SELF DOCUMENTATION CHECK 3. FAT SHALL BE CONDUCTED WITH THE DISTANCE BETWEEN THE PROCESSOR AND OTHER SUPPORTING PERIPHERIALS AS PER THE FINAL LAYOUT IN THE CONTROL ROOM. 4. DURATION OF FAT SHALL BE MINIMUM THREE(3) WEEKS. THE FAT PROCEDURE SHALL BE SUBJECT TO PURCHASERS APPROVAL. 5. FOR CLOSED LOOP CONTROLS VENDOR SHALL ALSO DEMONSTRATE THE PERFORMANCE USING SIMULATION SOFTWARE TO COVER THE RELATIVE PERFORMANCE OF THE BOILER PARAMETERS AND TURBINE PARAMETERS.
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TCE.5657A-C-500-002
INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 1 OF 3 SYSTEM TABLE 12 TABLE-12 TESTS TO BE PERFORMED FOR INSTRUMENTS
1. 2. 3.
Pressure indicators Calibration Hydro test (1.5 times max. Pr.) Pressure switches Calibration test/Hydro test/Contact rating test/Accuracy test/Repeatability Pressure Transmitters Calibration test/Hydro test/Leak test/Over range test/Accuracy test/Repeatability test. Differential Pressure Indicators Calibration test/Hydro test/Leak test/Over range test/Accuracy test/Repeatability test. Differential Pressure Switches Calibration test/Hydro test/Leak test/Over range test/Accuracy test/Repeatability test. Differential Pressure Transmitters Calibration test/Hydro test/Leak test/Over range test/Accuracy test/Repeatability test. Thermometers Calibration test/Material test//Accuracy test/Bore concentricity : 5% of wall thick/Hydrostatic test for TW (1.5 times max. pr.). Temperature switch Calibration test/Material test//Accuracy test/Bore concentricity : 1.5% of wall thick/Hydrostatic test for TW (1.5 times max. pr.)/Contact rating test. Resistance temperature detector assembly Calibration/Material test/Accuracy test/Bore concentricity test/Insulation test (<500 M at 500 V, DC) as per ISA, Hydro test for TW. Bore concentricity : 5% of wall thick, Accuracy test. Thermocouple assembly Calibration/Material test/Insulation test (<500 at 500 V, DC) as per ISA, Hydro static test (1.5 times max. pr.) More concentricity 5% of wall thick Temperature transmitters Calibration test/Accuracy test/Ambient temperature error test Thermowells Material test/Bore concentricity : 5% of wall thick/Hydrostatic test for TW (1.5 times max.pr) Interposing relay Functional test/temperature rise test/high voltage test/limits of operation
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4.
5.
6.
7.
8.
9.
10.
11. 12.
13.
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test/insulation test. 14. 15. 16. 17. 18. 19. 20. 21. Level gauges Hydrostatic test/Material test/Seat leakage test/Ball check test Level switches (magnetic) Material test/Contact rating test/Hydro test/Calibration test Level gauges (Probe) Material test/Contact rating test/ Hydro test/Calibration test Flow switch Material test/Hydro test/ (1.5 time max. pr)/function test Flow glasses Material test/Hydro test/ (1.5 time max. pr)/function test Variable are flow metes Calibration test/Material test/Hydrostatic test (1.5 time max. pr) Flow element 100% Radiography test/Hydro test/Calibration test/IBR certificate Control valves IBR certificate Form III C Hydrostatic test : IBR/MSS-SP-61/ANSI B 16.34 Seat leakage test : As per ANSI B 16-104 (Refer note-1) CV test : As per ISA procedure Magnetic particle test : As per ANSI B 16.34 special class (applicable for pr.> 70 bar & tem < 4000C Liquid penetration test : As per ANSI B 16.34 special class (applicable for pr > 70 bar & temp < 4000C Calibration and Hysteresis test (Refer note-1) Note-1: These tests shall be witnessed by PURCHASER / CONSULTANT Pneumatic Block Valves: a) IBR certificate : Form IIIC b) Hydrostatic test : ANSI B 16.34 c) Seat leakage test : As per ANSI B 16-104 (Refer note-1) d) CV test : As per ISA procedure e) Magnetic particle test : As per ANSI B 16.34 special class f) Radiography test : As per ANSI B 16.34 special class g) Liquid penetration test : As per ANSI B 16.34 special class h) Calibration and Hysteresis test (Refer note-1) i) Actuator leakage test (Ref. Note-1) Note-1: These tests shall be witnessed by PURCHASER / CONSULTANT Pressure Regulating Valves: a) IBR certificate : Form IIIC as applicable b) Hydrostatic test : ANSI B 16.34
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23.
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c) Seat leakage test : As per ANSI B 16-104 (Refer note-1) d) CV test : As per ISA procedure e) Magnetic particle test : As per ANSI B 16.34 special class f) Radiography test : As per ANSI B 16.34 special class g) Liquid penetration test : As per ANSI B 16.34 special class h) Calibration and Hysteresis test (Refer note-1) i) Actuator leakage test (Ref. Note-1) Note-1: These tests shall be witnessed by PURCHASER / CONSULTANT 24. 25. 26. 27. 28. 29. Position transmitters Calibration/hysteresis and Accuracy test Electro Pneumatic converters Calibration test/Accuracy Solenoid valves Hydro test/Seat leakage test/CV test/coil insulation test Air filter regulators Calibration test/Accuracy test Junction boxes Test for degree of protection/Material test Transmitter racks Hydro test, Air leak test for tubing/Piping & fittings, IBR certificate required for impulse pipes, tubes and fittings of all steam & water services Transmitter racks Verification of degree or protection. Test for enclosure type, Type tests & routine tests as per relevant Indian standards. Compensating cable Thermo-emf characteristic/Continuity test/Measurement on capacitance, inductance and loop resistance / insulation resistance /high voltage test as per latest IS/Tensile and elongation test/Oxygen index test /Any other test applicable.
