power plant control and Instrumentation specification

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

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

VOLUME – V SPECIFIC TECHNICAL REQUIREMENTS - INSTRUMENTATION AND CONTROL WORKS

TCE Consulting Engineers Limited 73/1, ST.MARK’S ROAD BANGALORE 560 001

MARCH 2009 (Ref. no.: MBPMPL/RfP/EPC/20 MBPMPL/RfP/EPC/2008-09/144) 08-09/144)

M MB BP PO OW WE ER R ((M MA AD DH HY YA AP PR RA AD DE ES SH H)) L LIIM MIIT TE ED D ANUPPUR TPP, PHASE – I, 1000 (+ 20%) MW, MADHYA PRADESH, INDIA

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

VOLUME – V SPECIFIC TECHNICAL REQUIREMENTS - INSTRUMENTATION AND CONTROL WORKS

TCE Consulting Engineers Limited 73/1, ST.MARK’S ROAD BANGALORE 560 001 March 2009

MB POWER (MADHYA PRADESH) LIMITED ANUPPUR PHASE-1 (1000+20%MW) THERMAL POWER PROJECT

Spec No.

SECTION: CONTENTS

TCE.5657A-H-500-001

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 STRUCTURAL WORKS

VOLUME - VII BID PURPOSE DRAWINGS

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TCE FORM NO. 329 R4


Spec No.

SECTION: CONTENTS

TCE.5657A-H-500-001

CONTENTS

VOLUME – V

PART - A SECTION – D5 INSTRUMENTATION AND CONTROL WORKS - BTG SUB SECTION

TITLE

NO. OF PAGES

D 5.1

SYSTEM DESCRIPTION/ PLANT OPERATION PHILOSOPHY

7

D 5.2

SYSTEM/EQUIPMENT/SERVICES TO BE FURNISHED

12

D 5.3

DESIGN, PERFORMANCE AND FUNCTIONAL REQUIREMENTS

23

D 5.4

SPECIFICATION FOR DCS / INSTRUMENTS TO BE SUPPLIED

27

D 5.5

TESTS AND INSPECTION FOR I&C SYSTEM EQUIPMENT

4

D 5.6

OTHER SERVICES

1

D 5.7

PERFORMANCE GUARANTEE

5

LIST OF TABLES SUBSECTION

NO. OF SHEETS

TITLE

TABLE- 1

TERMINAL POINTS

1

TABLE- 2

CONTROL SYSTEM HARDWARE / DCS INTERFACING

2

TABLE- 3

CODES AND STANDARDS

1

TABLE- 4

DATA TO BE FURNISHED WITH BID

2

TABLE- 5

LIST OF ESSENTIAL SPARES

4

TABLE- 6

LABORATORY AND TEST INSTRUMENTS

8

TABLE- 7

SIZE, MATERIAL & RATING F FOR IMPULSE PIPES / TUBES & FITTINGS

6

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MB POWER (MADHYA PRADESH) LIMITED Spec No.

SECTION: CONTENTS

ANUPPUR PHASE-1 (1000+20%MW) THERMAL POWER PROJECT

TCE.5657A-H-500-001

CONTENTS LIST OF TABLES SUBSECTION

NO. OF SHEETS

TITLE

TABLE- 8

GUIDELINES FOR PROVISION OF INSTRUMENTS AND SPECIFICATIONS

TABLE- 9

GUIDE LINES FOR SELECTION OF FLOW ELEMENTS

1

TABLE -10

GUIDE LINES FOR SELECTION OF CONTROL VALVES MATERIAL AND ACTUATOR TYPE GUIDELINE FOR PROVISION OF ANALYTICAL MEASUREMENTS

1

TABLE- 12

TESTS TO BE PERFORMED FOR DCS/PLC / PROGRAMMABLE CONTROL SYSTEM

4

TABLE- 13

FACTORY ACCEPTANCE TESTS FOR DCS/PLCs

3

TABLE - 14

TESTS TO BE PERFORMED FOR INSTRUMENTS

3

TABLE - 15

FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES)

5

TABLE - 16

TRAINING TO BE PROVIDED FOR OWNER’S PERSONNEL

1

TABLE - 17

ERECTION, FIELD TESTING AND COMMISSIONING REQUIREMENTS

6

TABLE - 18

COMPUTERISED MAINTENANCE MANAGEMENT SYSTEM (CMMS)

6

TABLE - 20

PERFORMANCE ANALYSIS, DIAGNOSTICS AND OPTIMISATION (PADO) SYSTEM

6

TABLE - 21

STATION LAN

2

TABLE - 22

MANAGEMENT INFORMATION SYSTEM

3

TABLE- 11

23

1

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TCE Consulting Engineers Limited

Volume – V SECTION: D 5.1

Spec No.

INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY

TCE.5657A-C-500-001

SHEET 1 OF 7

1.0

SYSTEM DESCRIPTION

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 sub systems/equipment namely Steam Generators (SG), Steam Turbine Generator (STG) and their associated auxiliaries, balance of the plant equipment / systems, plant electrical system of each unit, utility plants like coal handling plant, Ash handling plant, DM water plant and compressed air plant, plant electrical systems.

1.2

The overall I & C system design shall ensure the following:

1.3

(a)

Maximise safety for the plant personnel and equipment

(b)

Safe, reliable, efficient and easy operation of the plant under all operating conditions

(c)

Maximise availability and efficiency of the plant through system redundancy.

(d)

Consistent control & instrumentation philosophy – usage of standard functional modular hardware and software design.

(e)

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

(f)

Malfunction of any component or loss of supply leading to fail-safe condition

(g)

Provide accurate and reliable information to the plant operators and management.

(h)

Provide the operators the following facilities: (i)

Complete information for plant equipment status / abnormal and critical conditions.

(ii)

Alarm notification.

(iii)

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 centralised operation and monitoring of the total power plant from the central control room (CCR). I&C system shall consist of a functionally distributed microprocessor based system (DCS and other PLC control systems), with ISSUE

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SECTION: CONTENTS

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CONTENTS

VOLUME – V

PART - A SECTION – D5 INSTRUMENTATION AND CONTROL WORKS - BTG SUB SECTION

TITLE

NO. OF PAGES

D 5.1

SYSTEM DESCRIPTION/ PLANT OPERATION PHILOSOPHY

7

D 5.2

SYSTEM/EQUIPMENT/SERVICES TO BE FURNISHED

12

D 5.3

DESIGN, PERFORMANCE AND FUNCTIONAL REQUIREMENTS

23

D 5.4

SPECIFICATION FOR DCS / INSTRUMENTS TO BE SUPPLIED

27

D 5.5

TESTS AND INSPECTION FOR I&C SYSTEM EQUIPMENT

4

D 5.6

OTHER SERVICES

1

D 5.7

PERFORMANCE GUARANTEE

5

LIST OF TABLES SUBSECTION

NO. OF SHEETS

TITLE

TABLE- 1

TERMINAL POINTS

1

TABLE- 2

CONTROL SYSTEM HARDWARE / DCS INTERFACING

2

TABLE- 3

CODES AND STANDARDS

1

TABLE- 4

DATA TO BE FURNISHED WITH BID

2

TABLE- 5

LIST OF ESSENTIAL SPARES

4

TABLE- 6

LABORATORY AND TEST INSTRUMENTS

8

TABLE- 7

SIZE, MATERIAL & RATING F FOR IMPULSE PIPES / TUBES & FITTINGS

6

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TCE FORM NO. 329 R4

MB POWER (MADHYA PRADESH) LIMITED Spec No.

SECTION: CONTENTS

ANUPPUR PHASE-1 (1000+20%MW) THERMAL POWER PROJECT

TCE.5657A-H-500-001

CONTENTS LIST OF TABLES SUBSECTION

NO. OF SHEETS

TITLE

TABLE- 8

GUIDELINES FOR PROVISION OF INSTRUMENTS AND SPECIFICATIONS

TABLE- 9

GUIDE LINES FOR SELECTION OF FLOW ELEMENTS

1

TABLE -10

GUIDE LINES FOR SELECTION OF CONTROL VALVES MATERIAL AND ACTUATOR TYPE GUIDELINE FOR PROVISION OF ANALYTICAL MEASUREMENTS

1

TABLE- 12

TESTS TO BE PERFORMED FOR DCS/PLC / PROGRAMMABLE CONTROL SYSTEM

4

TABLE- 13

FACTORY ACCEPTANCE TESTS FOR DCS/PLCs

3

TABLE - 14

TESTS TO BE PERFORMED FOR INSTRUMENTS

3

TABLE - 15

FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES)

5

TABLE - 16

TRAINING TO BE PROVIDED FOR OWNER’S PERSONNEL

1

TABLE - 17

ERECTION, FIELD TESTING AND COMMISSIONING REQUIREMENTS

6

TABLE - 18

COMPUTERISED MAINTENANCE MANAGEMENT SYSTEM (CMMS)

6

TABLE - 20

PERFORMANCE ANALYSIS, DIAGNOSTICS AND OPTIMISATION (PADO) SYSTEM

6

TABLE - 21

STATION LAN

2

TABLE - 22

MANAGEMENT INFORMATION SYSTEM

3

TABLE- 11

23

1

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Spec No. TCE.5657A-C-500-001


SHEET 2 OF 7

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, 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. The DCS shall be provided on per unit basis and the individual unit DCS shall be suitably interconnected through redundant links. Control room shall be configured for the 2 unit / 3 unit / 4 unit configurations as follows. (i) If the configuration is selected for 2 units the control room shall be common and all the DCS cabinets related to the same shall be located in the electronic equipment room. (ii) if the configuration is selected for 3 units / 4 unit then a unit cubicle room shall be provided for each unit were the DCS cabinets related to the corresponding unit shall be located and the HMI equipment such as operator stations (OS), engineering station (ES), printers, etc. shall be located in a common central control room. 1.4

Auxiliary plant monitoring and analysis systems shall include the following: (a)

Vibration monitoring and analysis system

(b)

Performance analysis, diagnostics and optimisation system

(c)

Computerised maintenance management system

(e)

Management Information System (MIS)

(f)

Flame Monitoring & Analysis System

(g)

Boiler Tube Leak Detection System

(h)

Smart Transmitter Maintenance Facility

2.0

PLANT OPERATION PHILOSOPHY

2.1

OPERATION FROM CENTRAL CONTROL ROOM (CCR)

2.1.1

All equipment associated with main plant SG, STG and their associated auxiliaries and other auxiliary systems like compressed air /chemical dozing systems (HP & LP) etc. & plant electrical system shall be operable and / or monitored from VDU/Keyboard based Operator stations (OS) mounted on Control Desk. 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. CCR 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:

Inspite of individual DCS control station , central control station is required to be able to operate

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(a)

Complete monitoring of plant common Coal Handling Plant - PLC through redundant OPC link. *

(b)

Complete monitoring of plant common DM water plant & effluent treatment plant – PLC through redundant OPC link. *

(c)

Complete monitoring of the external river water system – PLC through redundant OPC link. *

(d)

Complete monitoring of plant Ash Handling Plant - PLC through redundant OPC link. *

(e)

Complete operation and monitoring of plant electrical system.

(f)

Complete Monitoring of unit specific Electro-Static Precipitator.

(g)

Complete monitoring of unit specific Mill reject Handling system.

(h)

Operation / Monitoring of unit specific DG Set.

(i)

Complete monitoring of unit specific A/C & Ventilation System.

Note: Thus * marked indicates that the control system are provided by the other vendors. 2.1.2

In addition to VDU/KB operation, limited back up operation/ monitoring facilities shall be provided on the CCR Unit control desk for emergency trip of the power plant. (a)

Emergency stop push buttons for boiler, STG and all HT & major auxiliaries for tripping the plant in the event of failure of VDU/KB based OS equipment.

(b)

Large Video Display Screen suitable for both operation and monitoring.

(c)

PA system and telephone sets.

2.1.3

Operation, control and monitoring requirement of Station Electrical system / equipment are detailed in Electrical specification.

2.2

LOCAL OPERATION

2.2.1

OPERATION FROM LOCAL CONTROL ROOM (CCR)

2.2.1.1

DG set will be primarily operated and monitored from DG set control room. However, remote operation and control of the same shall be made from DCS

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2.2.1.2

Switchyard will be operated and monitored from Switchyard building. All operation /monitoring from Switchyard building will be through VDU/Keyboard based OS.

2.2.1.3

For ESP control system, Local control panel based operation /monitoring facility may be provided if felt needed by Bidder.

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 DCS HMI as soft selection for drives covered in the DCS. 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 DCS for annunciation to operator in the control room.

2.2.2.1

In addition to the control room operation / monitoring facility, local 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)

All emergency stop pushbuttons shall be wired directly to MCC / Switch gears.

(b)

Status of all emergency stop pushbuttons for unidirectional drives (pump/fan etc) shall be monitored into the respective control system.

(c)

Local Open / Close pushbuttons (for motorised valves) commands shall be connected to the control system to ensure interlock / protection requirement.

2.2.2.2

Local / remote operation location selection shall be carried out from control room through OS.

2.2.2.3

Details of the terminal points between BTG and others are detailed in section D5 – TABLE- 1

3.0

PLANT CONTROL PHILOSOPHY

3.1

The control requirements of the main power plant comprising SG, STG with associated auxiliaries, balance of plant system/equipment like CW/ACW/Misc. water systems, plant electrical system, compressed air system etc. shall be implemented in microprocessor based Distributed Control System (DCS). The DCS shall be provided on per unit basis. ISSUE


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3.2

SG Integral control system will include Burner Management System (BMS) & Boiler protection system shall be from the plant DCS.

3.3

TG Integral control system will include Turbine governing & Turbine protection system shall be from the plant DCS.

3.4

PLC based control systems are envisaged for all other unit specific and plant common systems utility and auxiliary plants detailed below which are not covered in the DCS: (a)

Coal Handling Plant.

