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15.4.CONTROL PHILOSPHYOctober 30, 2008
Filed under: Uncategorized shivajichoudhury @ 5:23 am
Tags: CONTROL PHILOSOPHY
15.4 SPECIFIC CONTROL SYSTEM REQUIREMENTS
15.4.1 CONTROL PHILOSPHY OF COAL HANDLING PLANT
a. The control & instrumentation shall be through microprocessor based PLC system for the
entire Coal handling plant covering the total functional requirement of sequence control,
interlock and protection, monitoring, alarm , data logging etc.
b. The design of the control system and related equipment shall adhere to the principle of Fail
safe operation of all system levels i.e the failure of signal, failure of power or failure of
any component should not cause a hazardous condition and at the same time prevent
occurrence of false trips and provide reliable and efficient operation of the plant under
dynamic conditions.
c. The system shall provide an integrated control & monitoring of coal handling plant equipment
from a Main CHP Control Room. The control Room operator shall be provided with
color graphic displays of the Coal handling plant and with sufficient details to allow
proper control and monitoring of the plant function.
d. The entire Coal handling plant will be controlled from the following control points.
i) The overall operation and control of the entire Coal Handling Plant, with acontrol desk and
suitable control panel will be provided at the Main CHP Control Room .
The main Control Room of CHP shall have control desk in which the operating station
along with CRT and keyboard will be mounted and control panel shall have the CHP
mimic, indicating lamps, push buttons meters, totalizer etc. and the alarm fascia windows
at the top. CHP main Control Room will house system cabinets in addition to control
desk.
The main switchgear will be housed in the main control room building for CHP and
located near the crusher house, the I/O cards and the relays for drives and the equipments
which are around the crusher house shall be mounted in the system cabinets which are
located in the main control room building.
ii) The traveling Trippler and its associated drives shall be controlled from local panel located
near the bunker floor MCC room .The system cabinet for remote I/O cards relays and
interfacing equipment etc. for the Traveling Trippler drives and equipment shall be
located in its MCC room to provide status indication /alarms for traveling Tripler

operation in the main CHP control room. The system cabinets shall be suitable for
protection class IP-65 .
iii) Similarly Coal unloading operation for wagon rakes near track hopper area shall be
controlled from control panel located in the control room with in building near track
hopper. The ON/OFF operation of paddle feeders shall be controlled from this panel apart
from its local Control Panels. The control room in this building shall be provided with
glass panel to have full view of rakes unloading operation
The integrated weigh bridges shall be provided for the measurements of weight for each
wagon at wagon trippler complex. Each weighing bridge shall have built in diagnostic
and weight measurements software .The weigh bridges shall be controlled from the panel
located in control room at Tripler complex..
The remote I/Os relays, interfacing equipment etc. will be located in system cabinets in
building at Tripler complex to provide status indication/alarm of the unloading operation
in the main control room.
iv) Stacker Reclaimer shall be provided with PLC system. The remote I/O and relays will be
provided on operators cabin of stacker re-claimer to indicate Stacker re-claimer
operation in the main control room.
e. Following Equipment will come under sequential interlock scheme and can be started /
stopped from control desk in the main CHP control room with indication on CRT and
mimic panel with fault annunciation facility:
i. All belt conveyors.
ii. Vibrating feeders.
iii. Screens
iv. Crushers
v. Flap Gates.
The sequential control system shall provide stream selection from under ground conveyor
of track hopper, from crusher conveyor to stacking yard conveyor, from stacker re
claimer to staking yard conveyor during reclaim mode etc.
However, all the above mentioned equipment will have its local control panels/ station
for start / stop and /or any other function required with suitable lockable type local /
remote selector switch shall be housed in local panel and placed near drives
f. Following equipment will not generally come under interlock scheme and can be started /
stopped / controlled from its local panels shall be provided with status indication and
alarms on mimic at control panel in main CHP control room:
i. Belt Weigher :
ii. Bunker Level Indicator:
iii. Paddle Feeder :
iv. Stacker/Reclaimer:
v. Coal Sampling System.
vi. Mobile Trippler :
vii. Magnetic Separator in line.
viii. Ventilation system
ix. Dust extraction System.
x. Dust suppression System.
xi. Vibration monitoring system( for coal crushers)

g. Following equipment will be operated from its local panels without any indication in control
desk and mimic.
i. Electric Hoist.
ii. Sump pump
iii. Suspended magnets
h. All equipment systems and accessories supplied shall be from the latest proven product range
of a manufacturer.
One communication gateway shall be provided for hooking-up CHPcontrol system with
DDCMIS control system located in central control room of power plant.