30.
31.
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INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 1 OF 5 SYSTEM TABLE 13 TABLE 13: FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES)
CONTRACTOR shall prepare the engineering documents in this table & submit for PURCHASER / CONSULTANT review & approval. The engineering documents shall have all fields as listed under Details of Fields in this table and the CONTRACTOR shall furnish all the engineering documents, in CDs in addition to hard printout for each revision. Finally CONTRACTOR shall submit as installed and commissioned drawings / documents. SL. NO 1. TYPE OF DOCUMENTS Drive List DETAILS OF FIELDS 1, 2. Sl. no. (*), TCE tag number. General Data (a) (b) Bidder : Motor (Bidders name) (*), drive equipment (*). Type / Form : Type (Refer electrical data sheet M4-203-01) (*), reference standard (*), manufacturers dwg. No. Mounting, coupling method (*). Motor Equipment Location : Layout dwg. No. co-ordinates, elevation. Rating : Output (kW) (*), full load speed (RPM) (*), voltage. Enclosure, Indoor / Outdoor, starting method, direction of rotation, winding insulation class, Integral starter, Integral starter wiring diagram no. Space Heater : Number provided, Rating (kW) Performance at rated volts & Hz : Rated current (IFL) Amps (*) starting % IFL (*), starting current %IFL (*), power factor (*), starting torque %IFL, pull out torque.. Terminal box : Cable size (mm2), cable OD(mm), location.
(c) (d) 3.
Data required for electrical engineering : (a) (b)
(c) (d)
(e) 4.
Data required for instrumentation & control Type of control (interlocked / noninterlocked), Type of operation, Type of actuator, Control cable gland size, status / position feedback, actuator wiring diagram no., local control panel operation, control system scope.
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INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 2 OF 5 SYSTEM TABLE 13 TABLE 13: FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES) 5. Solenoid Valve Data (*)
(a) (b) (c) (d) (e) (f) (g) (h) (i) 2. Inputs to Bidder from Purchasers System
Sl. no. Service, fluid (*), quantity (*) Type : 2 way, 3 way, 4 way. Size : Pipe, Body, Orifice Operating conditions : Pressure (kg/cm2) CV : Selected, Rated/ Action : Coil # 1, (E/DE), Coil # 2 (E/DE) Coil : Single coil Voltage 110V AC, 220V DC. VA : Normal, Inrush.
Sl. No. signal category (analog / digital), signal type (isolated 4-20 mA DC / NO / NC / CO), No. of signals required by BIDDER, VENDOR tag no., TCE tag no., signal description, signal range / set value, signal destination in BIDDERs system, purpose, reference dwg. No. Remarks. Sl. No. signal category, signal type, no. of signals available to PURCHASER, VENDOR tag no., TCE tag no., Signal description, signal range / set value, signal location in BIDDERs system, purpose, Reference dwg. No., contact rating, Remarks. VENDOR JB No. service description, instrument / signal tag. No., terminal no., -/ com, terminal no. SH / NC, Incoming cable type, Incoming cable no., JB location, Remarks, Sl. No., signal description, signal category (AI / AO), source equipment, source equipment tag no., VENDOR tag no., signal type (RTD/T/C-4-20 mADC), terminal block no., terminal numbers (+, -, SH), Reference dwg. No. Sl. No. signal description, signal category (DI / DO), source equipment, no., VENDOR tag no., TCE tag no., contact type (NO / NC / CO), terminal block no., terminal numbers (NO, C, NC) Reference dwg. No., Remarks (a) Sl. no., (Service Status condition to be indicated for contact signals), Scope, Instrument type, (Indicator / Switch / Transmitter, etc.) General Data
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Outputs from BIDDERs System to PURCHASERs System
4.
Junction Box Schedule
5.
Terminal Details Analog
6.
Terminal details Digital
7.
Schedule of Instruments with Settings
(b)
TCE FORM NO. 120R2
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INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 3 OF 5 SYSTEM TABLE 13 TABLE 13: FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES) VENDOR tag, TCE tag, Location in elevation/rows/ columns, flow diagram reference
(c)
Design Data : (i) Pressure : (Kg/cm2, unit shall be mm wcl for sub-atmospheric pressure) : Normal operating pressure, maximum operating pressure, design pressure, design temperature. Temperature (0C) : Type of element (For RTD PT100, C4-53 & for T/C K.R.S.J, etc.,) normal operating temperature, maximum operating temperature, design temperature. Flow : Fluid, pipe size, velocity (mts/sec), viscosity, maximum pressure loss, normal flow (m3/hr), maximum flow (m3/hr), design flow (m3/hr), DP at maximum flow (mmwcl). Level : Normal level, maximum level, instrument range, engineering units. Accessories, body rating (ANSI), remarks (redundancy of instruments to be indicated here).