(b)

Ash Handling Plant

(c)

Plant Common Switchyard system

(d)

DM water plant & Effluent treatment plant etc.

(e)

Unit Specific ESP Control system (Bidder has the option to provide in place of DCS based control)

(f)

Unit Specific Mill reject system (Bidder has the option to provide in place of DCS based control)

(g)

DG Set

(h)

Fire Protection [PLC based] & Detection system [Microprocessor based]

(i)

A/C & Ventilation system

(j)

Any other plant system/equipment not covered in plant DCS system.

3.5

All PLC based utility plant control systems shall be interfaced with DCS through redundant bi-directional OPC link.

3.6

Switchyard control shall be implemented in separate independent control systems but will be interfaced with plant DCS through redundant bi-directional OPC link.

3.7

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.

3.8

Details of control system hardware envisaged for the total power plant with interfacing requirements with plant DCS are detailed in Section D 5, TABLE-2.

3.9

An overview of plant Instrumentation and Control system is illustrated in dwg. no ISSUE


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TCE.5657A-IC-SK-01. 3.10

Specific requirements pertaining to the control / monitoring of Electrical system including AVR, generator auxiliary systems such as seal oil / cooling system etc will be from CCR based DCS OS.

3.11

All different plant control systems like, DCS, PLC based control systems and other special monitoring and analysis systems (detailed at clause 1.4 above) shall be suitably interfaced for proper functioning.

3.12

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, Switchyard control system, Reservoir intake water system, DM Plant /Effluent Treatment Plant, ESP & Mill Reject. For others it shall be uni-directional link. If the distance of the utility plant control system and the central control room is exceeding more than 300meters fibre optic cable shall be made with necessary media convertors, patch cords, power supply arangments, etc.. both at the utility plant control system and at the central control room are in bidders scope.

3.13

Plant control system - DCS shall be interfaced with CMMS (Computerised Maintenance Management System) & MIS (Management Information System) system through redundant interfacing for necessary data exchange.

3.14

Performance analysis, diagnostics and optimisation (PADO) system shall be interfaced with respective Unit DCS through redundant interfacing for necessary data exchange.

3.15

Each unit TSI system shall be interfaced with respective unit DCS.

3.16

Vibration monitoring and analysis system for each unit shall be interfaced with respective Unit DCS through redundant interfacing for necessary data exchange.

3.17

Smart Transmitter Maintenance Facility shall be interfaced with respective Unit DCS through redundant interfacing for necessary data exchange.

3.18

A common time synchronisation system is envisaged for time synchronising of all programmable control systems like DCS, PLC control systems etc. for the whole station under Bidder’s scope of supply.

3.19

Dedicated earthing shall be provided for the control system. Earthing cable as required from the control room to the earth pit will be in bidders scope.

4.0

CODES AND STANDARDS

4.1

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 ISSUE


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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)

National Electricity Manufacturers Association (NEMA)

(b)

The Institute of Electrical and Electronic Engineers (IEEE).

(c)

Instrumentation Systems and Automation Society (ISA).

(d)

American National Standards Institute (ANSI).

(e)

Deutsche Industries Norman (DIN).

(f)

International Electrochemical Commission (IEC).

(g)

International Consultative Committee on Telephone and elegraphy (CCITT).

(h)

Verin Deutschar Eisecnhuttenleutte (VDE)

(i)

Indian Standard Institute (ISI).

4.2

Standards not indicated in the specification are acceptable (subject to approval by the Owner / Owner’s Representative) if they are established to be equal or superior to the standards indicated in the specification.

4.3

The VENDOR shall furnish English translation of all standards to which the equipment and systems offered conform to.

4.4

The specific codes and standards applicable are listed in Section D 5, TABLE-3.

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SECTION: D 5.2

TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL

SHEET 1 OF 12

SCOPE OF WORK-SYSTEM/EQUIPMENT/SERVICES

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 5.1, Design philosophy in Section – D 5.3, relevant technical specification in Section –D 5.4 and Testing requirements in Section-D 5.5 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.

Distributed Control System (DCS) [Per unit basis]

II.

Turbo-supervisory Instrumentation (TSI)

III.

PLC based control system for SG & TG auxiliary

IV.

Sequence Of Events Recording System

V.

Time Synchronisation Equipment

VI.

Control Desks and cabinets

VII.

Field Instruments including pipe mounted items and accessories

VIII.

Final control elements

IX.

Steam And Water Analysis System (SWAS)

X.

Gas Analysers & Stack Emission Monitoring System

XI.

Control desk

XII.

Large Video Screen Display System

XIII.

Vibration Monitoring And Analysis system

XIV.

Boiler Tube Leak detection system

XV.

Furnace Flame Monitoring and Analysis System for each unit.

XVI.

Smart Transmitter Maintenance facility

XVII.

Computerised Maintenance Management System (CMMS)

VIII.

Management Information System (MIS)

XIX.

Performance Analysis, Diagnostics and Optimisation (PADO) System

XX.

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.

XXI.

Auxiliary Power Supply System

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INSTRUMENTATION AND CONTROL SCOPE OF WORK-SYSTEM/EQUIPMENT/SERVICES

XXII.

2.0

Volume – V

SHEET 2 OF 12

Maintenance and Erection Tools and Tackles

XIII.

Laboratory and Test Instruments

XIV.

Essential Spares

XV.

Erection, Field Testing And Commissioning Including Erection Hardware

XVI.

Performance Test, Trial Operation And Guarantee Test

XVII.

Engineering Documentation

VIII.

Training Of Owner’s Personnel

XIX.

Consumables for Operation / Maintenance.

XX.

Inspection and testing of I&C system equipment.

XXI.

All the furniture in the Control Room(s), Maintenance Engineers rooms, Instrument lab, SWAS Room etc.

DISTRIBUTED CONTROL SYSTEM (DCS) An overview of the required control system is illustrated in Dwg. No. TCE. 5657A-IC-SK01. Bidder to select the required number of OS, OS/ES etc as per the number of unit selection [like 2 units / 3 units / 4 units configuration]. This system consists of Measurement system; Control System; Interlock, Protection and Sequential Control System; Sequence of events recording, Data Bus System for Control and Communication with the process, interfacing with other control systems and package control systems 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 Desk This system is detailed in Measurement system write-up in Section D 5.3 and relevant specification in Section – D 5.4.

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 located in the control desk. This system is detailed in write-up in Section D 5.3 and relevant specification in Section – D 5.4.

2.3

INTERLOCK, PROTECTION AND SEQUENTIAL CONTROL SYSTEM (OPEN LOOP CONTROL SYSTEM) Interlock, protection and sequential control system shall be complete with processor, signal ISSUE

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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 located in the control desk . This system is detailed in write-up in Section D 5.3 and relevant specification in Section – D 5.4. BOP Package signals [like DM storage tank level, bunker level indicator, etc] if any required for the interlock of the BTG package shall be suitably hardwired to the DCS. 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 5.4.

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 5.4.

2.6

HISTORISATION AND RETRIEVAL FACILITY Historical storage and retrieval facility shall allow collect and store data and parameters including trends, alarms and events from DCS data base periodically and automatically to removable data storage devices once every 24 hour for long term storage and retrieval. One number DAT drive shall be provided for the storing the data and parameters. This Historical storage and retrieval system [HSR] will be located at the computer room of the central control room. The system shall also have the facility to store and retrieve important plant data for a very long duration (one year).

2.7

ENGINEERING STATION (ES) ES equipment shall have operator station & printer to perform the functions of software generation and maintenance of DCS system in addition to OS functions. It shall also be used for monitoring the status of all equipment connected to DCS system. The system is detailed in relevant Section-D 5.4.

2.8

SOFTWARE Complete software for the microprocessor based 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-D4.4. The supply shall also include software for equipment performance calculation, Equipment capability curve, and alarm analysis etc,. All software used for the system shall be licensed version only.

2.9 2.9.1

DCS SYSTEM HARDWARE [Per unit basis] I/O Modules: As required considering the requirements detailed in Section D 5.3

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2.9.2 2.9.3

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Distributed Processing Units (Controllers): As required considering the requirements detailed in Section D 5.3 Operator Stations: (a) 2 nos Operator Stations with single VDU and single Keyboard/ mouse/ trackball for operator / Unit shall be provided for the boiler package per unit. (b) 2 nos Operator Stations with single VDU and single Keyboard/ mouse/ trackball for operator / Unit shall be provided for the Turbine package per unit. (c) 1 no SER viewing station with single VDU and single Keyboard/mouse/trackball for operator /Unit (d) 1 no Operator station with single VDU and single Keyboard/mouse/trackball for Shiftcharge Engineer / Unit. (e) Two (2) no.s Operator Station each with single VDU and single Keyboard/ mouse/trackball for Operator for plant station part. (f) Two (2) no.s Operator Station each with single VDU and single Keyboard/ mouse/trackball for Operator for plant common. (g) 1 no Operator station with single VDU and single Keyboard/mouse/trackball for plant common station Shift-charge Engineer / Unit. (h) Additional 1 no Operator station with single VDU and single Keyboard / mouse / trackball for Unit – 1 - unit cubicle room cum electronics equipment and relay room [applicable for 3 unit / 4 unit configuration]. (i) Additional 1 no Operator station with single VDU and single Keyboard / mouse / trackball for Unit – 2 - unit cubicle room cum electronics equipment and relay room [applicable for 3 unit / 4 unit configuration]. (j) Additional 1 no Operator station with single VDU and single Keyboard / mouse / trackball for Unit – 3 - unit cubicle room cum electronics equipment and relay room [applicable for 3 unit / 4 unit configuration]. (k) Additional 1 no Operator station with single VDU and single Keyboard / mouse / trackball for Unit – 4 - unit cubicle room cum electronics equipment and relay room [applicable for 4unit configuration]. (l)

Three number of operating station with single VDU and single keyboard / mouse / trackball / Unit. One for Electrical system, second for Mechanical systems and the third for C&I systems.

2.9.4

Engineering Station: (a) 1 nos Engineering Station (ES) with single VDU and single Keyboard/mouse/trackball for Maintenance Engineer / Unit for DCS system.

2.9.5

Printers / Unit: (a) Colour Laser Printer- 1 nos (A3 size) for Operator / Unit (b) Dot Matrix Printer- 1no for SER-A3 size / Unit. (c) Colour Laser Printer- 1 no (A3 size) for Engineering Station – common for all units [Connected to other unit Engineering stations through printer server]. (d) Colour Laser Printer- 1 no (A3 size) for Historical Storage & Retrieval Station (e) Colour Laser Printer- 1 no (A4 size) for unit # shift incharge (f) Colour Laser Printer- 1 no (A4 size) for plant common station shift incharge

2.9.6

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one (1) no terminal station with single VDU and single Keyboard/mouse separate from OS/ES stations along with a colour laser printer. Data storage device details as per Section D 5.4 2.10 DCS SYSTEM INTERFACING REQUIREMENT 2.10.1 Following interfacing facility shall be provided for DCS system / unit. Interfacing cables required for the applications are included in Bidder’s scope: (a)

(b)

One (1) no independent redundant bi- directional OPC link with Ethernet based TCPI/P protocol for following PLC based utility plant control systems (refer Section D5, TABLE-2). Interfacing cable as required with accessories are included in Bidder’s scope. Ash Handling Plant Control System (#) (i) Coal Handling Plant Control System (#) (ii) Switchyard Control System (SCADA) (#) (iv) DM Plant/ Effluent Treatment Plant Control System (#) (v) One (1) no redundant bi- directional OPC link with Ethernet based TCP- I/P protocol for UPS (#)

(c)

One (1) no redundant bi- directional OPC link with Ethernet based TCP- I/P protocol for ESP control system (#) (if PLC is provided).

(d)

One (1) no redundant bi- directional OPC link with Ethernet based TCP- I/P protocol for Mill reject control system (#) (if PLC is provided).

(e)

One (1) no redundant uni-directional OPC link with Ethernet based TCP- I/P protocol for A/C & Ventilation control system (#)

(f)

One (1) no redundant uni-directional OPC link with Ethernet based TCP- I/P protocol for Fire- Protection & Detection system (#)

(g)

One (1) no independent redundant bi- directional OPC link with Ethernet based TCPI/P protocol for MIS system (#)

(h)

One (1) no independent redundant bi- directional OPC link with Ethernet based TCPI/P protocol for CMMS system (#)

(i)

One (1) no independent redundant bi- directional OPC link with Ethernet based TCPI/P protocol for PADO system.

(j)

One (1) no redundant communication link with Ethernet based TCP- I/P protocol for Vibration monitoring & analysis system.

(k)

One (1) no redundant uni-directional OPC link with Ethernet based TCP- I/P protocol for Pre treatment & clarified plant (Raw water) (#)

(l)

One (1) no redundant uni-directional OPC link with Ethernet based TCP- I/P protocol for Condenser online tube cleaning system & self cleaning filter (#)

(m)

One (1) no redundant uni-directional OPC link with Ethernet based TCP- I/P protocol for external river water intake control room (#)

(n)

Redundant bi- directional communication links with suitable communication protocol for interfacing Numerical Protection Relays and Energy meters-as required. @

(o)

Any other communication link as required for proper functioning of the system.

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2 nos redundant bi- directional OPC link with Ethernet based TCP- I/P protocolSpare provision / Unit.