15.4.2 CONTROL PHILOSPHY OF ASH HANDLING SYSTEM.

15.4.2.1 Control Philosophy.
The control & instrumentation shall be through microprocessor based PLC system for the
entire Ash handling plant covering the total functional requirement of sequence control,
interlock & protection, monitoring, alarm data logging etc.
The PLC system shall be an integrated control and data acquisition system for providing
control & monitoring of Ash handling plant from a Main AHP Control Room. The control
room operator shall be provided with colour graphic displays of the Ash handling plant
and with sufficient details to allow proper control & monitoring of the plant function. The
operation of ash handling plant will be possible in Auto / Semi-auto / manual mode .
The entire Ash Handling plant will be controlled from the following control points:
For overall operation and control of entire Ash Handling Plant with fly ash system,
bottom ash system, ash water and slurry pumping system and ash disposal system, a
control desk along with control panels mimic will be provided at the Main AHP Control
Room.
i) In order to have ease of operation and maintenance, the Central Control Room of AHP shall
have control desk in which the operating station along with CRT and keyboard will be
mounted and the control panel shall have the AHP mimic, indicating lamps, push buttons,
control switches, indicating instruments/recorders etc. the alarm facia windows. AHP
Central Control Room will house system cabinets in addition to control desk.
Following Equipment will come under interlock scheme and can be started/stopped from
control desk with indication on CRT and mimic panel with fault nnunciation facility:
a. All Pumps/Blowers and Compressors .
b. Bottom Ash system.
c. Fly ash system, comprising of ash extraction from ESPs & duct hopper to buffer
hopper located near ESPs and fly ash transportation system from buffer hopper to
storage silos.
d. Ash slurry disposal system.
e. Bottom ash over flow system comprising of bottom ash over flow water storage tanks,
settling tank, ash over flow water pumps, sludge pumps etc.
f. Silo system.
g. All Motorized valves
h. All pneumatic operated valves.

For local operation in the Bottom Ash area one (1) no. Bottom ash control panel/cubical
is provided for each unit .this panel shall provide control for clinker grinders, bottom ash
discharge valves, jet pumps for ash slurry transport etc.
ii) A control panel/cubicle shall also be provided in MCC room near silo area for fly ash
collection system. The panel shall provide control for dry pneumatic ash extraction
transportation and unloading system
iii) The system cabinet associated with various local controls shall be located near the local
control panels. These cabinets shall accommodate I/O cards, relays, interfacing
equipments etc. To provide status indication/ alarms etc. for various drives/ valves
/equipments in main AHP control room.
iv) The system cabinets associated with other system/equipment being controlled from main
control room shall be located in the main AHP control room. The various local control
panels envisaged will be located/installed in different areas for ease of operation of
different sub systems. Suitable alarm/annunciation system will be provided to warn of
any mal-functioning g of the ash handling system.
v) The control panel shall be provided with adequate nos. of facia type annunciation windows for
audio-visual summary fault annunciation purpose.
vi) One communication gateway along with suitable cables shall be provided for hooking up the
ash handling control system with DDCMIS control system located in the central control
room of the power plant.
vii) All instruments like vacuum/pressure switches, pressure gauges transmitter, level ontrollers,
level switches/indicators, level probes, flow indicators and any other special instruments
for remote measurements in the main control room shall be provided by the contractors

15.4.3 CONTROL PHILOSPHY OF PLANT WATER SYSTEM.

The control & instrumentation shall be through microprocessor based PLC system for the
entire Plant water system covering the total functional requirement of sequence control,
interlock & protection, monitoring, alarm data logging etc.
The PLC system shall be an integrated control and data acquisition system for providing
control & monitoring of Plant water system from a DM plant Control Room. The control
room operator shall be provided with colour graphic displays of the entire system with
sufficient details to allow proper control & monitoring of the plant function. The
operation of plant water system will be possible in Auto / Semi-auto / manual mode
The entire Plant water system will be controlled from the following control points:
For overall operation and control of entire Plant water system i.e.Raw water system,
Chlorination plant for raw water system and DM plant system, a control desk along with
control panels mimic will be provided at the DM plant Control Room.
i) In order to have ease of operation and maintenance, the l Control Room of DM plant shall
have control desk in which the operating station along with CRT and keyboard will be
mounted and the control panel shall have the Plant water system mimic, indicating lamps,
push buttons, control switches, indicating instruments/recorders etc. the alarm facia
windows. DM Control Room will house system cabinets to accommodate I/O cards ,drive
cards, controllers etc. with the associated system.

ii) The following local control panels are envisaged .which are located near their associated
system.
a) Raw water system local control panel
b) Chlorination plant local control panel for raw water treatment and CW water treatment
c) Chlorination plant local control panel for potable water system.
d) CW treatment plant local control panel
e) Transfer of acid/Alkali local control panel for DM plant
f) Any other control recommended by contractor
iii) The local control panel shall be provided with adequate nos. of facia type annunciation
windows for audio-visual annunciation to warn operator for any mal functioning.
iv) All instruments like vacuum/pressure switches, pressure gauges transmitter, level controllers,
level switches/indicators, level probes, flow indicators and any other special instruments
for remote measurements in the main control room shall be provided by the contractors
v) The system cabinet associated with various local controls shall be located near the local
control panels. These cabinets shall accommodate I/O cards, relays, interfacing
equipments etc. to provide status indication/ alarms etc. for various drives/ valves
/equipments in DM Plant control room.
vi) The following minimum safety inter locks shall be provided in the system for pumps and
drives.
a) water level in the sump very low
b) Pressure at pump discharge due to accidental closure of valve- high
c) Winding temp of Motor(for HT drives)high
d) Temperature of pumps thrust bearing (HT drives only)-High
e) Bearing vibration (for HT drives only)-High
vii) Emergency stop of drives has also been envisaged from the local push button (lockable stay
put type) provided near the drive. This local push button will be directly wired to
Switchgear/MCC. To monitor the HT/LT drives following minimum signals shall be
exchanged between Switch gear/MCC and PLC system:
a. Drive start/stop command.
b. Drive status feedback (ON/OFF)
c. Ready to start.
d. Electrical trips (from SWGR/MCC).
viii) DM plant PLC system shall be provided with suitable communication gateway for
monitoring through DDCMIS in central control room
15.4.3.1 SYSTEM DESCRIPTION :
A) RAW WATER SYSTEM CONTROL.
i) The pre treatment plant is controlled from PLC, and the chemical dosing is envisaged only in
manual mode from local. The Dosing pumps ,Tank agitator, Sludge pumps and
clarifloculator bridge pumps can be operated from remote (i,e.PLC) as well as local
control panel.
ii) Drives on the clarifier bridge i.e. rake mechanism drive motor and floculator agitator motor
shall be operated from local start/stop push buttons to be located near it.
iii) The clarified water storage sump level is controlled by raw water inlet control valve with
respect to the level in the clarified water sump .