(ii)
(iii)
(iv) (v)
8.
List of panels / cabinets & Sl. No., control room layout reference, description, control room mounted tag no., panel / cabinet, location, qty / unit, scope, equipment dimensions height (mm), width (mm), depth (mm), weight (kg), power dissipation (walts), reference dwg. For panel mounting dwg. No. showing external wiring, remarks. 3rd party instrument list Sl. No., description, TCE tag no., VENDOR tag no., location, qty. / unit, scope, dimensions-height (mm), width (mm), depth (mm), weight (kg), power dissipation (watts), reference dwg. No., showing mounting details, reference dwg. No. showing external wiring, remarks. Sl. No., equipment, no. of equipment, no. of bearings / equipment type of bearing, total no. of bearing, speed-normal, maximum, vibration frequency-normal, maximum : vibration range VRMS (MM/Sec), vibration alarm value VRMS (mm/Sec.), vibration trip value VRMS (mm / sec.).
9.
10.
List of bearing vibration measurement (to be furnished for all HT drives in BIDDERs scope).
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11. 12.
INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 4 OF 5 SYSTEM TABLE 13 TABLE 13: FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES) Equipment List Equipment, equipment code, equipment location, remarks.
Cable List (For all cables in BIDDERs scope)
Cable scope, cable no., cable type, source, source location, destination, destination location, signal tag no., service description, remarks, cable length in metres. Loop Drawings shall be submitted for all signals between the field instruments & system cabinet / local panels in BIDDERs scope of supply. The loop drawing shall indicate the field instrument tag no., service, field JB no. (to which the instrument is connected), system cabinet no., CRT / CPU indicator / to PURCHASERs system. The drawing shall also indicate the terminal numbers, polarity & cable numbers for all junctions & hardware / components forming the loop. Loop drawing shall be prepared for each & every signal going to BIDDERs system.
13.
Loop Drawings
A. 1.0 2.0
NOTES : APPLICABLE TO ALL THE DOCUMENTS LISTED ABOVE : Wherever * is indicated, information shall be furnished along with the bid, Balance information shall be furnished during detailed engineering. The details of fields listed in this table is preliminary only. Any additional field (column) requirements of PURCHASER, as finalised by PURCHASER during detailed engineering shall be incorporated. The field width for all the field of dbases, will be given by PURCHASER during detailed engineering. There shall be no duplication of VENDOR tag nos. The VENDOR tag number shall match exactly with VENDOR flow diagrams. TCE tag no., will be furnished at the detailed engineering stage. Data called for in each field of the engineering documents shall be explicitly filled & not referring to some other drawing. NOTES : APPLICABLE TO DRIVE LIST This drive list shall comprise of the following equipment in BIDDERs scope. (i) (ii) (iii) All motor operated unidirectional and bi-directional drives. All control valves / control dampers. Solenoid valves / Pneumatic block valves.
3.0 4.0 5.0 6.0 B. 1.0
2.0 3.0
All drives shall have the facility for manual operation. The information to be furnished under Data required for Electrical Engineering is required for : (i) Electrical Auxiliary system finalisation by PURCHASER.
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INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 5 OF 5 SYSTEM TABLE 13 TABLE 13: FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES)
(ii) 4.0 5.0 6.0 7.0 8.0 C. 1.0 2.0
MCC procurement / finalisation by PURCHASER.
Hence, the information marked * shall be furnished with the bid, positively. Wherever more than one drive of same type is there, Ex. BFP lube oil pump 1, BFP lube oil pump 2, etc., each shall be listed. Three (3) nos., cable glands shall be provided for each Actuator for PURCHASERs control & instrumentation cables, in addition to cable gland for power cable. If some of the drives are supplied by any of the subunits of the Main VENDOR, then a column shall be added and the reference of the unit shall be indicated. Drives shall be listed in the order of the process flow path. Where there is multiple branches of identical system, drives of a particular branch (say 4) shall be listed first followed by identical listing for the second branch, etc.. NOTES APPLICABLE TO TERMINAL DETAILS ANALOG / DIGITAL All terminals including spares shall be listed. For each source equipment, terminal details, the following details shall be added : (a) (b) 3.0 Valve actuator make Valve actuator model DC Starter Valve actuators Local Panels Motor terminal boxes for winding Any other service as applicable.
The specified format is applicable for the following :
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TABLE-14: TRAINING TO BE PROVIDED FOR OWNERS PERSONNEL