2.10.2 All OPC links shall be of latest version suitable for time stamped data transfer. 2.10.3 @- Communication protocol will be decided during detail engineering stage. It is the Bidder’s responsibility to offer communication link with protocol suitable for communication between DCS & Other supplied equipment. 2.10.4 #- If control system for this application is located in a different building or the distance is exceeding more than 300 meters (different from DCS system) then Communication link cable for this application shall be through Fibre Optic cable with necessary El.-Optical converter, media convertor, patch cards and de-converter units at both ends in bidders scope. 2.11 Interface Server: DCS shall be provided with an interface server together with a colour laser printer for connecting to PADO, CMMS & MIS system 2.12 DCS Make/ Model Qualification: Offered DCS make / model shall have been designed, manufactured and commissioned for at least 2 thermal power projects of minimum 600 MW size units or higher in last 5 years, with scope of work involving at least automatic boiler controls for super critical boilers and unit auxiliaries 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 3.0 TURBOSUPERVISORY INSTRUMENTATION (TSI) SYSTEM TSI system shall be as detailed in Section D 5.3 4.0

PLC BASED CONTROL SYSTEMS PLANT AUXILIARIES

4.1

PLC based control system complete with all hardware and software shall be provided for the SG / TG plant auxiliaries not covered in the DCS. The system is detailed in Section D 5.3 / D 5.4

4.2

PLC Control System Interfacing

4.2.1

All PLC based control systems shall be interfaced with DCS through redundant OPC link with Ethernet based TCP/I-P protocol. Communication link shall be Bi-directional.

5.0

SEQUENCE OF EVENTS RECORDING ( SER ) SYSTEM SER shall be of capacity not less than 576 points for each unit. Resolution shall be one milli second. The system is detailed in Section D 5.4.

6.0

TIME SYNCHRONISATION EQUIPMENT GPS based time synchronisation equipment for plant I&C system equipment time synchronisation shall be supplied. The system will include master clock and slave clocks for usage in the plant. The system is detailed in Sections D 5.4. This shall remain common for all the units.

7.0

CONTROL DESK AND CABINETS

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Control desk and system cabinets shall be complete with all instruments and control equipment duly mounted and pre-wired. The specifications for these items are given in Section-D 5, TABLE-8. Complete furniture like ergonomically designed chairs, racks for manuals and tables for monitors and printers shall be provided in control rooms, MEE room. 8.0

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 5, TABLE-8.

9.0

FINAL CONTROL ELEMENTS All final control elements as required are included in Bidder’s scope. The technical requirements are detailed in Section D 5, TABLE-8

10.0

STEAM AND WATER ANALYSIS SYSTEM Complete SWAS system including sample conditioning panel and analysers are included in Bidder’s scope. The system is detailed in Section D 5.4. SWAS shall be provided individually for each unit. Common SWAS for all units is not acceptable.

11.0

GAS ANALYSER AND STACK EMISSION MONITORING SYSTEM All gas analysers required for process control and monitoring and stack monitoring system are included in Bidder’s scope. Gas analysers required for process control and monitoring is detailed in Section D 5.3. Stack emission monitoring requirement is detailed in Section D 5.4. Required analyser panels for the GAS analyser and stack emission monitoring system shall be provided individually for each unit and the same shall be located in the ESP control room.

12.0

CONTROL DESK The specifications for these items are given in Section-D 5, TABLE-8. Control desk shall be located in central control room.

13.0

LARGE SCREEN VIDEO DISPLAY SYSTEM 4 nos. Large screen video display system of rear projected type shall be supplied for mounting in central control room and 1 no each in coal handling plant and ash handling plant local control room and the same shall be provided along with its independent controller. The system shall be complete with video screen, workstation for display control and all accessories. Screen size shall be 84 inch. The system is detailed in Sections D 5.4.

14.0

VIBRATION MONITORING AND ANALYSIS SYSTEM

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Vibration monitoring and analysis system shall be supplied for steam turbine generator bearings and all HT and major drives and driven equipment bearings. The system is as detailed in Section D 5.4. Vibration monitoring system shall be provided individually for each unit. 15.0

BOILER TUBE LEAK DETECTION SYSTEM A microprocessor based Boiler tube leak detection system complete with all hardware, software and accessories shall be provided for each unit. The requirements are detailed in Section D 5.4

16.0

FURNACE FLAME MONITORING SYSTEM Furnace flame monitoring and thermo graphic flame analysis system complete with all hardware, software and accessories including display arrangement in CCR (central control room) shall be provided for each unit. The system is detailed in Clause no 14.0, Section D 5.4, VOL IV of this specification.

17.0

SMART TRANSMITTER MAINTENANCE FACILITY A PC based dedicated smart transmitter maintenance facility common for all the units shall be provided. The system is detailed in Section D 5.4

18.0

COMPUTERISED MAINTENANCE MANAGEMENT SYSTEM (CMMS) Computerised maintenance management system (CMMS) suitable for use with maintenance management of a modern power generation utility equipment & systems is included in Bidder’s scope. The CMMS system to be provided shall have it’s data base completely populated, system customised for power plant application and fully functional. The scope of work and technical details of the CMMS system is detailed in Section D 5, TABLE-18. This shall be provided common for all the units.

19.0

MANAGEMENT INFORMATION SYSTEM (MIS) MIS system is included in Bidder’s scope. The requirements are detailed in Section D 5, TABLE-22. This shall be provided common for all the units.

20.0

PERFORMANCE ANALYSIS, DIAGNOSTICS AND OPTIMISATION SYSTEM (PADO) PADO system for each unit is included in Bidder’s scope. The requirements are detailed in Section D 5, TABLE-20.

21.0

INSTRUMENTATION AND SPECIAL CABLES 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. are included in Bidder’s scope. The requirements are covered in Section D 5, TABLE-8 of this specification. ISSUE

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SCOPE OF WORK-SYSTEM/EQUIPMENT/SERVICES

22.0

AUXILIARY POWER SUPPLY SYSTEM 230 V AC UPS and 24 V DC power supply for DCS system shall be provided for Instrumentation and Control system. The details of the above power supply system are covered in Section D 3- Electrical section.

23.0

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.

24.0

LABORATORY AND TEST INSTRUMENTS Laboratory and test instruments are included in Bidder’s scope. Calibrating instrument, the associated work bench with power supply distribution sockets, instrument air distribution and storage facility for record maintenance to be provided. Instrument air set with air filter, regulator, etc. (instrument air piping up to I&C laboratory to be provided). The requirements are detailed in Section D 5-TABLE 6.

25.0

ESSENTIAL SPARES Scope of supply includes I&C system essential spares as detailed in Section D 5,TABLE-5.

26.0

ERECTION, FIELD HARDWARE

26.1

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. CONTRACTOR’s scope of work will include any additional instruments supplied by other contractors/ OWNER which is required for proper & satisfactory performance of the power plant.

26.2

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 5, Table-8.

27.0

PERFORMANCE TEST, TRIAL OPERATION AND GUARANTEE TESTS

TESTING

AND

COMMISSIONING

INCLUDING

ERECTION

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 5.5 of the specification. The performance and Guarantee test shall be conducted by the OWNER after trial operation as detailed in Section D 5.5 of the specification. The CONTRACTOR shall prove the guarantee of the system and equipment supplied. 28.0

ENGINEERING DOCUMENTATION CONTRACTOR shall prepare engineering documents for OWNER / CONSULTANT review and approval. Format for important documents are detailed in TABLE-15.

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OTHER SERVICES

29.1

TRAINING OF OWNER’S PERSONNEL

SHEET 10 OF 12

The CONTRACTOR shall provide training to OWNER’s personnel as specified in Section D 5.6 of the specification. 29.2

PERFORMANCE GURANTEE TEST INSTRUMENTATION The CONTRACTOR shall provide PG test instrumentation as specified in Section D 5.6 of the specification.

30.0

CONSUMABLES

30.1

The following consumable shall be supplied / Unit:

31.0

(a)

Printer Paper

50,000 sheets (For Both A3 & A4 size).

(b)

Toner of each type

4 nos

(c)

Ink Cartridges :

(i) Colour - 10 nos, (ii) Mono-10 no.

(d)

Fuses

5 Nos. each type.

(e)

DVD R/W

100 nos

(f)

CD R/W

200 nos

(g)

Insulation Tape

100 rolls

(h)

Teflon tape

100 rolls

(i)

Calibration gases for span & zero checking for each gas analyser included in scope-1 no gas cylinder (Cylinder capacity suitable for 12 no.s calibrations).

(j)

Reagents for 12 no.s charges for SWAS analysers.

FURNITURE All the furniture in the Central / Local control Room (s), Maintenance Engineers rooms, Instrument lab, SWAS Room & for I&C equipments functioning etc. as required to be located in different plant buildings under Bidder’s scope are included in Bidder’s scope of supply. The requirements are detailed in Section D 5.3 of this specification.

32.0

INSPECTION AND TESTING FOR I&C SYSTEM EQUIPMENT

32.1

The Owner or Owner’s 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 DCS. Bidder shall call for inspection / witnessing the conductance ISSUE

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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 Contarctor’s responsibility to schedule the inspection & testing of different equipment / systems in a properly phased manner. 32.2

Inspection and testing requirements for different I&C system equipment are tabulated in Section D 5.5 and Section D 5, TABLE-12 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.

32. 3

The following minimum equipment shall be considered for Inspection (witness) at manufacturer’s works (Contractor’s and sub suppliers) by Owner as specified:

32.4

33.0

(a)

Integrated DCS testing including testing of communication links.

(c)

All control valves

(d)

SWAS system analysers.

(e)

Gas Analysers.

(f)

Large Video Screen Display (LVS).

(g)

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 DCS systems as detailed in Section D 5.5 of the specification. The CONTRACTOR shall prove the guarantee of the system and equipment supplied.

(b)

Vibration monitoring & Analysis System

(c)

Flame monitoring & Analysis System

(d)

Performance Analysis, Diagnostics and Optimisation System

(e)

Computerised Maintenance Management System

(f)

Management Information System

(g)

Boiler Tube Leak Detection System

(h)

Smart Transmitter Maintenance Facility

GENERAL

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Uniformity of Hardware

33.1.1 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 33.1.2 Following equipments shall be of same make, series and family of hardware at minimum: (a)

Pressure and Temperature Gauges

(b)

All pressure, Differential pressure, level & flow transmitters of differential pressure type& Temperature transmitter.

(c)

Programmable Logic Controllers (PLC)

(d)

Video Display Unit / Keyboard

33.2

All the systems in the Bidder’s 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 Bidder’s scope of work and supply.

33.3

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.

33.4

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 adjustment. During this period, supervision and maintenance of total instrumentation equipment shall be the scope and responsibility of the Contractor’s personnel.

33.5

Availability of Spares & Services Spares and services for DCS / PLC related equipment/systems shall be available for 15 years from the date of handing over of plant by Contractor. Bidder shall furnish the guarantee for the same in the bid offer. The guarantee shall be re-confirmed by 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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1.0

INSTRUMENTATION INSTRUMENTATION AND CONTROL SYSTEM PHILOSOPHY

1.1

MEASUREMENT MEASUREMENT SYSTEM (MS)

1.1.1

The measurement system consist of primary sensors, various function modules, processors, VDUs and peripherals, back up panel hardware and power supply racks integrated together to perform monitoring function of non-controlled variables and interact with other parts of DCS. All analogue parameters will be displayed. For all drives, status indication will be displayed. The system requirements are specified in relevant Section-D 5.4.

1.1.2

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.

1.2

CONTROL SYSTEM

1.2.1

Design Features (a)

No single random fault in the entire automation and control system will cause a load loss, forced outage or unit trip.

(b)

No two simultaneous simultaneo us faults shall lead to or potentially cause damage to plant

(c)

Safety related instrumentation and control shall be designed with a fail- safe mode.

(d)

No single fault shall jeopardise the functioning of the entire system.

(e)

The control and automation system and the field instruments and actuators as well as it’s support systems, power supplies and data networks shall be immune to the electromagnetic interference and shall conform to the internationally accepted standards.

(f)

To meet the t he operational and safety requirements, the control system hardware hardware and software shall shall conform conform to a modular, hierarchical hierarchical architecture. The system system hierarchy shall shall be at four levels. The closed loop (i.e. (i.e. modulating) functions functions and open loop (i.e. sequence or on/off) functions shall form separate elements at each of the hierarchical hierarchical level.

1.3

CLOSED LOOP CONTROL SYSTEM (CLCS)

1.3.1

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. equipment/system.

1.3.2

The CLCS shall have the following features: (a) Provision of predictive predictive and/or adaptive controls in addition to PID controls as required by the system. (b)

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which need to be changed during load changes, start-up, shutdown, normal or under any other emergency conditions. (c)

Fixed set point point at the software level/hardware 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.

(d)

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.

(e)

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 operator station.

(f)

Characterisation of final control element to suit the various applications applications with respect to load or otherwise as dictated by the process.

(g)

Function generator to provide necessary characterisation or variation of set points with respect to load, speed or any other requirement. requirement.

(h)

Soft Auto Auto /M /Manual anual station interlocks to drive drive the final control elements to a su suitable itable position for safe plant operation in the event of process/equipment abnormal conditions.

(i)

Blocking/Interlocking Blocking/Interlocking function as dictated by process/equipment. process/equipment.

(j)

Monitoring of loop failures or any hardware failure in the loops.

(k)

Fail safe operation operation of final final control control elements in case of failure failure of of motive power or signal.

(l)

All controllers shall be freely configurable with respect to requisite control algorithms.

(m)

The system being supplied should be such that when permissible limits are exceeded, an automatic switchover from an operation governed by max. efficiency, to an operation governed by safety & availability

1.4

OPEN LOOP CONTROL SYSTEM (OLCS)

1.4.1

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 ISSUE


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safety. 1.4.2

The OLCS shall have the following features as a minimum:

1.4.2.1

Features-General Requirements Requirements (a) The logic and sequence control shall be Digital distributed microporcessor microporcessor based and programmable. programmable. (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 philosophy of command command to energise a relay or solenoid valve. (d) Where there is is more more than one pump or fan for the the same service (say 2 pumps), 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) All the contacts of the sensors used in protection circuit shall be monitored. (f) 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 Features-Interlock Requirements 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.

1.4.2.3

(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.

(c)

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.)

(d)

Isolation of the tripped equipment from the main process.