iv) All the chemical dosing/solution tank shall be provided with local level indicator and low
level switch ,which shall be interlocked with respective dosing pumps i.e the pump shall
trip in case of the low level in the respective tank.
v) The sludge sump shall be provided with low and high level switch and selected pump
whichever in auto shall start automatically when sludge sump level is high and stop
automatically when sump level is low.
B) CHLORINATION PLANT CONTROL.
( control for CW water treatment, Raw water treatment)
i) The chlorination plant shall be controlled manually from local control panel located in
chlorination system main control building. The control of all the drives and auxiliaries
shall be implemented from this panel. The control panel shall have operators interface
devices as selector switches, indicating lamps, push buttons and other required indicators.
ii) The control panel shall also provided control for absorption system to be located in main
chlorination building.
iii) Provision shall also be given for local operation of pump/drives from control Box.
Emergency trip push buttons shall be provided for all such drives which needs immediate
stopping due to any mal- functioning of equipment or due to health/operator hazards.
Provision shall be made to operate the booster pumps through selector switch.
iv) Local starting shall be possible through remote/local selector switch on control panel or in
MCC. Tripping of / emergency stop of dries motors locally shall be permissible
irrespective of position of remote/local selector switch. provision for locking the local
stop push buttons after tripping the motors from local push buttons shall be provided.
v) A window based annunciator system shall be provided in local control panel for all major
alarms/trip conditions. The annunciation system shall also include alarms for abnormal
level conditions in caustic solutions preparation cum recirculation tanks,
vi) The chlorination of potable water system shall be separately carried out through chlorine
cylinder .This arrangements is located near by DM plant building .The operation
&control is similar to above and operated through a local control panel located there.
C) D.M. PLANT CONTROL.
i) The operation and control of Dematerializing Plant shall be through a PLC in Auto/semi auto
mode. However, there shall be provision to changeover to manual operation. The control
operation philosophy shall include sequential control like semi-auto/remotemanual/manual , facility like step numbering, step time elapsed time, hold/release push
button through CRT, flow of control logic (sequence of various steps) for smooth
operation of the entire plant .
ii) DM plant control system shall be designed so that complete Operation, Control & monitoring,
interlocks, logic etc. of Raw Water system and associated clarified sump pumps, Raw
water chlorination system, service water pumps, CT make up pumps, Potable water
pumps control, DM feed pumps etc.shall be provided from DM plant control room
iii) The operator will initiate the operation of regeneration/rinsing/backwashing of a particular
ion-exchange unit/filter based on the criteria described below, but the change from one
step of the sequence to the next will be automatic. The system will employ a logical
system, which will link the various steps such as closing/opening of different valves,
starting/stopping of various pumps, which make a sequence.
iv) Filters/lon exchange units will be automatically isolated from the system as follows:
Pressure Sand Filter : On passing predetermined volume of water or high

Differential pressure across the filter bed.

Activated Carbon Filter : On passing predetermined volume of water or on reaching
preset residual chlorine level of high
Differential pressure across the filter bed.
Cation : On reaching high sodium leakage or on passing of
Predetermined volume of filtered water whichever
Occurs first.
Anion Unit : On reaching higher conductivity & Silica at
Outlet or on passing of predetermined volume of
Decationised water, whichever occurs fist.
Mixed Bed Unit : On reaching higher conductivity, pH at outlet or
On passing of predetermined volume of deionised
Water or on reaching preset silica level, whichever
Occurs first.
v) As state above, the isolation of the exchanger unit from the system will be displayed on CRT.
The operator will then select the particular vessel to be regenerated through option and
selected for regeneration. On selecting the option the regeneration cycle shall start
automatically. During regeneration, the progress of different sequence/sub-process shall
be displayed to the operator in the form of step number as well as step description which
is in progress, the set time for that.
vi) The progress of the sequence shall be displayed to the operator through suitable means. The
system will incorporate the necessary safety systems, locking systems and manual
emergency system. On failure of logic system, in between , the failure shall be
annunciated to the operator and all the valves corresponding to that unit, being
regenerated shall close automatically.
vii) A graphic depicting the complete plant process operations shall be designed properly and be
available on CRT. The graphic shall indicate the different filters, exchanger units,
measuring tanks, opening/closing of all valves (motorized and solenoid operated), ON /
OFF of different pumps and blowers etc. Color coding shall be used to differentiate lines
for different services such as normal water lines, backwash lines, Acid / Alkali lines etc.
viii) Separate conductivity measurement, silica mesurement and pH measurements shall be
employed for ensuring the various parameters in the effluent and in the rinse line of
caution, anion and mixed bed exchanger units for normal and rinsing operation. The
conductivity cell in the rinsing line shall be automatically isolated during the first half of
the rinsing cycle and shall be connected automatically during the second half of rinsing
cycle when the conductivity is less than 100 micromhos/cm excess over the rinse water
conductivity.
ix) Discharge valves of all pumps of the entire plant, connected with semi-auto/remote manual
operation shall be pneumatically operated: and all pumps, pneumatically operated valves,
drive motors of all the other equipment and other accessories, pneumatic on-off valves,
etc. shall be completely suitable for remote manual operation from operating
console/panel. All drive motor shall also be provided with arrangement of local stopping.
Tripping of drive motors from local panel shall be permissible irrespective of the position
of local-remote selection option. Local stop push-button shall be locked after tripping the
motor from local.