SL. NO. TYPE OF TRAINING NO. OF PERSONS DURATION OF TRAINING
1.0
PLANT OPERATION TRAINING
1.1
Each Type Of Plant auxiliary through PLC OS-Training for Control Engineers
SYSTEM MAINTENANCE TRAINING
12
4 Weeks each
2.0
2.1 2.2
I&C Engineers In PLC System Hardware & Software For All Other Instruments/ Systems
6 4
2 Weeks Each Adequate Training
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TABLE-15: ERECTION, FIELD TESTING AND COMMISSIONING REQUIREMENTS

1.0 ERECTION REQUIREMENTS
1.1
The actual location of transmitter racks, junction boxes and other instruments shall be decided by the Bidder depending on the site conditions considering the layout and maintenance aspects. The Bidder shall get prior approval as per approved quality assurance plan of the Purchaser / Purchasers Representative before any installation work starts. If any work is carried out by the Bidder before prior approval from Purchaser / Purchasers Representative and modification is sought by Purchaser / Purchasers Representative later, then the work shall be redone by Bidder without any cost / material implications to the Purchaser / Purchasers Representative. Impulse / sample piping, air supply and pneumatic tubing, cable trays and equipment shall be supported rigid enough to prevent vibration and anchored sufficiently to prevent strains on equipment installed. Supporting clamps shall be provided atleast at every one metre distance for better rigidity. Impulse / sampling piping shall be provided with adequate slope, (preferably 1:10). Hanger and supports shall be so installed as not to interfere with free expansion and contraction of the piping and tubing between anchors. Suitable vibration dampners, etc., shall be provided wherever necessary. In addition, care shall be taken that the arrangement of impulse / sampling piping, air supply and pneumatic tubing from detrimental sagging, mechanical injury, abuse due to unusual service conditions from sources other than those due to pressure, temperature and vibrations. All impulse lines of joints shall be welded type unless otherwise specified. Argon arc welding shall be employed. All the panels, desk, cabinets supplied by the Bidder shall be welded or bolted to the floor channel. TESTING REQUIREMENTS The Bidder shall set up his own instrument laboratory. The calibration equipment shall cover complete range and shall have the desired accuracy of not less than 0.1%. All the calibration equipment shall have the certification from National Physical Laboratory (NPL) or IDEMI for the duration of Contract Period. The Bidder shall follow the standard procedures for calibration of various instruments and as set by the manufacturer of instruments and as instructed by the Purchaser including any requirements of field calibration. First, the calibrations shall be carried out independently by the Bidder and later in the presence of Purchaser who shall certify the same. Proper documentation in this regard shall be maintained and handed over to the Purchaser. All the instruments shall be calibrated for the entire range of the instrument for which it is designed. Calibration shall include test for repeatability. After first commissioning, the instruments shall be tested for calibration again to check whether the instrument maintains its zero and maximum of the range.
1.2
1.3
1.4
2.0
2.1
2.2
2.3
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2.4 All instruments and control equipment shall be calibrated to read correctly to the satisfaction of equipment supplier / Purchaser.
2.5
All switches shall be tested for the actuation of both normally open and normally closed contacts at the desired set points and also for the fixed / differential settings. All the float operated level switches shall be tested for the movement of the float and linkages to make to break the switch contacts by filling up with water before installation. For such tests, necessary testing set up required shall be arranged by the Bidder. All the conductivity type probes and switches shall be tested for performance before installation. Air leak tests shall be performed on all flue gas impulse / sample lines, air supply and pneumatic lines. Necessary equipment such as portable compressor, connecting pipes, materials, cables and test gauges shall be provided by the Bidder. Hydro test shall be performed for all other impulse lines / sampling lines. Necessary equipment such as hydro test pumps and temporary piping to the required point, fill pump etc., materials such as temporary gaskets, miscellaneous fasteners, etc. tools and tackles including test pressure gauges, etc. are to be provided by the Bidder. For all electrical actuators of the valves, functioning, setting and performance of limit switches / torque switches of various positions shall be checked before and after installation of the actuators. The position transmitters for inching applications shall also be calibrated. Pneumatic actuators shall be calibrated at site.