(e)

Any other conditions for safe starting and shutting down the equipment.

Features-Sequence Features-Sequence Control Requirements Requirements Sequence control shall be provided to start and stop the equipment and the associated auxiliaries. auxiliaries. The sequence control shall shall have the following following features: (a) Once the start-up or shutdown of an equipment 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). Protection commands shall have priority over manual commands & manual commands shall ISSUE


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prevail over auto commands.

1.4.2.4

(b)

Criteria check up for each stage of operation with monitoring and displaying.

(c)

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 (DCS/PLC).

(d)

Adequate time delay between the steps as dictated by the process to establish an operating parameter or healthiness of an equipment.

(e)

Normally, the auxiliaries of the standby equipment should be running (as applicable) so that the standby equipment is started without loss of time.

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)

Any of the permissive conditions becoming abnormal thereby producing a dangerous condition in operating the equipment.

(c)

The conditions from process such as dry flow conditions, flashing conditions or any other conditions that may create cavitation.

2.0 2.1

DCS DESIGN REQUIREMENTS GENERAL The Instrumentation and Control System called for in this specification shall consist of a functionally distributed microprocessor based system (DCS) with integral or stand alone type Sequence of events recording, Time synchronisation equipment, SWAS, Vibration Monitoring system, CCTV, Large Screen Video Display system, Performance Analysis , Diagnostics & Optimisation system, interfacing with various utility plant PLC based control system, Switchyard SCADA system, and a plant wide Computerised Maintenance management system (CMMS) & Management Information system and various miscellaneous monitoring and control systems– all capable of operating together as an integrated system along with Local panels, plant control desk, system cabinets, field instrumentation and associated erection hardware.

2.2

DCS System- Specific Design Requirement The microprocessor based distributed control system (DCS) 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.

(b)

Portability – Ability to develop the application for the Plant Information and Management system in personal computer environment and download the same to DCS.

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(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.

(d)

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).

(e)

Upward compatibility – Conformance to International standards for communication network and fool proof provision for expandability with investment protection.

SALIENT FEATURES OF DCS System shall run on the latest Windows NT/2000/XP operating system. The system shall support the following : - Open : Ability to run third party application - Multitasking : Pre-emptive, with high responsiveness - Human Interface : Comfortable look and feel of GUI-ICON interface - Interconnectivity : Standard Interfaces like OLE, DDE, DCOM, OPC etc. - Networking : Should support standard TCP/IP, IPX/SPX, and NETBUI Protocols by default. - Integration : Should provide seamless integration with minimum Glues / Patchworks 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, redundant 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 : The Node connectivity on the open side shall support Network infrastructure based on TCP/IP protocols. Network Access Security with Rights.

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Minimum of three access levels viz. Operator, Engineer, Manager for access by third party applications and Workstation management. 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. If the mode of configuration is of client server architecture then the servers shall not be counted as the operating station. Data Exchange Procedure Shall support Real time process data (with Time stamp) availability on the plant information network to be viewed at desktop PCs. 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. ISSUE


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3.0


SHEET 7 OF 23

DCS SYSTEM PERFORMANCE REQUIREMENTS (Under worst loading conditions as defined in Clause 3.1): (a)

Scanning rate of analog signals

Maximum 1 sec for measurement

(b)

Scanning rate of digital signals

Maximum. 100 ms

(c)

Scanning rate of pulse signals

Max. 100 ms

(d)

Loop execution time for CLCS

Maximum 250 ms (For all Loops)

(e)

Loop execution time for OLCS

Maximum 100 ms (For all Loops)

(f)

Controller output update for CLCS

Every 250 ms (For all CLCS Loops)

(g)

Controller output update for OLCS

Every 100 ms (For all OLCS Loops)

(h)

Updating rate of Analog display

Max. 2 seconds (for measurement)

(i)

Updating rate of Analog display

Max. 1 second for OLCS/CLCS

(j)

Updating rate of Digital value display

Max. 4 seconds (for measurement)

(k)

Updating rate of Digital value display

Max. 1 second for OLCS/CLCS

(l)

Time for display in VDU screen

Max 1-2 seconds on demand

(m)

Keyboard command execution time *

Max. 1 sec

(n)

Controller Loading

Max. 60 %

(o)

Data Bus Loading

Max. 50 %

(p)

Overall system availability

99.7 %

* - The response time for screen update after the execution of the control command from the time the command is issued 3.1

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)

All closed loop controls in operation

(c)

All open loop controls in operation

(d)

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(e)

Control/information request is initiated on control VDU.

(f)

In burst mode operation, 100 digital alarms are generated per second for a period of 10 seconds.

(g)

All printers in operation.

3.2

DCS System Reliability / Availability Requirement

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.

3.2.2

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:

3.2.3

(a)

Qualitative: Failure modes and effect analysis, common mode failure analysis, single failure analysis and fault failure analysis.

(b)

Quantitative: Comparative analysis, sensitivity analysis, studies and associated mathematical modules.

DCS 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 DCS 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

DCS system availability test duration shall be minimum 6 months on a continuous basis.

3.2.5

The system shall be considered unavailable (weightage factor=1.0), if any, of the following conditions occur: (a)

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(b)

Failure of all Operator Station

(c)

Loss of MMI capability through failure of control room operator keyboard

(d) (e)

Malfunction of analog /digital input system in the loss of more than 5% of the total number of inputs Failure of > one controller

(f)

Total failure of historisation facility/capability

Weightage factor for various partial failures to be considered shall be as follows: (a)

Loss of one critical CLCS / OLCS loop

0.20

(b)

Loss of one non-critical CLCS / OLCS loop

0.10

(c)

Loss of one complete DPU (both main and standby controller)

0.50

(d)

Loss of one DPU (redundant in operation)

0.30

(e)

Loss of I/O (For Redundant Modules) > 2%

0.20

(f)

Loss of I/O (For Non-Redundant Modules) > 5%

0.20

(g)

Loss of one OS

0.20

(h)

Loss of data bus (redundant in operation)

0.3

3.2.7

DCS system availability shall be guaranteed by the Contractor. Availability guarantee test shall be conducted as specified in Section D 1.5 of this specification. Contractor to prove the guaranteed system availability of 99.7%.

4.0

REDUNDANCY AND AVAILABILITY REQUIREMENTS

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.

4.2

For Measurement System, redundancy at sensor level and I/O module level is not required

4.3

Both CLCS & OLCS shall be configured with Redundant I/O channels for each sensor/signals. Where redundant sensors are provided redundant I/O channels shall be provided for each sensors/signals. Redundant channels shall be allotted from different input module for input and output.

4.4

Triple redundant I/O channel shall be provided for Boiler & Turbine protection control systems for each unit.

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4.5

Redundant sensors shall be provided for all control applications.

4.6

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.

5.0

SPARE PHILOSOPHY FOR DCS/SER I/O CHANNELS: (a)

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.

(b)

10% hot spare I/O modules (installed) shall be provided.

(c)

10% spare slots for I/O modules distributed among the control processors.

(d)

10% spare rack space shall be provided and distributed among the control processors.

6.0

GROUPING OF CONTROLLERS

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 ex.: Feed water pump, necessarily the two shall be implemented in different controllers) and fulfilling the following specific requirements: (a) I/O channel & module requirements considering redundancy and spare channel requirement (b)

Controller Loading considering the specified loop execution time (spare processing capacity shall be minimum 40%)

6.2

Control loop grouping philosophy to be followed in minimum are detailed in Clause 19.0 of this specification.

6.3

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.

6.4

The system availability for DCS 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.

7.0

GENERAL GUIDELINES FOR FIELD INSTRUMENTATION The various field instruments shall confirm to the specifications as per Table-6. 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.

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8.0

SELECTION OF RANGES FOR INSTRUMENTS

8.1

The ranges of the instruments shall be selected based on the following philosophy indicated below:

8.2

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.

8.3

For temperature measurement, the maximum operating temperature will be within 80 to 90% of the maximum scale range.

8.4

For pressure switches and temperature switches, the set points shall fall within 40% to 70% of the scale range selected.

8.5

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.

8.6

For flow measurement, the maximum range shall be fixed at about 10 to 15% above the maximum operating flow.

8.7

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.

8.8

For gas analysers (if included in scope), the maximum range will be around 10 to 15% higher than the recommended alarm settings.

9.0

PG TEST POINTS

9.1

Pressure, temperature and flow test points shall be provided in line with latest performance test code requirements.

9.2

In addition, pressure and temperature test points shall be provided for the following services: (a) At the discharge of all pumps and fans (b)

At the inlet and outlet of the heat exchangers for the fluid media involved

(c)

Adequate number at the Combustor at different zones

(d)

At the inlet and outlet of each control valve

9.3

Pressure test points shall be complete with root valves and shall terminate with a nipple.

9.4

Temperature test points shall be provided with thermowell.. ISSUE


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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)

2

25 NB

>=62 bar OR 425 degree C

(ii)

1

15 NB

< 62 bar AND425 degree C.

B. Level measurement a)

Level Gauge & Switch

(i)

2

25 NB

>=62 bar OR425 degree C

(ii)

1

25 NB


b)

Level transmitter (displacement type)

(i)

2

40 NB


(ii)

1

40 NB


c)

Stand pipe for level measuring instrument

(i)

2

80 NB


(ii)

1

80 NB


C. Flow measurement i)

2

25 NB


ii)

1

25 NB


D. Sampling system measurement (steam & water service) i)

2

25 NB


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INSTRUMENTATION AND CONTROL SYSTEM –DESIGN, PERFORMANCE & FUNCTIONAL REQUIREMENTS 1

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11.0

CONTROL ROOM LAYOUT

11.1

Central control room shall be common for both the units. However, each unit shall have its own separate area/ desk for control & monitoring of SG, STG & BOP auxiliaries i.e. control room shall have distinct sections, one for each unit though not physically separated but clearly distinguishable. Control room shall be configured for the 2 unit / 3 unit / 4 unit configurations as follows. (i) If the configuration is selected for 2 units the control room shall be common and all the DCS cabinets related to the same shall be located in the electronic equipment room. (ii) if the configuration is selected for 3 units / 4 unit then a unit cubicle room shall be provided for each unit were the DCS cabinets related to the corresponding unit shall be located and the HMI equipment such as operator stations (OS), engineering station (ES), printers, etc. shall be located in a common central control room. The detailed configuration for the 2 unit / 3 unit / 4 unit configuration shall be referred to drawing no: For the 3 unit / 4 unit configuration the cables connecting between the unit cubicle room and the central control room shall be of fibre optic cable with necessary media converters etc. The fibre optic cable shall be of multi mode type. The DCS shall be provided on per unit basis. The individual unit DCS and plant common DCS shall be suitably interfaced through redundant links.

11.2

The control room shall be partitioned to different rooms to house the following equipment:

11.3

11.4

(a)

Control in the main control room.

(b)

Large Screen Video Display Unit and CCTV video screen shall be located in main control room.

(c)

The system cabinets, marshalling cabinets & Electrical auxiliary cabinets in the electronic cubicle room adjacent to main control room.

(d)

Maintenance Engineer's VDUs (ES) with keyboards, printers and other peripherals in Maintenance Engineer's Room.

(e)

Uninterrupted power supply system (UPS) in UPS room.

Item (a) to (e) referred above will be located in an air-conditioned Control Room having false roof and false flooring. The control room will be partitioned with glass between the following rooms: Main Control Room and Maintenance Engineer's Room. Main control room and Electronic cubicle room. Maintenance Engineer’s Room and Electronic Cubicle Room. Electronic Cubicle Room and UPS Room. The control room shall be located in the TG floor of the station building. The Control desk shall face the turbine floor with a glass partition to enable for viewing of the TG equipment.

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11.5

Double doors shall be provided for control room entry with air curtains at entrance.

11.6

Control room floor shall be provided with anti static matting.

11.7

Ambient condition in the control room shall be as follows: (i) Temperature: 23.0 +/- 2 deg. C (ii) Relative humidity: 55%+/- 5%.

11.8

The control room shall be designed with diffused illumination illumination uniformly over the entire 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.

11.9

Following furniture shall be provided for the central control room and utility plant local control rooms: For Central control room (a) Cushioned revolving, independently independently adjustable seat and back chairs to be located at control room and at MEE room for f or all OS and ES/OS.

11.9.1

(b)

Cushioned revolving, independently independently adjustable seat and back chairs to be located at Shift charge room for all OS.

(c)

Metallic Printer console.

(d)

Metallic table of Glass top with lockable drawer at two side and sliding drawer at middle for shift charge room.

(e)

Metallic table of Glass top with horse shoe shaped table with vertical file mounting arrangement (two layer) to house approx. 80 No.s of files and lockable drawers at both end for MEE room.

(f)

Metallic consoles for MEE room Engineering Engineering stations with drawer at end ,for MEE room.

(g)

Any other equipment to be located in control room shall be provided with metallic tables.

(h)

Metallic half consoles for mounting operator station video monitors. In addition to the above furniture as required shall be provided for the Instrument lab.

11.9.2

Similar applicable furniture shall shall be provided for each utility plant local local control room.

12.0

SPECIFIC DESIGN REQUIREMENTS

12.1 A

VALVE ACTUATOR / DCS / MCC INTERFACE Drives less than 200 kW - Unidirectional

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1 2

Volume – V

INSTRUMENTATION INSTRUMENTATION AND CONTROL SYSTEM –DESIGN, PERFORMANCE & FUNCTIONAL REQUIREMENTS Signal Type

Service Feedbacks from switchgear to DCS Motor running Motor stopped

3

MCC disturbed

4

Local emergency stop operated

5

Motor current

DI DI DI

SHEET 15 OF 23

Remarks

It includes THERMAL O/L OPTD / CONT. SUPP. SUPP. FAIL / MCC ISOLATED

DI AI

Applicable for rating 50 kW and above.