x) Although the basic demineralising process is semi-automatic in nature, following operations

shall be performed manually.
Unloading and Transfer of Acid.
a. Hydrochloric acid will be unloaded from the road tank-cars by operating any one of the acid
unloading pumps. Opearation shall be controlled from local panel.
b. Hydrochloric acid, stored in over ground tanks, will be led remote manually by gravity to the
acid measuring tanks for cation, mixed bed units to fill up to the desired level.
Subsequent transfer of acid from the measuring tanks to the ion-exchanger units as
required in regeneration operation is however automatic.
Unloading, Preparation and Transfer of Alkali.
a. Caustic solution will be unloaded from the road tank-cars by operating any one of the Caustic
unloading pumps. Operation shall be controlled manually from local panel.
b. Caustic solution, stored in over ground tanks, will be led remote manually by gravity to the
caustic measuring tanks for anion, mixed bed units to fill up to the desired level.
Subsequent transfer of caustic from the measuring tanks to the ion-exchanger units as
required in regeneration operation is however automatic.
c. All operations in items (a) and (b) will be controlled manually from the local panel.
d. Transfer of alkali to the respective measuring tanks for anion and mixed bed exchanger units
will be done remote manually. However, subsequent transfer of alkali to respective ion
exchanger units will be automatic.
Neutralization of Waste from DM Plant.
a. After completion of regeneration of one cation and one anion exchanger, the waste generated
during regenerations will be thoroughly recirculated in the neutralizing pit and if
necessary, acid/alkali solution will be added to make the waste slightly alkaline.
b. When required pH of waste solution has been reached, the waste solution will be pumped to
the effluent treatment plant area and the effluent shall conform to IS-2490. The pump will
automatically be tripped when the level in neutralization pit reaches very low.
c. Priming of pumps operating under suction lift and operations as in (a) and (b) will be done
manually. All pump operation shall be controlled from the local panel.
D) CW TREATMENT PLANT CONTROL
(for make up to condenser)
The operation and control philosophy of circulating water treatment plant shall be as
below:
i) Sulphuric acid shall be unloaded by two no. unloading pumps into over ground acid storage
tanks. Acid shall be subsequently transferred to acid dosing tanks by using above
unloading pumps.
ii) The sulphuric acid dosing pumps operation shall be auto and manual from local control panel.
In the auto mode ,the rate of acid dosing shall be controlled by auto adjusting of the
stroke of the pumps by sensing of ph of circulating water. However the starting and
tripping of the dosing pumps shall be controlled by the level switches of the dosing tanks.
iii) During normal operation sulphuric acid dosing pumps shall operate in the auto mode and
inject sulphuric acid to maintain the ph of circulating water at desired level so that
alkalinity remains with in desired limits.
iv) The operation of other chemical dosing pumps like anti scalant dosing pumps, anti corrosion
dosing pumps and biocide dosing shall be manual from local control panel operation of
the pumps shall be guided through the level of the respective tanks.

15.4.4 CONTROL PHILOSPHY FOR COMPRESSED AIR SYSTEM

15.4.4.1 CONTROL PHILOSOPHY.
i) Complete automation of the Compressed Air System and Air drying Plant shall be based on
dedicated microprocessor based PLC Control System. The Control System shall be
comprising a Processor Unit, Input./Output modules, LCD screen display The PLC l will
be housed in local control panel located in compressor room/compartment. .
ii) The local control panel shall house PLC hardware (processors, I/O cards, relays, cables etc)
LCD screen , Alarm annunciators configured in PLC. Indication lamps, witches,
Start/Stop push buttons, Auxiliary relays, Motor current etc.,through the local control
panel, local, manual and automatic operation of the compressed air system shall be
carried out for local operation of the system
iii) Each compressor shall be suitable for individual and / or parallel operation with other
compressors at any demand rate from zero to maximum capacity . Each compressor shall
be suitable for start up and operation of a second or third operating with the first
compressor in operation at all load with no instability in performance.
iv) The operating compressor for units shall be on automatic mode .both service air & instrument
air is is fed from the same and common compressor. The compressors shall be utilized for
On-off/load control as decided by the operator. All necessary instruments /controller and
interlock /protection /monitoring and sequential logics controls shall be provided for
implementation andare achieved by PLC.
v) Each air dryer shall be provided with independent microprocessor PLC, heater, set of absorber
. With a selector switch ,the particular air dryer is selected and then the operation is fully
automatic. Start up and shut down permissive interlocks for compressor and air drying
plant shall be provided for safe operation of the equipment.
vi) Hooking up with central control room DDCMIS will be done through proper gateway and
communication cables.
vii) All process connection and piping materials including pipes, valves, manifolds and fittings as
required for connecting all field instruments shall be provided.