COMMISSIONING REQUIREMENTS
2.6
2.7
2.8
2.9
2.10
3.0
3.1
Prior to taking the instruments in service, all impulse lines, sampling lines and air supply lines shall be blown as required with the establishment of adequate line pressure and temperature conditions to keep the lines thoroughly clean. On-line i.e., without removing control valves from the pipe, calibration of the positioners and stroking of control valves / control dampers shall be carried out as required during control system tuning. Pre-commissioning checks, individuals loop checks, power initialisation, verification of system functioning, trouble shooting final solutions to application and / or instrument problems, etc., is Bidders responsibility. All the required software and hardware changes shall be incorporated as required for successful commissioning to Purchasers satisfaction. Any other tests as may be directed by the Purchaser/Purchasers Representative.
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3.2
3.3
3.4
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3.5 After delivery of the equipment, the Bidder shall locate all the equipment including electronic cards in its final position, check all the power wiring, grounding and interconnection cables, all in accordance with manufacturers recommendations. The Bidder shall perform initialisation of system power, field loading of system configuration / software and data base, demonstration of system functionality to verify conformance with manufacturers instructions and specifications, tuning of control loops, implementation of any configuration changes including hardware, software and additional tappings / instruments, cabinets as required and providing general trouble shooting and final solutions to application and / or instrument problems.
SPECIFIC REQUIREMENTS FOR ERECTION, TESTING, CALIBRATION AND COMMISSIONING
4.0
4.1
The erection of instrumentation system shall be carried out generally conforming to General Technical standards (clause 24.0 of Section D3.3). However, the Bidder shall select and adopt methods and procedures for equipment erection to suit the nature of equipment and erection, involved according to the best modern practice and his own experience.
SCOPE OF WORK FOR ERECTION
4.2 4.2.1
The Bidder shall be required to erect all cabinets, consoles, desks, all cables, conduits, equipment of PLC etc required for completion PLC package covered in this specification. The Bidder shall provide all supervisory, skilled, semiskilled and unskilled labours including instrument tube fitters, licensed cable jointing mechanics etc., tools and tackles, consumable, erection materials required for the complete installation, transport vehicles, hydraulic jacks, welding sets, mobile cranes, blowers and other necessary equipment for timely efficient erection and testing. The Bidder shall maintain proper record of the materials at the place of storage for quick identification as and when required. The Bidder shall carry out all repairs to damages that might have suffered during transit or in subsequent storage and replacement of all lost parts. The Bidder shall furnish a detail erection schedule, which shall be finalised along with the offer keeping in view the overall erection and commissioning schedule. The erection schedule as agreed with the PURCHASER shall be strictly adhered to by the Bidder. The erection work shall include but not limited to the following: (a) Transportation of the tested and calibrated equipment to the place of installation without any damage. (b) Installation of PLC equipment as per bill of material and as per relevant approved G.A and disposition drawing.
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4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
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(c) (d) Installation of the necessary cable and racks with posts, brackets, and fasteners. Installation and termination of electrical, measuring, control, power supply, and signal lines, from the available / to be erected marshalling cabinets to I/O cabinets System cabinets as per relevant interconnecting and terminating drawings prepared by the successful Bidder. This includes laying of all control cables, compensating cables etc. Supply, fabrication and erection of structural steel plates, angles, pipes required for supporting cable trays complete with bolts and nuts. Providing identification of cable by engraved Aluminium tag plates at both ends inside the cabinets, consoles as per cable schedule. Preparation of separate earthing pits as recommended by the PLC system supplier, laying and connection of the earthing cables from different equipment to the respective earthing pit.
(e) (f) (g)
4.3
ERECTION
4.3.1 4.3.1.1
Cabinets and desk