Commands from DCS to switchgear 6

Command to start motor

7

Command to stop motor

DO DO

Output interposing relays to be mounted in independent relay cabinets of the DCS.

Direct to switchgear.

Lockable type emergency stop push buttons to be provided.

Local push button station to switchgear 8 B

Local emergency stop

LT drives – bidirectional (integral starters) Sl. no.

Service

Signal Type

Remarks

Feedbacks from valve actuator to DCS 1

Limit switch opened

DI

2

Limit switch closed

DI

3

Opened torque switch not operated

DI

4

Closed torque switch not operated

DI

5

Position feedback

AI

Applicable for inching valves.

DI

It includes THERMAL O/L OPTD / CONT. SUPP. SUPP. FAIL / MCC ISOLATED

Signals from Integral starter panel to DCS 6

Integral starter panel disturbed

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Local mode selected

SHEET 16 OF 23

DI

Commands from DCS to integral starter 8

Command to open

DO

9

Command to close

DO

C

Output interposing relays shall be mounted in independent relay cabinets of the DCS.

Solenoids Sl. no.

Service

Signal Type

Remarks

Feedbacks from valve limit switches to DCS 1

Limit switch opened

DI

2

Limit switch closed

DI

Commands from DCS to switchgear DO

3

D

Command to open / close

Output interposing relays will be mounted in independent relay cabinets of the DCS; Command shall be to energize or deenegize decided based on fail safe condition; For solenoids with dual coils, two independent independent outputs shall be provided for open and close.

DRIVES ABOVE 200 kW (3.3 kV and 11kV) – UNIDIRECTIONAL UNIDIRECTIO NAL Sl. no.

Service

Signal Type

Remarks

Feedbacks from switchgear to DCS 1

Motor running

DI

2

Motor stopped

DI DI

3

Motor tripped on fault

It includes DIFFERENTIAL PROTN OPTD, COMPOSITE MOTOR PROTN OPTD, S/C PROTN OPTD.

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INSTRUMENTATION AND CONTROL SYSTEM –DESIGN, PERFORMANCE & FUNCTIONAL REQUIREMENTS DI

4

Breaker ready to close

5

Breaker in remote

DI

6

Control circuit fault

DI

7

Local emergency stop operated

DI

8

Motor current

AI

9

Motor kW

AI

SHEET 17 OF 23

It includes BREAKER IN SERVICE, TRIP CIRCUIT HEALTHY, MASTER TRIP RELAY RESET and SPRING CHARGED.

Commands from DCS to switchgear 10

Command to start motor

DO

11

Command to stop motor

DO

Output interposing relays will be mounted in independent relay cabinets of the DCS.

Direct to switchgear .

Lockable type emergency stop push buttons to be provided.

Local push button station to switchgear 12

Local emergency stop

12.2

Both open / close torque switches and Limit switches shall be individually wired to DCS.

12.3

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.

12.4

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.

12.5

All transmitters shall be SMART type with integral local LCD indication and HART protocol.

12.6

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 DCS or PLC is not preferred.

12.7

Switches (pressure, temperature, level & flow etc.) shall be provided only for critical equipment trip such as BFP/ CEP trip etc. Wherever possible, transmitters shall be provided with required redundancies for all other purposes.

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12.8

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.

12.9

Interrogation voltage for the Digital inputs shall be of 24VDC.

12.10

All motorised isolation and inching service valves and dampers shall be provided with integral starters.

12.11

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.

12.12

All outdoor field equipment shall be provided with epoxy painting.

12.13

All outdoor field instrument / panel /cabinet shall have IP-65 protection. Canopy for the same shall be provided.

12.14

All panel / cabinet / desk shall have following colour scheme: (a) Exterior: RAL 7035 with texture finish. (b)

Interior: Brilliant white with glossy finish.

12.15

Uniform KKS tag numbering philosophy through out the plant shall be used.

12.16

Individual continuous purging shall be provided for all Air and Flue gas transmitters. The tap points for these services shall be “Y” shaped. The purging line shall be shall be connected near the root valve only and not at the Transmitter end.

12.17

Emergency trip push buttons with front covers, one for each turbine shall be provided near the turbine.

12.18

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.

12.19

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.

12.20

All motorised bypass valves shall be inching type and shall be provided with position transmitters of non-contact type.

12.21

When floor openings are considered for LP heaters and HP heaters, the corresponding stand pipe and displacement type level transmitter dimensions (along with impulse piping and root valve) shall be added radially. The standpipe and mounted instruments should not foul with the civil structures or any mechanical system part.

12.22

Conductivity type dedicated level switches shall be used for heater level applications.

12.23

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12.24

JBs, FTCs and local panels. Fused terminals shall be used in marshalling cabinets at Control room for all analog signals.

12.25

Instrumentation cables shall be laid in separate cable trays.

12.26

Cable number tags and markings will be provided at every 30 meters along the entire length of cable.

12.27

Instrumentation cable trays will be run on the top in the cable gallery.

12.28

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.

12.29

All instrument marshalling / system / local control panels shall be provided with gland plates [4 quadrants] at the bottom for glanding the cables.

13.0

SPECIFIC INSTRUMENTATION REQUIREMENTS FOR STEAM GENERATOR

13.1

Redundant speed sensor shall be provided with each coal feeder and shall provide an output to the feeder speed control. All feeder speed sensor tachometer-feedback circuits shall be suitably shielded from any electrical and mechanical interference.

13.2

A no-coal flow detector complete with amplifier and pick-up located at the outlet of each coal feeder shall be provided to detect no-coal flow.

13.3

Coal flow measurement with the help of conveyor speed and active load cells shall be provided for each feeder. The coal flow rate along with the integrator shall be made available in plant DCS.

13.4

Superheater tube metal thermocouples shall be provided on every fourth tube connected to the intermediate superheater outlet headers, the intermediate reheat outlet headers & the final super heater/ reheater outlet header.

13.5

Furnace gas temperature probes on each side of furnace for monitoring of gas temperature at the furnace outlet. The probes shall be moveable type.

13.6

Furnace flame monitoring system with UV type flame scanners. The system shall conform to NFPA requirements.

13.7

Three (3) nos O2 analysers shall be provided at economiser outlet or air pre-heater inlet (for each limb) for use with combustion control. Additionally, one (1) no O 2 analyser shall be provided at air pre-heater outlet ( for each limb) for monitoring.

14.0

SPECIFIC INSTRUMENTATION GENERATOR

14.1

Turbo-Supervisory Instrumentation (TSI): Following turbo-supervisory measurements shall

REQUIREMENTS

FOR

STEAM

TURBINE

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be provided in minimum. The system shall be microprocessor based and shall be interfaced with DCS through redundant communication link: (a)

Shaft Eccentricity

(b)

Absolute and relative shaft vibration in both X & Y direction for steam turbine and generator.

(c)

Differential expansion of HP, IP & LP sections of steam turbine

(d)

Overall expansion of HP & IP section of steam turbine.

(e)

Absolute bearing vibration in both X & Y direction for each bearing of steam turbine and generator.

(f)

Bearing metal and drain oil temperature

(g)

Axial shift of rotor.

(h)

Turbine metal temperature

(i)

Main stop and control valve position.

(j)

Main steam and reheat steam temperature

14.2

Digital speed monitoring device with three speed probes for measuring turbine speed and each of the HT drives having a variable speed.

14.3

For steam turbine driven BFP following turbo-super-visory instrumentation shall be provided: (a) Axial shift of rotor. (b)

Differential expansion

(c)

Overall expansion

(d)

Speed Pick ups (3 nos.)

(e)

Turbine casing and bearing metal temperature for all bearings

(f)

Absolute bearing vibration in both X & Y direction for each bearing of steam turbine.

(g)

Stop valve metal temperature

14.4

Three (3) measuring devices / transducers for measurement of active electrical power of the generator.

14.5

Following temperature measurements shall be provided for turbo- generator set: (a)

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Generator stator winding, core, babbitt metal and cooling air.

15.0

CLOSED LOOP CONTROL SYSTEM FOR SG&TG AND ITS AUXILIARIES

15.1

The closed loop controls shall be provided for all controls as per system requirement including all the loops specified in various Sections.

15.2

A co-ordinated master control system to enhance the response of boiler and turbine control system under all operating conditions while maintaining the outputs of the turbine, boiler and all major plant auxiliaries within their safe operating system shall be provided. This system shall be suitably designed for the operation on co-ordinated mode, boiler follow mode, turbine follow mode and manual mode with automatic run-up, run-down, runback, directional blocking and load limiting features in the co-ordinated mode.

15.3

The co-ordinated Master Control shall consists of the following : (a)

Unit load demand control for co-ordinated mode operation during normal operating condition. In this mode the load demand signal shall be sent simultaneously to the Boiler and Turbine Controls.

(b)

Boiler follow mode control for operation during start-up conditions and when turbine control is on manual. In the boiler follow mode, the megawatt load control will be the responsibility of turbine control system with boiler controls responsible for throttle pressure control.

(c)

Turbine follow mode control for operation during abnormal conditions of boiler and its controls and transition modes like runback, etc. In this mode, the megawatt control will be the responsibility of the boiler and throttle pressure will be controlled by the turbine control system.

(d)

In manual mode, the fuel flow and air flow equipment can be directly positioned by the operator and the turbine governor shall be capable of operable manually or automatically to maintain steam pressure.

15.4

The closed loop control system shall be provided as per the guidelines given under para 1.3 of this section.

15.5

The Contractor shall submit a brief write up on CLCS function for all SG, TG and balance of plant controls along with the bid.

16.0

OPEN LOOP CONTROL SYSTEM FOR SG & TG AND ITS AUXILIARIES

16.1

The open loop controls shall be provided as per system requirement.

16.2

The open loop control system shall be provided as per the guidelines given under para 1.4 of this section.

16.3

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17.0

CONTROLS INCLUDED IN DCS

17.1

Steam Generators (SG) start-up/ shutdown sequence including SG protection and burner management system, soot blowing controls, Fans, blowers (if applicable) controls for boiler and auxiliaries. All SG closed loop controls like fuel flow, temperature & pressure, air flow, SA/PA pressure, SH/ RH steam temperature, furnace draft etc..

17.2

Automatic steam turbine run-up system (ATRS), Auto synchronisation through ATRS, turbine protection, Electro-hydraulic turbine controls (EHTC), automatic turbine tester (ATT), turbine stress evaluator, etc. All turbine analog controls like gland steam, lube oil etc.

17.3

Co-ordinated Master Control

17.4

Regenerative cycle controls like heater drain, deaerator level, deaerator pressure, hotwell level, CEP controls, BFP controls, Hotwell makeup, Vacuum Bkr.vlv gland seal water pressure control.

17.5

Balance of plant controls like auxiliary steam, CW & Circulating cooling water system, Emergency cooling water system (if applicable), etc.

17.6

Utility drive like compressors, AC & ventilation system, ESP.

17.7

Operation & Monitoring of electrical system (as per Section D 3.29).

18.0

CRITICAL CONTROL LOOPS Following CLCS loops are considered critical, for which triple redundant sensors shall be provided for all involved parameters involved in the loop. Parameters involved will also include parameters used for compensation. For the balance control loops, only dual redundant sensors shall be provided. (a)

Furnace draft

(b)

PA Flow Control,

(c)

SA Pressure control

(d)

SA Flow control

(e)

O2 correction control

(f)

Steam Temperature Control

(g)

Turbine Governor control, HPBP, LPBP

(h)

HP Bypass steam pressure and temperature control

(i)

HP Bypass steam pressure and temperature control

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(j)

Deaerator level

(k)

Hotwell level control

(l)

BFP Minimum recirculation flow control

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CONTROL LOOP GROUPING PHILOSOPHY The following critical loops would be implemented in separate dedicated dual/triple redundant controllers of the same DCS system.Balance loops shall be grouped suitably without compromising availability, specified spare I/O capacity and spare processing capacity:

20.0

(a)

Boiler protection system in line with NFPA guidelines and/or with TUV or equivalent approval (2 out of 3 concept)

(b)

Turbine protection with TUV or equivalent for approval. (2 out of 3 concept).

(c)

Electro-hydraulic governing control.

(d)

Boiler start-up / shutdown sequence logic including BMS

(e)

Turbine start-up / shutdown sequence logic (ATRS) including Auto synchronisation.

(f)

Furnace Draft Control

(g)

Combustion control ( Air and Fuel flow control)

(h)

Steam Temperature Control

(i)

HP Bypass system, LP Bypass system.

(j)

Deaerator Control

(k)

Any other as per the Manufacturer recommendation or process requirements.

STATION BLACKOUT Availability of all equipment, drives, emergency power supplies, controls, logics required for the protection/safe operation of the Boiler/Turbine and auxiliaries during Emergency blackout shall be ensured. All the related drives shall operate automatically on the occurrence of blackout. All such drives required during emergency and blackout shall be 220 V DC (solenoid operated) to ensure availability and shall be designed for fail-safe mode. All the required controls shall be available as the system to be powered from UPS. The UPS sizing shall consider this requirement.

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INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM - TECHNICAL SPECIFICATION

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1.0

DISTRIBUTED CONTROL SYSTEM (DCS)

1.1

MEASUREMENT AND CONTROL SYSTEM

1.1.1

CONTROL PROCESSOR (DISTRIBUTED PROCESSING UNIT (DPU) 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 non- volatile memory to store programmes, standard software to perform control data acquisition and diagnostic functions. Battery back up (if applicable) for duration not less than 72 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, runups, run downs, over rides, analogue hold and any other techniques as may be necessary. d) Point Status and Quality feed back 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 (i) Number of I/O channels - 32 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 DO’s. Relay boards are not acceptable. (h) Number of I/O channels - 32

1.2 1.2.1

1.2.2

1.2.3

Analog Input Modules shall have the following features:

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Transmitter power supply at 24 V DC Input filtering for noise level 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 Number of I/O channels - 16

1.2.4

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 (e) Number of I/O channels - 16

1.2.5

Design Features/Requirements of Process Controllers (DPU)

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. All controllers shall be freely configurable with respect to requisite control algorithms.