15.4.5 CONTROL PHILOSOPHY OF FUEL OIL STORAGE AND HANDLING SYSTEM

i) Two no control panels (Local control panel-1 & Local control panel-2) are envisaged for
control and operation for fuel oil unloading, storage & transfer system. Local control
panel-1 shall be placed at fuel oil pump house for control and operation of HFO/LSHS &
LDOunloading, storage and transfer operation. & Local control panel-2 shall be located
in Fuel oil pressuring and heating building for control and operation of HFO/LSHS &
LDOday storage tank.
ii) When the unloading header & the piping at the pump suction becomes filled with oil and the
steady supply is ensured at the suction pipe the unloading pumps shall be started manually
from push buttons in the local control panel-! located in the fuel oil unloading pump house.
These pumps shall,however, trip automatically in the event of high level in the respective
oil (LDO or HFO/LSHS) storage tank. Standby pump shall start automatically whenever
any operating pump trips due to any fault ( echanical / electrical) or discharge header

pressure low. The differential pressure across the suction duplex strainer high initiates
alarms to change the duplex strainer position.
iii) The transfer pumps to day tank shall be started manually from push buttons in the above local
control panel-1. These pumps trip automatically when the level in the source storage tank
goes low or the level of respective day oil tank goes high. These pumps will also be
prevented from starting in case of low level in the respective source storage tank, or high
level in respective day oil tank or high pressure drop across the respective suction strainer.
Stand-by pump shall start automatically whenever any operating pump trips due to any
fault (mechanical/electrical) or discharge header pressure goes low.
iv) The drain oil pump will start/stop automatically on high/low level initiation. Further there
should be provision for alarm also. The standby pump shall also operated automatically
in case the operating pumps trip.
v) Local emergency stop push button shall be provided for all electrical drives.
vi) Steam flow to HFO/LSHS storage and day tank floor coil heater shall be controlled by
pneumatically operated control valve (ON-OFF type) to maintain the desired oil
temperature.
vii) Steam flow to suction heater of HFO/LSHS day tanks shall be regulated through
pneumatically operated control valve on the steam supply line to the suction heater and
the same shall be actuated from heater outlet oil temperature.
viii) The Local control panel-1 & Local control panel-2 panel shall include start/stop buttons for
all drives, status indication etc. and shall also include complete annunciations (alarm &
indication) with TEST/ACKNOWLEDGE/RESET push buttons.
ix) One communication gateway shall be provided by hooking up the system with DDCMIS for
monitoring from central control room
x) All the instruments shall be supplied as required with all necessary accessories for safe and
efficient running of the plant.

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15.9 INSTRUMENTS AND CONTROL CABLESOctober 25, 2008

Filed under: Uncategorized shivajichoudhury @ 10:18 am
Tags: instrumentation cable
15.9 INSTRUMENTS AND CONTROL CABLES
15.9.1 All interconnecting cabling required for C&I systems/equipment, inter-panel
cabling, power supply cabling etc.) shall be included in the scope of this
specification. The cables supplied shall include but not be limited to the
following :
i) Control cables (1.1 kV, multi-core, 1.5 sq. mm) stranded copper conductor, PVC
insulated, steel wire armoured and PVC sheathed, flame retardant low smoke.
ii) Instrumentation cables
iii) Pre-fabricated cables
iv) All special cables i.e. screened, twisted pair co-axial, heat resistant, etc. required
for C&I system.
v) Power supply cables. These shall be Red, Yellow, Blue, Black coloured for three
phase with neutral system. For DC these shall be coloured Red & Black.
vi) Compensation cable for Thermocouples.
vii) Any other required for C&I systems not specifically brought out above.
15.9.2 Laying, termination and ferruling of all cables covered in this specification
shall be included in the tenderers scope. Requisite wiring schedules and
cable schedules shall be prepared by the successful bidder and shall be
subject to approval by purchaser. All cables shall be terminated with proper
lugs. At external terminals inside the panel, there should be sufficient space
so as to ensure easy replacement and fixation of external cables.
15.9.3 The cables in hot zone shall be fire and heat resistant type and be laid in
insulated heat proof conduits upto junction boxes located far away from hot
zone.

15.9. 4 Special earthing requirements of the system, earthing details etc. should be
brought out by the bidder for the equipment being supplied. All earthing shall
be done with green coloured leads to have proper distinction. Two copper
earth bases of 755 mm should be provided in each panel.
15.9.5 The philosophy of termination of various type of filed instruments/designs
shall be submitted in advance for the approval of the owner.

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15.11 Plant Communication System

Filed under: Uncategorized shivajichoudhury @ 10:15 am
Tags: Plant communication system
15.11 PLANT COMMUINICATION SYSTEM
15.11.1 The system shall consists of electronic private automatic branch exchange
(EPABX ), public address for the complete power plant including switchyard,
coal handling areas, ash handling areas, CW and other off site areas.
Electronic Private Automatic Branch Exchange (EPABX)
Plant communication system shall include a private telephone exchange. The
telephone exchange shall be 32 bit microprocessor base Electronic Pvt.
Branch exchange (EPABX) for industrial telephone communication system.
The exchange shall have facility to connect D.O.T / truck lines
The EPABX shall be of approved technology of department of
telecommunication, Government of India. It shall have fully non blocking
architectural.
EPABX shall have `1 no. 200 lines, expandable to 256 lines including 8 P&T
and digital lines.
15.11.2 The exchange shall be suitable for high speed digital data and voice
communication and shall have the facilities to connect data terminals from
fax machine and personal computers along with telephone services.