The Bidder shall arrange for the transportation and handling of cabinets and desks from stores to work site suitably without any damage. If any damage is observed before handling, this shall be brought to the notice of the PURCHASER. Before installation of cabinets and desks, the necessary openings and inserts required to be made on the floor by the Bidder shall be checked and then after proper alignment, the cabinets and desks shall be installed on the floor by the Bidder. All necessary civil work to be carried out for this shall be in Bidders scope of supply. The cabinets and desks shall be cleaned by blowing air to remove dust or foreign particles. The Bidder's scope of work and supply shall also include tightening of wires, replacement of broken items and retouching of damaged painted surface of cabinets those has taken place during transport from store to work site and during installation. The Bidder's scope of work and supply shall also include tightening of wires, replacement of broken items and retouching of damaged painted surface of cabinets those has taken place during transport from store to work site and during installation.
4.3.1.2
4.3.1.3
4.3.1.4
4.3.1.5
4.3.2 4.3.2.1 4.3.2.2 4.3.2.3
Cables, cables trays and conduits

All electrical work shall conform to the rules and regulations of Indian Electricity Act. All cables shall be tested for insulation level. Cable ends shall be properly cleaned. The entry to and exit from pipes shall be smooth and free from burr where cables are run through pipes. Cable shall be pulled into the pipes in such a way that there shall
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be no damage to the cables. 4.3.2.4 4.3.2.5 4.3.2.6 Flexible conduits shall be provided wherever necessary. Cable in hot areas shall have proper heat protection. A minimum distance of 400 mm shall be kept between instrument / signal cables and power cables. Each tray shall be filled with a maximum of two layers for instrument and control cables and one layer for power cables providing 20% spare space in the number of layers specified. Instrument Cable Trays, shall be erected vertically as far as possible to avoid dust accumulation. All the cables laid shall be tied individually to the Tray. Thermocouple cables shall be run completely independent of all other cables with minimum separation as per relevant standard and with cross over at right angles. The cabling accessories shall include cage-clamp type terminal blocks, splicing materials, crimping tools, cable support grips, insulating tapes, GI flexible conduits, conduit fittings, GI perforated covered trays, supports, accessories, and cadmium plated trays & cable glands.
4.3.2.7
4.3.2.8
4.3.2.9 4.3.2.10
4.3.2.11
4.4
LOOP TESTING
The action of the controller is set as prescribed. Controller settings for various modes of operation (Proportional band, reset and rate action) are at nominal value. For current signals, 4 20 mA shall be injected and checked the loop for 0%, 25%, 50%, 75% and 100% of fullscale inputs. For temperature loops with thermocouples, a known milli volt signal shall be injected and the output display shall be checked for input signals of 0%, 25%, 50%, 75% and 100%. For temperature loops with RTDs, a known resistance shall be injected in the control cable through decade resistance box and output display shall be checked for 0%, 25%, 50%, 75% and 100%. For field mounted switches for alarms / interlocks, the action shall be simulated by disconnecting the wires / shorting the terminals and the function of the associated system shall be checked.
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
ISSUE R0
TCE FORM NO. 120R2
Spec No.
TCE.5657A-C-500-002