1.2.5.2

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.

1.2.5.3

The distributed processing unit shall be provided with redundant floating power supply. The power supply modules, which are vital to the system’s 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).

1.2.5.4

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 operator’s intervention. Mode changeover in either direction shall be bumpless. Simultaneously, a message should appear on the video-monitors of the ISSUE

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Operator's/Engineer's work station indicating the failure. 1.3

OPERATOR STATIONS (OS)

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 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.

1.3.1.1

1.3.1.2

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.

1.3.1.3

Alarm Notification/Actions :

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.

1.3.1.5

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.

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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 boiler and turbine startup logs and turbine 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

Performance Calculations: Using one hour average data of process parameters, the system shall have the capability to calculate present value, expected value and deviations for parameters like plant heat rate (net and gross), turbine heat rate and efficiencies, boiler efficiency, heat exchanger performance, condenser performance-TTD, major drives efficiency calculation, auxiliary power consumption. The performance calculation package shall be based on standards like ASME, BS & HEI.

1.3.7

Equipment Operating History

1.4

Facility to accumulate run time from initial commissioning and last overhauls of the equipment. ENGINEERING STATIONS (ES)

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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

DATA BUS SYSTEM

1.5.1

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. 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 •

1.5.2

1.6

CENTRAL PROCESSING UNIT FOR MAN MACHINE INTERFACE (CPU) 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 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 ISSUE

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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

1.8.2

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. 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 DCS. 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.

1.9 1.9.1

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 •

1.10

CD ROM DRIVE & CD WRITER The features shall include: 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 PRINTERS The following types of printers shall be provided: Dot matrix type character printer , 132 column width with minimum speed • 400 cps for printing operator requested functions and graphics. Print colours shall be black and red. The operator shall be able to direct logs, reports etc. to any printer assigned to his console. The interface shall be either RS232C or RS422A. All printers shall be of A3 size. Colour graphic printer shall serve as a hard copy device to copy diagrams • •

1.11

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from the colour VDU’s for documentation and graphic diagram development functions. Minimum 7 colours to be provided. The same shall facilitate printing of graphics from OS of the corresponding unit. However Multiplexer unit shall be provided to facilitate printing of graphics from any of the ES VDUs. All printers shall be of A3 size. Noise levels for the Printers at 1 meter distance shall be < 45 dB • 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 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 DPU’s 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 steam/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 DCS shall be licensed version only. •

2.0 2.1

BMS AND BOILER PROTECTION SYSTEM A microprocessor based independent fault tolerant control system shall be provided for BMS & Boiler protection system. BMS & Boiler protection system shall be independent for each boiler.

2.2

System shall be provided with redundancy (both processor and I/O modules).

2.3

The system shall preferably be of same family of hardware and software as of DCS system and shall directly sit on the plant data bus. Alternatively, System shall be interfaced with plant DCS through redundant bi- directional OPC link. However, all time critical signal exchanges shall be hardwired.

2.4

System shall be provided with redundant power supply modules with power supply provided through redundant feeders.

2.5

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with a resolution of 1 m ili-second for 576 points per unit. 2.6

The system shall be able to provide fault diagnostics covering up to 99% on all the possible internal failure of hardware.

2.7

System shall be able to carry on-line modification of application programme. Necessary tools for engineering modification shall be provided.

2.8

Redundant sensors shall be provided for each field input condition for BOILER protection where ever feasible and practicable.

2.9

Protection system output shall be directly hardwired to f ield control elements.

2.10

Where the same field sensor signal is used for both Boiler protection and plant DCS, field sensor shall be directly connected to the protection system and the input signal to plant DCS shall come as an output from protection system.

2.11

Other requirements detailed for DCS system in this specification will also be applicable.

3.0

TURBINE PROTECTION SYSTEM

3.1

A microprocessor based independent fault tolerant control system shall be provided for Steam Turbine protection system. Steam Turbine protection system shall be independent for each boiler.

3.2

System shall be provided with redundancy (both processor and I/O modules).

3.3

The system shall preferably be of same family of hardware and software as of DCS system and shall directly sit on the plant data bus. Alternatively, System shall be interfaced with plant DCS through redundant bi- directional OPC link. However, all time critical signal exchanges shall be hardwired.

3.4

System shall be provided with redundant power supply modules with power supply provided through redundant feeders.

3.5

System shall have an integrated sequence of event recording and alarming facility with a resolution of 1 mili-second for all input signals.

3.6

The system shall be able to provide fault diagnostics covering up to 99% on all the possible internal failure of hardware.

3.7

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Necessary tools for engineering modification shall be provided. 3.8

Triple redundant sensors shall be provided for each field input condition for turbine protection where ever feasible and practicable.

3.9

Protection system output shall be directly hardwired to f ield control elements.

3.10

Where the same field sensor signal is used for both Boiler protection and plant DCS, field sensor shall be directly connected to the protection system and the input signal to plant DCS shall come as an output from protection system.

3.11

Other requirements detailed for DCS system in this specification will also be applicable.

3.12

Tripping devices shall be designed to operate on DC supply. The trip coils shall be monitored continuously for healthiness & failure shall be a larmed.

3.13

Turbine protection system shall be implemented in 2 out of 3 voting logic. Three Independent trip channels each have its own & dedicated processing modules, controllers, I/O modules etc. shall be used to achieve above logic. The outputs of three channels will be used to implement 2 out of 3 voting logic in two relay units, the output of which will be fed to the two turbine trip relays.

4.0 4.1

TURBO-SUPERVISORY INSTRUMENTATION SYSTEM

The Tenderer shall provide and install all locally mounted turbine supervisory instruments (TSI) system required for the safe operation of the turbine generator unit.

4.2

The TSI system shall be of microprocessor based.

4.3

TSI system shall be interfaced with plant DCS through redundant communication link.

5.0 5.1

PLC BASED CONTROL SYSTEM FOR AUXILLIARY PACKAGES

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 fr om the VDU station. The system shall have facility for connecting to DCS using hot redundant bi-directional OPC communication link. ISSUE

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5.2

The redundant UPS power supply shall be provided for the PLC system.

5.3

Design & Functional Requirements of PLC

5.3.1

As detailed above at Clause no 1.0 for DCS system shall be applicable for each PLC based control systems equipment also.

5.3.2

Spare Philosophy For I/O Channels: As detailed Clause no 2.3 of section D5.3 for DCS system shall be applicable for each PLC based control systems.

5.3.3

Grouping Of Controllers: As detailed Clause no 6.0 of section D 5.3 for DCS system shall be applicable for each PLC based control systems. Performance requirements: As detailed in clause no 3.0 of section D 5.3 for DCS system shall be applicable for each PLC based control system [excluding Digital input scan rate].

5.3.4

PLC shall specifically meet the following requirements: (a)

PLC shall have extensive self-diagnostic capability. Self diagnostics shall include both module level diagnostics as well as channel level diagnostics

(b)

PLC shall have redundant processors/controllers. fulfilment of both the following requirements:

This shall mean the

(i)

Automatic synchronisation of primary processor/controller of PLC with secondary processor/controller

(ii)

Bumpless switchover to secondary processor/controller of PLC when the primary fails.

(c)

Automatic program and data equalisation in the event of any on-line program / edit executed in the primary processor/controller of PLC.

(d)

Automatic “Forcing Bit” update in the secondary processor/controller of PLC when any “ Forcing is applied in the primary processor/controller of PLC.

(e)

Communication speed shall be minimum 2 MBPS.

5.4

Reliability / Availability requirements for PLC based control system shall be as per Clause No 3.2, Section D 5.3, VOL. V of specification.

6.0

SEQUENCE OF EVENT RECORDING ( SER )

6.1

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equipment including processor. Resolution shall be one (1) millisecond for inputs. The capacity of SER shall be minimum 576 points / Unit. The system shall support automatic printing on occurrence of fault or on demand; operator initiated reports viz. Point and system configuration, historical buffer, point delete and inhibit, assigning NO/NC/CO & binary contact; time delay on for selected points, time delay on return to normal signals (selectable), inhibit return to normal (selectable) user configurable printing format, pre fault, post fault and snap shot designations. SER shall have facility for calling various reports, programming various functions, initiating various diagnostic tests and printer control. 6.2

Self Diagnostic Features like scanner test (a periodic test for communication between several levels), functional test by simulating abnormal Conditions shall be provided.

6.3

One (1) no dedicated SOE viewing station shall be provided for each unit. SOE viewing station shall be similar to DCS OS video display monitor.

7.0

TIME SYNCHRONISATION EQUIPMENT

7.1

Time synchronisation equipment shall be complete with all hardware and software to receive the synchronising signals from remote satelite and provide outputs to synchronise plant wide all programmable control systems like DCS system equipment, Electrical equipment, SCADA , SER, all utility plant PLCs , Boiler & Turbine protection system and any other control systems to ensure a common time reference. The system shall be based on Global Positioning system reference and shall include GPS antenna, GPS receiver, signal processing unit etc. Time accuracy shall be 1 PPM.

7.2

7.3

Global Positioning System to which the Master Clock gets synchronised, shall be an absolute system to provide continuously 3 dimensional position fixing, velocity measurement and Time reference generation. The system shall be designed in a 100% redundant configuration and will include two master clock systems. The master Clock shall be configured as Real Time Clock with display of time in 24 hrs format and date and shall drive slave clocks located in different plant control buildings. Total 50 nos slave clocks shall be provided. The offered master clock system shall consist of the following minimum items: GPS Antenna GPS Receiver Signal Processing Unit Local and Remote display units (slave clocks) Power supply All required cables, mounting accessories, cabinet for the processing electronics etc..The fully wired panel shall accommodate GPS receiver, Signal Processing ISSUE

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Unit, Power supply Unit shall be supplied as required. Technical features shall be as follows: GPS Antenna Type : Helical Noise : Less than 2.6 dB GPS Receiver : Microprocessor based Tracking method : Code / Carrier tracking Output data format : IRIGB Communication speed : > 9600 BPS Output rate : every second Signal Processing Unit : Microprocessor based Digital type Reference : OCXO with stability of 1 PPM. Time Accuracy : 1 PPM The number of serial ports shall be as required for the total plant different control systems.

8.0

STEAM AND WATER ANALYSIS SYSTEM (SWAS)

8.1

The steam and water chemical sampling system shall be designed to monitor the chemistry of the steam and 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.

8.2

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 the SWAS as 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 SWAS shall include the following:

8.2.1

Sample conditioning panel with all accessories-Typical scheme for sampling is illustrated in dwg. No TCE.5657A-IC-SK-02.

8.2.2

Analyser panel housing cells, analysers, monitors etc.

8.2.3

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 SWAS panels shall be designed for ready access of components for easy maintenance. The layout and general arrangement of these panels shall be subject to Owner’s approval.

8.3

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8.4

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.

8.5

Each sample stream with the required flow rate shall be finally cooled from approximately 45oC to 25oC +/- 1oC or a preset temperature required by the analyser through an individual primary cooler before passing the sample to the respective measuring cells and analyser. The primary cooler shall use condensate quality auxiliary cooling water. All samples will be passed through cartridge type filters before being cooled in respective primary coolers. Additional cooler (secondary cooler) if required to bring down the sample temperature of 25oC or to a temperature suitable for the analyser shall be provided after primary cooler. Samples shall be cooled in secondary cooler by chilled water. Two identical 100% capacity chiller units, 100% capacity chilled water pumps, 100% capacity chilled water circulation pumps and storage tank with automatic make up for the secondary cooling as detailed above shall be provided. 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 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 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. 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

8.6

8.7

8.8

8.9

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weather and water proof. Output shall be isolated 4-20 mA DC linear signal. Online reading shall be provided at Main Plant Control room Hydrazine Analyser Polaro graphic type, Solid state/micro-processor based system with an acc uracy 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. 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 & 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. GAS ANALYSERS AND STACK EMISSIN MONITORING SYSTEM Following gas analysers shall be provided for stack emission monitoring for each unit and the same shall be located in the ESP control room. All gas analyser signals shall be connected to plant DCS: (a) NOX (b)

SO2

(c)

CO

(d)

O2

(e)

Particulate Emission (PEM)

SO2 Measurement Sampling type, infra red technique microprocessor based/solid state system with an accuracy of + 2%, response time of 90% within 3 seconds having features like auto & manual calibration, self diagnostics etc. IP 54 or equivalent degree of protection for enclosure. Output shall be isolated 4-20 mA DC linear signal. Accessories like purge System for cleaning the window, heat shield mounting plate shall be provided. Online reading shall be provided at Main Plant Control room SO2 analyser with sampling system shall be an efficient system which can remove the moisture from the hot f lue gas ( 150 Deg C) without reducing Flue gas temperature and without diluting the SOx in sample and provide a moisture free flue gas sample as an input to the analyser supplied by vendor. The vendor has to ensure that the moisture removal does not alter the composition of constituents of ISSUE

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the Flue gas and removed moisture shall not be acidic. The tapping shall be taken from the ID fan discharge before entering to stack. Moisture: 40-50% (40 gram /m3). This measurement shall be most reliable as this will be utilise for automatic feeding of the limestone powder for SOx control in addition to fulfil pollution control norms. Sox & Nox analyser shall be housed in the enclosed room near chimney with window A/C. Nox Measurement Sampling type, Infra red technique microprocessor based/solid state system with and accuracy of + 2%, response time of 90% within 3 seconds having features like auto & manual calibration, self diagnostics etc. IP 54 or equivalent degree of protection for enclosure. Output shall be isolated 4-20 mA DC linear signal. Accessories like purge System for cleaning the window, heat shield mounting plate shall be provided. Online reading shall be provided at Main Plant Control room. Oxygen Analyser Direct insertion, insitu type analyser with an accuracy of + 1% FSD, repeatability of +0.5 FSD, response time of 90% within 5 secs, auto and manual calibration having zirconia probe +sensing element IP 54 or equivalent degree of protection for enclosure. output shall be isolated 4-20 mA DC linear signal. Accessories like back purge system shall be provided. Online reading shall be provided at Main Plant Control room. The analyser shall be designed by considering the moisture in Flue gas and to ensure continuous measurement without any choking of probe. Necessary heating/Purging as required shall be provided. O2 Analysers shall be located at the vertical inlet & outlet of Air Pre-heater. Carbon Monoxide Measurement Non dispersive infra red technique insitu type system with an accuracy of + 3% of FSD, response time of better than 4 secs having features like auto zero & span calibration, auto temperature compensation, auto indow cleaning device etc IP54 or equivalent degree of protection for enclosure. Online reading shall be provided at Main Plant Control room. Particulate emission measurement Optical Trans receiver type or TRIBO ELECTRIC METHOD type microprocessor based/ solid state system with an accuracy of + 2% of FS, response time of 90% with in 5 seconds having features like auto zero calibration and correction, auto span calibration and window check. IP54 or equivalent degree of protection f or enclosure. Output shall be isolated 4-20 mA DC linear signal. Air purge system with air blower shall be provided. The analyser shall be located at Chimney at elevation as per Pollution board norms. Online reading shall be provided at Main Plant Control room Sampling system: The Flue gas sampling system which is designed for measuring SO2 & Nox shall be provided and housed in a Air conditioned enclosure near chimney at 0.0 m eter level. The sampling system shall comprise of : Sample probes. Temperature controlled heated sample line. ISSUE

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Moisture removal system. Sample coolers. Solenoid valve system. Calibration bottles filled with reference gas for calibration. Multi component analyser system. Appropriate protection for lightning shall be provided. Regulated power supply : Tube light with power socket. 10.0

LARGE SCREEN VIDEO DISPLAY SYSTEM (LVS)

10.1

Large Screen Video Display systems shall be provided at the control rooms. 4 nos shall be provided at Central Control Room for each unit.