15.11.3 The battery and battery chargers combination shall be such as to ensure
continuity of D.C. supply to EPABX system at all times without even
momentary interruption of serviced.
15.11.4 The facility to be provided by EPBAX system shall include but not limited to
the following:
i. Hold for enquiry
ii. Shuttle on enquiry calls.
iii. Call store and retrieve.
iv. Wait on busy
v. Pick-up
vi. Call transfers.
vii. Conference
viii. Automatic call back.
ix. Call diversion.
x. Music on hold.
xi. Auxiliary equipment assess.
xii. line lock out.
xiii. Howler tone alert.
15.11.5 Operator Console.
The operator console shall have PC base maintenance cum-operation /
Administration facilities along with necessary display (VDU), key board printer
etc. and include but not limited to the following features;i. Subscriber calling.
ii. Call hold.
iii. Camp on ringing.
Iv,. Camp on busy.
v. Prevention of double cam on.
vi. Serial calls.

vii. Call monitoring.

viii. Busy over right.
ix. Abbreviated dialing.
X, Answering priority
xi. Call sequencing.
xii. Paging access.
xiii. Station busy display.
xiv. Incoming call type display.
xv. Trunk number and type display.
xvi. Waiting call display.
xvii. System alarm display
xviii. Digital clock.
xix. Listen in
xx. Night / off duty service.
xxi. Departmental calls.
xxii. First party release.
xxiii. On line package replacement.
xxiv. Direct station selection.
xxv. Direct inward dialing.
15.11.6 Telephone set.
The telephone sets shall be of the following types :
Desktop push button operated decadic type with tone dialing (ordinary)
Type A.
Desktop push button operated decadic type with tone dialing and 10 nos.
memory storage type B
Same as type A but wall mounted type instruments type C
Flamproof telephone instruments type D.

15.11.7 Telephone cables.

Telephone cable shall be 0.5 mm dia annealed electrolitic copper conductor
both inner and outer sheet PVC insulated, color coaded twisted pair, laid up ,
taped galvanized round / flat wire armoured conforming to IS-1554.
Cable sizes shall be standardized in terms of the no. of pairs , which shall be
100 pairs, 50 pairs, 20 pairs, 10 pairs, and 5 pairs.
15.11.8 Junction boxes.
The telephone junction boxes shall be of MS steel / fibre having IP-52 degree
of protection for outdoor duty and IP-42 for indoor duty. It will be complete
with jumper , terminal block, earthing , studs suitable for terminating OR
looping telephone cables.
15.11.9 Public Address (PA) System.
Distributed PA system shall be supplied for the main plant, offsite areas and
CHP areas. PA system shall be micro-processor based and user
programmable. The system shall comprise of four (4) sub-groups, namely
Sub-group-1 for Unit No.1. Sub- group-2 for Unit No.2 , Sub-group-3 for
Common Areas like Switchyard and Offsets, Sub-group-4 for CHP area. List of
distribution of PA system Field Call Station (CCS) is given in Annexure-B.
15.11.10 The system shall have four (4) channel party and page system with facility
of inter connection among the sub-groups through Master Call Station (MCS).
The system shall be operative without interruption even on station AC supply
failure. Incoming supply shall be fed from main plant UPS.
15.11.11 The PA system for coal handling plant area, shall be suitable for heavily
dusty atmosphere. This system shall avoid use of handsets, as these are
susceptible to pilferage in such areas.
15.11.12 System details
a) PA system shall have four (4) channels party / channel page system.
Following communication modes are possible:
i. Between Field Call Station (FCS) in the same subgroup without the help of Master
Call Station (MCS).
ii. Between Master Control Station and any Field Call Station (FCS),
iii. Between an EPABX subscriber with the Field Call Station (FCS) through EPABX
interface.

Individual system shall be expandable with maximum number of sets per

system limited to 100 nos.
b) each group shall consist of the following main equipment.
i. Indoor/Outdoor, column/wall/desk-mounted Field Call Stations (FCS) with built inamplifiers of adequate output capacity. Extension amplifiers shall be provided
for desktop mounted handset station wherever needed.
ii. Horn type loudspeakers.
iii. Indoor cone type loudspeakers.
vi. Main junction boxes & distribution boards and junction boxes for handset station
and for loudspeakers etc.
v. Weatherproof canopy / box for outdoor handset stations.
vi. Acoustic hoods.

vii. Cables.
viii. Conduits, if required.
ix. Central Control Exchange.
x. One desk mounted type Master Call Station (MCS).
c) Desk mounted HS for unit control rooms shall have snap action self return micro
switches for different functions such as PAGE, LOUDSPEAKER MUTE and
SIREN, LED indicating lights, a built-in-loud speaker and dynamic, noise
canceling microphone.
d). Desk mounted Master Control Station (MCS) shall have a multifunction keyboard, a backlit display, a press to page switch, a gooseneck microphone with
dynamic noise-canceling and a built in speaker. The communication from MCS
to any field station is a hands-free voice switch duplex communication
without requiring number dialing.
e) Outdoor/Indoor FCS shall be provided at various locations of the plant and
auxiliary buildings. In some areas for noisy areas such as turbine hall, mills
etc. HSs shall be provided with acoustic hoods to cut down the ambient noise
for proper communication.
f) Where cable trays are not available cables shall be laid directly along the wall.
g) The outdoor LS shall be of weather proof die cast aluminum construction.
h) All outdoor HSs shall be provided in the weatherproof boxes with canopies.