4.4.6 Any equipment required by the Bidder for testing, calibration and commissioning shall be brought by the Bidder at site. The list of such equipment shall be furnished along with the offer.
COMMISSIONING
4.5
4.5.1
The Bidder shall take care to complete all pre-commissioning activities and simulation tests after erection to suit the over all start up of respective plant equipment. The pre-commissioning activities of the system shall be completed at least two (2) days in advance as per the schedule of plant start-up. The controllers shall be tuned as per the process requirement. The list of set points, alarms / interlocks, settings for the controllers shall be furnished in the standard format and handed over to the PURCHASER. Control loops shall be put in auto mode as per the operational requirement of different phases. Bus Worst loading conditions calculation shall be proved at the time of commissioning. Before taking over of the plant by the PURCHASER, all the system and auto control loops shall run satisfactorily for at least one month at varying loads without disturbing any adjustment. During this period, supervision and maintenance of the system shall be the scope and responsibility of the Bidder. The performance test shall be carried out for the system offered and certificates to these effects shall be approved by the PURCHASER.
4.5.2
4.5.3
4.5.4
4.5.5 4.5.6
4.5.7
ISSUE R0
TCE FORM NO. 120R2
Spec No.
TCE.5657A-C-500-002


Power Plant Control and Instrumentation Specification

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Power Plant Control and Instrumentation Specification

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Anuppur Thermal Power Project, Phase-1, 1000 (+20%) MW

MB POWER (MADHYA PRADESH) LIMITED

SPECIFICATION NO. TCE.5657A-H-500-001 FOR EPC SPECIFICATION

VOLUME V SPECIFIC TECHNICAL REQUIREMENTS - INSTRUMENTATION AND CONTROL WORKS

MARCH 2009 (Ref. no.: MBPMPL/RfP/EPC/2008-09/144)

MB POWER (MADHYA PRADESH) LIIMIITED MB POWER (MADHYA PRADESH) L M TED

SPECIFICATION NO. TCE.5657A-H-500-001 FOR EPC SPECIFICATION

VOLUME V SPECIFIC TECHNICAL REQUIREMENTS - INSTRUMENTATION AND CONTROL WORKS

MB POWER (MADHYA PRADESH) LIMITED

TCE FORM NO. 329 R4

MB POWER (MADHYA PRADESH) LIMITED

VOLUME V PART - B SECTION D6 INSTRUMENTATION AND CONTROL WORKS - BOP

TCE FORM NO. 329 R4

MB POWER (MADHYA PRADESH) LIMITED

CONTENTS LIST OF TABLES

TCE FORM NO. 329 R4

TCE Consulting Engineers Limited

Volume V SECTION: D 6.1

INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY

(f) (g) (h)

TCE FORM NO. 120R2

TCE Consulting Engineers Limited

Volume V SECTION: D 6.1

INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY

2.0 2.1 2.1.1

(c) (d) (e) 2.2 2.2.1

LOCAL OPERATION OPERATION FROM LOCAL CONTROL ROOM (CCR)

TCE FORM NO. 120R2

TCE Consulting Engineers Limited

Volume V SECTION: D 6.1

INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY

TCE FORM NO. 120R2

TCE Consulting Engineers Limited

Volume V SECTION: D 6.1

INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY

TCE FORM NO. 120R2

TCE Consulting Engineers Limited

Volume V SECTION: D 6.1

INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY

(b) Ash handling plant:

TCE FORM NO. 120R2

TCE Consulting Engineers Limited

Volume V SECTION: D 6.1

INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY

(c) DM water plant & Effluent treatment plant:

TCE FORM NO. 120R2

TCE Consulting Engineers Limited

Volume V SECTION: D 6.1

INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY

(e) Raw water and pre-treatment system:

TCE FORM NO. 120R2

TCE Consulting Engineers Limited

Volume V SECTION: D 6.1

INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY

TCE FORM NO. 120R2

TCE Consulting Engineers Limited

Volume V SECTION: D 6.2 SHEET 1 OF 8

TCE FORM NO. 120R2

TCE Consulting Engineers Limited

Volume V SECTION: D 6.2 SHEET 2 OF 8

TCE FORM NO. 120R2

TCE Consulting Engineers Limited

Volume V SECTION: D 6.2 SHEET 3 OF 8