10.2

LVS shall be primarily used for: Large Screen Video Disin Contr a) Display of important data, graphics coming from the PC, Workstation, Video etc. b) To provide real time clear luminous view to share information between operators and decision-makers. c) To control /operate using a dedicated Keyboard. The Large Screen Graphics Wall shall be installed in the Control Room. The overall screen size shall be 84” Diagonal to be used as an integrated, • single large screen and also to have picture in picture facility. The overall resolution of the graphics wall shall be min. 2560 x 2048 pixels. It • should be possible to have the whole screen of the Large Screen Graphics Wall to behave as a single logical screen or in multiple nos of screens (minimum 4 nos) and the control of the same shall be from a dedicated Graphical Control Unit (Controller) linked to all the operator station. The Large Screen System shall have the functionality to pre configure and • save various display layouts to be accessed at any given point of time with a simple mouse click. The system shall be configured such that any of the operators sitting on the • same Ethernet shall be able to work on the Large Screen sitting at his own position with his local keyboard & mouse in addition to the dedicated Key board of the LVS. This LVS shall be used as an OWS with its own dedicated electronics. It shall be possible to show the mirror images of the operator stations in freely • resizable and repositionable windows. The offered system shall be able to work in 24 / 7 days environment and is of • industrial nature. The Rear Projection Module shall have the following specifications • i) ii) iii)

The Graphics Wall shall be made up of multiple rear projection modules stacked up in multiple rows and columns. The rear projection modules must be based on Single Chip DLP Rear Projection technology. Each of the Rear Projection Module shall have resolution of 2560 x ISSUE

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11.0

2048 pixels and offers 3.7 million colours. iv) Each Rear Projection module shall be equipped with in - built dual lamp system to offer redundancy at the lamp level. The average minimum lamp life shall be 6,000 hrs (for each UHP Lamp). Irrespective of the system is running from single lamp or dual lamp the brightness shall be constant. The brightness uniformity shall be >95%. – The contrast shall be 600:1 (Typical). – The luminance on each rear projection module is 250 cd/m2 – (typical) using single lamp. Each of the Rear projection modules shall have an optical – dimmer arrangement to adjust the brightness of individual projection module automatically to have a completely uniform graphics wall without compromising contrast & colours. The screen to be used is high contrast and wide viewing angle. The seam • between adjacent screens achieved shall be <0.4mm. The screen surface shall not be reflective. The half gain angle of the screen used shall be ± 35° horizontal as well as vertical. The input to projection module shall be Digital to have a flicker free image on the Large Screen Graphics Wall. The system shall be designed such that the expansion is possible on top as well as on sides. The system shall have rear access only for the maintenance purposes to avoid any misalignment of the screens in the front. The Display Controller shall have the following specifications: The display controller shall have scalable display control unit. – In an industrial 19” rack mounted casing based on P IV 3 Ghz (Min.). – The min. memory of 256MB expandable upto 1 GB. – The unit shall be equipped with a 48X or better CD ROM, 3.5” Floppy – Drive. The hard Disk shall be of 60 GB, 7200 rpm. – Shall have 10/100 MBPS Ethernet port for LAN connection. – Supplied with a Keyboard and mouse with adequate cable extension. – Based on WINDOWS 2K OS. – Min. 4 Digital Graphics Output to be connected to 4 rear projection – modules. The system shall have future expansion possibilities. VIBRATION MONITORING AND ANALYSIS SYSTEM

12.0

GENERAL

12.1

The vibration monitoring and analysis system shall provide critical analysis of health of rotating machines on continuous on-line basis and shall guide the plant maintenance personnel regarding the nature of fault and the maintenance action required.

12.1.1

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functional system. Bidder’s offered system shall include but not limited to the details specified in subsequent paragraphs. 12.1.2 12.2

12.2.1

Vibration monitoring and analysis system shall be independent for each unit.

DESIGN AND FUNCTIONAL REQUIREMENT The vibration monitoring and analysis system shall provide condition monitoring and analysis of the bearings of all critical machines, equipments with HT drives and their driven equipment. These shall include but not limited to the following: (a)

Steam Turbine

(b)

Generator

(c)

ID Fans

(d)

FD Fans

(e)

PA Fans

(f)

Mills

(g)

Boiler Feed Pumps

(h)

Condenser Extraction Pumps

(i)

CW Pumps

(j)

ACW Pumps

(k)

Any other equipment with HT drives

12.2.2

The vibration monitoring system shall be complete with proximity type vibration sensors, signal conditioning cards, amplifiers, special cables, vibration monitor (if required) etc. together with all necessary equipment and accessories. Eddy current type proximity vibration sensors shall be provided.

12.2.3

Vibration sensors shall be provided for measurement in both X (horizontal) and Y (vertical) axis at 900 angle to each other for each bearing.

12.2.4

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 s ystem.

12.2.5

Vibration pickup shall meet the following requirements: (a)

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(b)

Enclosure protection- IP 65

(c)

Pick ups suitable to function in temperature range of (-)10 0 To (+) 200 0 C.

12.2.6

Vibration monitoring system shall provide the vibration measurement in the form of 4-20 mA DC signal to be directly connected by hardwired cable to plant DCS for monitoring. Limit value generation (soft) for alarm and protection applications for the auxiliaries and their drive equipment shall be carried out in DCS or applicable control system (PLC).

12.2.7

Vibration monitoring and analysis system shall be an independent microprocessor based system (PC based). The system shall be interfaced with unit DCS system through redundant communication link. The system shall interface with plant DCS for any process signals which may be required to perform condition monitoring functions through soft link.

12.2.8

Vibration analysis system shall be knowledge based with the capability of dynamic data analysis and provides complete information about machines. This will include machinery management software including analysis of generator overhang for data acquisition and predictive maintenance.

12.2.9

The vibration analysis system shall be able to carry out the following tasks:

12.2.10

(a)

To determine the exact nature of fault in the rotating machines like misalignment, shaft crack, bearing looseness, dynamic un-balancing of rotor etc. indicating the magnitude of vibration and phase angle information and the corrective action to be undertaken by maintenance personnel. For example, in case of dynamic un-balancing of rotor, the system shall provide the guidance about the appx. mass needed to be added to the rotor with the direction information.

(b)

To provide the guidance about predictive maintenance requirement of the machines. Predictive maintenance requirement guide shall also include the “Period of safe operation of machines available at any given point of time’.

The analysis system shall be able to carry out the following types of analysis to meet the tasks of analysis system detailed above. The system shall not require the intervention of vibration expert to determine the nature of the fault: (a)

On line spectrum/harmonic analysis of the vibration measurements.

(b)

The system shall have facility to generate and analyse the following: (i)

Bode Plot

(ii)

Time wave form

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INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM - TECHNICAL SPECIFICATION (iii)

Orbit Analysis

(iv)

Shaft centreline

(v)

Cascade Plot

(vi)

Water fall

(vii)

Bar graph

(viii)

Current values

(ix)

Spectrum

(x)

Alarms – amplitude and spectral

(xi)

Data collection during start up and coast down

(xii)

Operating point for pumps and fans

SHEET 20 OF 27

12.2.11

The analysis software should be capable of outputting direct message on video monitor of the exact nature of fault.

12.2.12

The system shall have facility to store bulk data for 5 years duration with facility for retrieval of the same. The system shall have facility to share all the data in the hard disk/ back up media and provide user friendly utilities to retrieve and analyze stored data.

12.2.13

The system shall be provided with redundant UPS power supply. The power supply provision shall be such that on failure of one power supply the other power supply shall cater to the requirement of the equipment so as never to hinder the functioning of the system in any manner due to power supply failure.

12.2.14

Vibration measurements as a minimum to be provided as per the following: Sl. Drive Motor Pump / Fan no. 1.0 ID fan, PA i) DE - 2 vibrations pick-ups in ‘X’ fan and FD and ‘Y’ axis. fans ii) NDE - 2 vibrations pick-ups in ‘X’ and ‘Y’ axis. BFP (Turbine i) Front end of shaft - 2 vibrations 2.0 driven) pick-ups in ‘X’ and ‘Y’ axis. ii) Rear end of shaft - 2 vibrations pick-ups in ‘X’ and ‘Y’ axis. iii) Keyphasor iv) Axial thrust v) Eccentricity vi Differential expansion vii) Case expansion ISSUE

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3.0

BFP (Motor driven)

4.0

Boiler Feed Booster Pump

5.0

CEP

6.0

CCC pump

7.0

OCCW pump

8.0

FC pump

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viii)Reverse rotation detection. i) DE - 2 vibrations pick-ups in ‘X’ and ‘Y’ axis. ii) NDE - 2 vibrations pick-ups in ‘X’ and ‘Y’ axis. iii) Keyphasor iv) Reverse rotation detection.

i) DE - 2 vibrations pick-ups in ‘X’ and ‘Y’ axis. ii) NDE - 2 vibrations pick-ups in ‘X’ and ‘Y’ axis. i) DE - 2 i) DE - 2 vibrations pick-ups in ‘X’ vibrations and ‘Y’ axis. pick-ups in ii) NDE - 2 vibrations pick-ups in ‘X’ and ‘Y’ ‘X’ and ‘Y’ axis. axis. ii) NDE - 2 vibrations pick-ups in ‘X’ and ‘Y’ axis. i) NDE - 2 vibrations pick-ups in ‘X’ and ‘Y’ axis. ii) Thrust bearing - 2 vibrations pick-ups in ‘X’ and ‘Y’ axis. i) DE - 2 i) DE - 2 vibrations pick-ups in ‘X’ vibrations and ‘Y’ axis. pick-ups in ii) NDE - 2 vibrations pick-ups in ‘X’ and ‘Y’ ‘X’ and ‘Y’ axis. axis. ii) NDE - 2 vibrations pick-ups in ‘X’ and ‘Y’ axis. i) DE - 2 i) DE - 2 vibrations pick-ups in ‘X’ vibrations and ‘Y’ axis. pick-ups in ii) NDE - 2 vibrations pick-ups in ‘X’ and ‘Y’ ‘X’ and ‘Y’ axis. axis. ii) NDE - 2 vibrations pick-ups in ‘X’ and ‘Y’ axis. i) DE - 2 i) DE - 2 vibrations pick-ups in ‘X’ ISSUE

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Mills

vibrations pick-ups in ‘X’ and ‘Y’ axis. ii) NDE - 2 vibrations pick-ups in ‘X’ and ‘Y’ axis. i) DE - 2 vibrations pick-ups in ‘X’ and ‘Y’ axis. ii) NDE - 2 vibrations pick-ups in ‘X’ and ‘Y’ axis.

SHEET 22 OF 27

and ‘Y’ axis. ii) NDE - 2 vibrations pick-ups in ‘X’ and ‘Y’ axis.

-

DE – Driven End NDE – Non-Driven end

12.3

VIBRATION ANALYSIS SYSTEM HARDWARE/ SOFTWARE/ INTERFACING REQUIREMENT

12.3.1

Each Vibration analysis system shall include all hardware and software as required for proper functioning of the system including but not limited to the following:

12.3.2

(a)

One (1) no Server (With PC, Video Display Unit, Keyboard /Mouse )

(b)

One (1) no user station (With PC, Video Display Unit, Keyboard/ Mouse and Colour Laser Printer)

(c)

Vibration analysis software with all relevant User’s license.

(d)

Server & User PCs operating licenses.

(e)

Bulk data storage and retrieval facility

(f)

Redundant OPC communication link with all necessary hardware and software.

(g)

System cables etc.

All software user licenses shall be valid for entire life of power plant. User should not have to pay any recurring license fee during the usage period of the system.

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12.3.3

It shall be possible to upgrade the installed system with the latest available version of the software model during the plant life.