i) For areas where false ceiling will be provided, cone type speakers shall be suitable
for false ceiling mounting.
j) All outdoor type handsets and speakers shall be provided with dust and weather
proof, pilfer proof enclosure with locking facilities.
15.11.13 Walky Talky System
Walky Talky System shall be a two-way radio communication system with an
effective reach of 5 km. Radius. The system shall comprise of repeater, a VHF
antenna and 20 Nos. talk-back transreceivers.
Repeaters are special relay station which re-transmit one users transmission
to another. If comprises of receive, transmitter, interface controller, power
supply and duplexer.
As soon as repeater receives a valid signal its transmitter turns on. The receives
audio is fed into the transmitter, which then retransmits the same.
Retransmission usually happens on a different frequency so that it does not
load the receiver and create a loop. The duplexer provides additional isolation
of 0-1000 dB.
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15.2.0 General RequirementsOctober 30, 2008
Filed under: Uncategorized shivajichoudhury @ 5:27 am
Tags: 15.2.0 General Requirements
15.2.0 General Requirements
15.2.1 The Contractor shall provide Control & Instrumentation systems PLC based control
systems for station auxiliaries equipment mounted/local instruments and transmitters
including sensing elements as required, Local instrument enclosures/racks, Local gauge
boards/racks, Process Connection and Piping, Sample lines, Electric Power Supply
System, Actuators for valves, Instrumentation Cables etc. as identified in the
specification.
15.2.2 The Contractor shall provide all material, equipment and services so as to make a totally
integrated Instrumentation and Control System together with all accessories, auxiliaries
and associated equipments ensuring operability, maintainability and reliability. The work
shall be consistent with modern power plant practices and shall be in compliance with all
applicable codes, standards, guides, statutory regulations and safety requirements in
force.
15.2.3 The Contractor shall include in his proposal all instruments and devices, which are needed
for the completeness of the system. Same shall be subject to approval of the purchaser
during detailed engineering. All instruments and control equipments like primary and
secondary instruments etc. shall meet the functional requirements . In addition, all
electrical instrument solenoid valves which are located in the field/hazardous locations
shall be provided with explosion proof enclosure suitable for hazardous areas described
in National Electric Code (USA), Article 500, Class-I, Division-I. All field wiring should
be through conduits. All fittings, cable glands etc .shall be strictly as per NEC
recommendation article, 500 to 503.,
15.2.4 All instrumentation and control equipment, instruments, instrumentation support steel
work for gauge board, cabinet, local remote instruments and pipe work shall be suitable
for guaranteed performance at the ambient, humid, dusty and corrosive conditions
prevailing at site and specified elsewhere. Environmental test for all electronic items shall
be carried out as per IS: 2106 or equivalent standard acceptable to the owner. All indoor
equipment shall be suitable for continuous safe operation at ambient of 50 degree
centigrade and also during periods of air conditioning failure without any loss of
function, or departure from the specification requirements covered under this

specification. The panels/desk/cubicles located in air conditioned area and indoor shall
comply with the requirement of protection class IP-42 and panels located in outdoor areas
shall be IP-65 as per IS: 2147. All outdoor instruments and control devices shall be
suitable for ambient of 80 Degree centigrade and humidity of 95%. Degree of protection
for outdoor equipment shall be minimum IP-65 as per IS: 2147.
15.2.5 The equipment offered shall be of proven make and design, ensuring reliability, safety,
efficiency and long continuous trouble-free service with high economy and low
maintenance costs. The C&I system offered shall meet the operation requirements in all
regimes, control philosophy, design concepts, sizing and design criteria as indicated in
various sections of this specification. The equipments/devices offered shall be suitable for
satisfactory operation at ambient temperature specified with dusty, humid and corrosive
conditions faced in thatl area and their design principles shall take into account but not be
limited to the following :a) Interchangeability and expandability
b) Malfunction identification
c) Maintainability
d) Shock and vibration proofing
e) Short circuit proofing
f) Over-voltage protection
g) Easy access to all components
h) Highest class workmanship general finish
i) Adequate space availability for connecting external cables.
j) Noise immunity including immunity against radio frequency interference and
electromagnetic interference to be provided with opto/galvanic isolation.
k) Avoidance of overheating of electronic components
l) Fail safe operation: It shall be ensured by the bidder that failure of any sensor,
transmitter, controller, final control element, power or control supply shall not
cause a hazardous condition. Further, such a failure should provide audio and
visual alarms.
m) Surge protection for electronic components as per IEEE-472.
n) Selection of high quality equipments/material.
15.2.6 All equipment/systems covered under the specification shall be subject to inspection and
tests as per the relevant standards including any additional tests considered necessary by
the purchaser during manufacture, erection and on completion of the work. The approval
of the purchaser on passing of such inspection of test will not, however, prejudice the
right of purchaser to reject the equipment if it does not comply with specification
requirements when erected or does not give satisfactory performance in service.
15.2.7 The responsibility for safe, efficient and reliable operation of the equipment/system
supplied shall rest with the bidder. Approval of the drawings by purchaser/consultant
shall not in any way relieve the bidder of his obligation/responsibility in this respect.
15.2.8 Contractor shall include in his bid a detailed Bill of Material (BOM) for each of the
systems.
15.2.9 All panels, desks, cabinets shall be provided with a continuous bare copper ground bus.
The ground bus shall be bolted to the panel structure on bottom on both sides. The
contractor shall submit with the offer recommended grounding scheme required for

control system. The exact grounding scheme shall be finalized during detailed
engineering.
15.2.10 The control system and various equipment shall conform to the requirements specified in
the section -6 of BTG package, which are not specifically covered herein

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15.2.0 General RequirementsOctober 30, 2008
Filed under: Uncategorized shivajichoudhury @ 5:27 am
Tags: 15.2.0 General Requirements
15.2.0 General Requirements
15.2.1 The Contractor shall provide Control & Instrumentation systems PLC based control
systems for station auxiliaries equipment mounted/local instruments and transmitters
including sensing elements as required, Local instrument enclosures/racks, Local gauge
boards/racks, Process Connection and Piping, Sample lines, Electric Power Supply
System, Actuators for valves, Instrumentation Cables etc. as identified in the
specification.
15.2.2 The Contractor shall provide all material, equipment and services so as to make a totally
integrated Instrumentation and Control System together with all accessories, auxiliaries
and associated equipments ensuring operability, maintainability and reliability. The work
shall be consistent with modern power plant practices and shall be in compliance with all

applicable codes, standards, guides, statutory regulations and safety requirements in

force.
15.2.3 The Contractor shall include in his proposal all instruments and devices, which are needed
for the completeness of the system. Same shall be subject to approval of the purchaser
during detailed engineering. All instruments and control equipments like primary and
secondary instruments etc. shall meet the functional requirements . In addition, all
electrical instrument solenoid valves which are located in the field/hazardous locations
shall be provided with explosion proof enclosure suitable for hazardous areas described
in National Electric Code (USA), Article 500, Class-I, Division-I. All field wiring should
be through conduits. All fittings, cable glands etc .shall be strictly as per NEC
recommendation article, 500 to 503.,
15.2.4 All instrumentation and control equipment, instruments, instrumentation support steel
work for gauge board, cabinet, local remote instruments and pipe work shall be suitable
for guaranteed performance at the ambient, humid, dusty and corrosive conditions
prevailing at site and specified elsewhere. Environmental test for all electronic items shall
be carried out as per IS: 2106 or equivalent standard acceptable to the owner. All indoor
equipment shall be suitable for continuous safe operation at ambient of 50 degree
centigrade and also during periods of air conditioning failure without any loss of
function, or departure from the specification requirements covered under this
specification. The panels/desk/cubicles located in air conditioned area and indoor shall
comply with the requirement of protection class IP-42 and panels located in outdoor areas
shall be IP-65 as per IS: 2147. All outdoor instruments and control devices shall be
suitable for ambient of 80 Degree centigrade and humidity of 95%. Degree of protection
for outdoor equipment shall be minimum IP-65 as per IS: 2147.
15.2.5 The equipment offered shall be of proven make and design, ensuring reliability, safety,
efficiency and long continuous trouble-free service with high economy and low
maintenance costs. The C&I system offered shall meet the operation requirements in all
regimes, control philosophy, design concepts, sizing and design criteria as indicated in
various sections of this specification. The equipments/devices offered shall be suitable for
satisfactory operation at ambient temperature specified with dusty, humid and corrosive
conditions faced in thatl area and their design principles shall take into account but not be
limited to the following :a) Interchangeability and expandability
b) Malfunction identification
c) Maintainability
d) Shock and vibration proofing
e) Short circuit proofing
f) Over-voltage protection
g) Easy access to all components
h) Highest class workmanship general finish
i) Adequate space availability for connecting external cables.
j) Noise immunity including immunity against radio frequency interference and
electromagnetic interference to be provided with opto/galvanic isolation.
k) Avoidance of overheating of electronic components

l) Fail safe operation: It shall be ensured by the bidder that failure of any sensor,
transmitter, controller, final control element, power or control supply shall not
cause a hazardous condition. Further, such a failure should provide audio and
visual alarms.
m) Surge protection for electronic components as per IEEE-472.
n) Selection of high quality equipments/material.
15.2.6 All equipment/systems covered under the specification shall be subject to inspection and
tests as per the relevant standards including any additional tests considered necessary by
the purchaser during manufacture, erection and on completion of the work. The approval
of the purchaser on passing of such inspection of test will not, however, prejudice the
right of purchaser to reject the equipment if it does not comply with specification
requirements when erected or does not give satisfactory performance in service.
15.2.7 The responsibility for safe, efficient and reliable operation of the equipment/system
supplied shall rest with the bidder. Approval of the drawings by purchaser/consultant
shall not in any way relieve the bidder of his obligation/responsibility in this respect.
15.2.8 Contractor shall include in his bid a detailed Bill of Material (BOM) for each of the
systems.
15.2.9 All panels, desks, cabinets shall be provided with a continuous bare copper ground bus.
The ground bus shall be bolted to the panel structure on bottom on both sides. The
contractor shall submit with the offer recommended grounding scheme required for
control system. The exact grounding scheme shall be finalized during detailed
engineering.
15.2.10 The control system and various equipment shall conform to the requirements specified in
the section -6 of BTG package, which are not specifically covered herein

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