12.4

DESIGN DATA

12.4.1

Server Unit (a)

Pentium latest model & version

(b)

Memory-1024 MB RAM

(c)

Hard Disk Drive-160 GB or Higher

(d)

DVD / CD ROM Drive-50X

(e)

DAT Drive-Required

(f)

Network Interface- Required

(g)

Server Operating System-Required

(h)

External Modem- Required, 56 k V.90

12.4.2

User Station PC: Industrial grade PC of latest model / configuration with Owner’s/ Consultants approval.

12.4.3

Video Display Unit (Server PC / User Station PC): 21" colour TFT LCD 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 Sixteen (16) colours shall be provided. Anti-reflection feature shall be provided. The VDUs shall be of table top mounting type. All VDU's shall have dedicated keyboard. .

12.4.4

Colour laser printer : Colour laser printer shall serve as a hard copy device to copy diagrams from the colour VDU for documentation and graphic diagram development functions. Minimum 7 colours to be provided. Interfacing- RS 232C/ 422A. Size- A3. Noise levels for the Printers at 1 meter distance shall be < 45 dB.

12.4.5

Bulk data storage and retrieval facility suitable and sufficient to store 5 years data.

12.5

SYSTEM IMPLEMENTATION

12.5.1

System shall be delivered fully implemented and shall be user tested at site. It is the Contractor’s responsibility to demonstrate the proper functioning of the system ISSUE

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to User’s personnel. 13.0

BOILER TUBE LEAK DETECTION SYSTEM

13.1

Tube leak detection system for each unit shall be independent and shall consist of number of high grade audio electronic microphone type audio detectors with a display sound level range of 50 to 150 dB and head amplifiers with a maximum operating temperature of 90 oC to be provided . The number of sensors shall be as required to cover complete boiler tube zones (but minimum 24 nos.) The measurement system shall have adequate number of channels corresponding to number of sensors and an accuracy of logarithmic conversion + 2% shall be provided. The display unit shall match the display unit in the VDU. The output shall be 4-20 mA / channel. The level of leakage shall be displayed in the form of bar charts and alarms shall be generated on occurrence of tube leakage. One speaker, power supply failure alarm and steam leak alarm shall be provided.

14.0

FURNACE FLAME MONITORING AND ANALYSIS SYSTEM

14.1

FLAME MONITORING-GENERAL

14.1.1

Furnace flame monitoring and analysis system shall provide analysis of flame conditions on continuous on-line basis and shall guide the plant operation personnel regarding the nature of flame and combustion process and the corrective action required.

14.1.2

The system to be provided shall include all necessary hardware, software, firmware and interfaces required for implementing a fully functional system. Bidder’s offered system shall include but not limited to the details specified in subsequent paragraphs.

14.1.3

Furnace flame monitoring and analysis system shall be independent for each unit.

14.2

FLAME MONITORING-DESIGN AND FUNCTIONAL REQUIREMENT

14.2.1

The flame monitoring and analysis system shall provide flame condition monitoring and thermo-graphic analysis of the flame in the furnace and also for each burner.

14.2.2

The system shall be complete with video camera, signal conditioning cards, amplifiers, special cables. etc. with all necessary equipment and accessories.

14.2.3

Sufficient number of cameras shall be provided so as to cover all burner flames so as to be able to carry out thermo-graphic analysis. The camera for burner flames should be expected to withstand the same shall not be less than the maximum temperature.

14.2.4

Flame monitoring cameras shall be provided with advance/ retract facilities with cooling arrangement through water etc. Advance/ retract unit shall be designed for suspended use.

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14.2.5

Necessary protection for automatic camera retraction on loss of cooling medium etc. shall be incorporated. Scanner fans for cooling the flame detectors by redundant scanner fans, one AC and the other DC operated shall be provided.

14.2.6

The analysis software should be capable of outputting direct message on video monitor of the exact nature of fault.

14.2.7

The system shall have facility to store bulk data for 5 years duration with facility for re-trieval of the same. The system shall have facility to share all the data in the hard disk/ back up media and provide user friendly utilities to retrieve and analyze stored data.

14.2.8

The system shall be provided with redundant UPS power supply. The power supply provision shall be such that on failure of one power supply the other power supply shall cater to the requirement of the equipment so as never to hinder the functioning of the system in any manner due to power supply failure.

14.2.9

The system is illustrated in dwg. No. TCE.5657A-IC-SK-01.

14.3

FLAME ANALYSIS REQUIREMENT

14.3.1

Each Furnace flame analysis system shall include all hardware and software as required for proper functioning of the system including but not limited to the following:

SYSTEM

HARDWARE/

SOFTWARE/

INTERFACING

(a)

Video camera unit for each burner (with advance/retract facility mounted)

(b)

One (1) no Server (With PC, Video Display Unit, Keyboard /Mouse)

(c)

One (1) no user station (With PCs, Video Display Unit, Keyboard/ Mouse and Colour Laser Printer)

(d)

Flame analysis software with all relevant user’s license.

(e)

Bulk data storage and retrieval facility

(f)

Redundant OPC communication link with all necessary hardware and software.

(g)

System cables etc.

14.3.2


14.3.3


14.4

DESIGN DATA ISSUE

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Server Unit (a)

Pentium latest model & version

(b)

Memory-1024 MB RAM

(c)

Hard Disk Drive-160 GB or Higher

(d)

DVD / CD ROM Drive-50X

(e)

DAT Drive-Required

(f)

Network Interface- Required

(g)

Server Operating System-Required

(h)

External Modem- Required, 56 k V.90

14.4.2

User Station PC: Industrial grade PC of latest model / configuration with Owner’s/ Consultants approval.

14.4.3

Video Display Unit (Server PC / User Station PC): 21" colour TFT LCD 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 Sixteen (16) colours shall be provided. Anti-reflection feature shall be provided. The VDUs shall be of table top mounting type. All VDU's shall have dedicated keyboard. .

14.4.4

Colour laser printer : Colour laser printer shall serve as a hard copy device to copy diagrams from the colour VDU for documentation and graphic diagram development functions. Minimum 7 colours to be provided. Interfacing- RS 232C/ 422A. Size- A3. Noise levels for the Printers at 1 meter distance shall be < 45 dB.

14.4.5

Bulk data storage and retrieval facility as required.

14.5

SYSTEM IMPLEMENTATION

14.5.1

System implementation shall take into account the stabilisation of fuel firing equipment characteristics while in service for some period (say plant commissioning period) and the varying characteristics coal being available in the plant. However, the system shall be user tested at site. It is the Contractor’s responsibility to demonstrate the proper functioning of the system to User’s personnel. ISSUE

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SHEET 27 OF 27

14.5.2

It is preferred that Contractor’s implementation team will involve ultimate user’s O&M personnel during system im plementation.

15.0

SMART TRANSMITTER MAINTENANCE STATION

15.1

A dedicated standalone PC based Smart transmitter Station (STMS) shall be provided for centralized configuration, maintenance, diagnostic and record keeping of all electronic smart transmitters. Transmitter signals shall be wired parallel to DCS control system and HART modules of stms, which will be connected to PC through suitable communication modules. Complete diagnostic, record keeping, calibration and configuration, event and log reports, historical data base records of all transmitters shall be possible from the STMS.

16.0

INSTRUMENTATION AND SPECIAL CABLES

16.1

Specification of instrumentation and special cables application guidelines are listed in Section D 5, Table-8. CONTRACTOR shall supply as per these specifications and deviations if any are subject to approval by OWNER / CONSULTANT.

17.0

QUALITY ASSURANCE

17.1

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.

ISSUE

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TCE FORM NO. 120R2



Spec No. TCE.5657A-C-500-001

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/Engineer’s 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 5, TABLE-14 and any other tests as required by the Standards and Codes.

2.0

TESTS AND INSPECTION FOR DCS

2.1

Tests for DCS system will include the following: (a)

Factory Acceptance Test (FAT): To be carried out at DCS system CONTRACTOR’s / Sub-Vendor’s 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.

(b)

Site Test (SAT): Involves tests for site commissioning, guarantee tests for system performance & availability to be conducted in the presence of Owner.

2.2

Factory Acceptance Test (FAT)

2.2.1

FAT shall be a complete integrated test of the DCS system and carried out at CONTRACTOR’s / Sub-Vendor’s 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 DCS system equipment / total system together with the guideline for Factory acceptance test (FAT) procedure are detailed in Section D 5, TABLE-13. The CONTRACTOR shall submit a detailed "Factory Acceptance Test Procedure" in line with the above specified guidelines for Owner / Consultant approval.

2.2.2

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’.

2.3

Site Test (SAT)

2.3.1

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:

ISSUE


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SECTION: D 5.5

Spec No. TCE.5657A-C-500-001


SHEET 2 OF 4

(i)

Calibration of monitoring and control equipment

(ii)

Integrated loop test wiring, Simulation input from site

(b)

Trial Operation of the DCS system functioning.

(c)

Performance Guarantee Test for I&C systems

(d)

Availability Guarantee Test for DCS system

3.0

TRIAL OPERATION OF THE DCS SYSTEM

3.1

Trial operation test of DCS 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.

3.2

Test shall be conducted at site by Contractor’s personnel in the presence of the Owner / Consultant.

3.3

Test shall be a “Total Integration Test of the whole DCS System” including the testing of communication links.

3.4

Test duration shall be of 14 days out of which 72 hours shall be continuous operation performing all the specified functions.

3.5

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.

3.6

Total interruption period (system outage time) shall be calculated as detailed in 5.4 below.

4.0

PERFORMANCE GUARANTEE TEST FOR I&C SYSTEM

4.1

After successful trial operation, the OWNER shall conduct performance guarantee test for a period of 14 days in the presence of CONTRACTOR’s 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.

4.2

Following tests to be performed during the PG test:

4.2.1

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


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Spec No. TCE.5657A-C-500-001


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

Response time for each type of update as per the specification shall be checked on line by suitably recording each activity.

4.2.3

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.

4.2.4

Checking of the time activated and on demand reports.

4.2.5

Functional inter-changeability of the Operator Stations and printers shall be checked.

4.2.5

Time synchronisation with master clock shall be tested.

4.2.6

Specified serial links shall be established and proven.

4.2.7

The calculations / documents earlier furnished for establishing the specified system availability, shall be demonstrated with due consideration for the running plant.

4.2.8

The specified MIS functions, Performance Calculations etc., shall be checked.

4.3

PG Test Methodology

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.

4.3.2

Contractor shall declare the system fit for checking after completing the modification / rectification. The specific test shall be repeated for proper functioning.

4.3.3

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.

4.3.4

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.

4.3.5

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.

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Spec No. TCE.5657A-C-500-001


SHEET 4 OF 4

4.3.6

During all the above tests, Contractor shall ensure that the disturbance to the process is minimum.

4.4

PG Test Result Interpretation

4.4.1

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 5.3.

4.4.2

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.

4.5

The DCS System PG test shall be carried out to Owner’s satisfaction. The last 5% of the total supply payment will be released only after successful completion of DCS system PG test.

5.0

AVAILABILITY GUARANTEE TEST FOR DCS SYSTEM

5.1

The test shall demonstrate the specified guaranteed DCS system availability of 99.7% for a continuous period of 6 months as specified in Section D 5.3 or as agreed for the project.

5.2

The test period shall be a continuous period of 6 months.

5.3

DCS system availability shall be computed as specified in Section D 5.3.

5.4

During the test period, the Owner’s 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 Contractor’s engineer by using the spare and as per trouble shooting procedure furnished by DCS System Vendor.

5.5

The Contractor shall depute their representative/ engineer for the total duration of ‘Availability Guarantee Test” covering 24 hrs. of the day.

5.6

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.

5.7

The DCS System “Availability Guarantee Test” shall be carried out to Owner’s satisfaction. The last 5% of the total supply payment will be released only after successful completion of DCS system “Availability Guarantee Test”.

ISSUE


TCE FORM NO. 120R2


Spec No.

SECTION: D 5.6

TCE.5657A-C-500-001

1.0

Volume – V

INSTRUMENTATION AND CONTROL OTHER SERVICES

SHEET 1 OF 1

TRAINING OF OWNER'S PERSONNEL

1.1

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.

1.2

The type of training with number of personnel to be trained and the quantum of training to be provided are detailed in TABLE- 16.

1.3

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.

1.4

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.

1.5

CONTRACTOR shall include in his bid a detailed description of the proposed training for the OWNER's personnel.

2.0

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 5.5, 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.

ISSUE

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TCE FORM NO. 120R2

Volume – V


Spec No.

SECTION: D 5.7

TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – PERFORMANCE GUARANTEE

SHEET 1 OF 5

1.0

MEASUREMENT SYSTEM (MS)

1.1

Accuracy of each instrument shall be as specified in Section-D 5.3 & D-5.4 of specification.

2.0

DCS SYSTEM

2.1

CLOSED LOOP CONTROL SYSTEM (CLCS)

2.1.1

The control system shall be capable of regulating the control devices to achieve the performance guarantees specified below.

2.1.2

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.

2.1.3

The limits of deviations from set point for the following shall be different for constant pressure and variable pressure operation: Particulars

Item

(a)

Steady state

(b)

Ramp between 60% TG MCR and 100% SG MCR condition:

(c)

Drum Level Deviation (if applicabl e)

Superheater Outlet Pressure Deviation

Superheater Outlet Temp. Deviation

+/- 0.2 kg/cm

+/- 2.0 C

+/- 15mm

(i)

Rate of 1% per minute

+/- 0.3 kg/ cm 2

+/- 3 0C

+/- 15 mm

(ii)


+/- 0.5 kg/cm 2

+/- 5 0C

+/- 20 mm

(iii)


+/- 1.0 kg/cm 2

+/- 8 0C

+/- 25 mm

(iv)


+/- 10 0C

+/- 50mm

Step load change from 100%

+/-1.5 kg/cm 2 +/- 5.0 kg/cm2

+/- 20 0C

+/- 100 mm ISSUE

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Spec No.


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SG MCR in case of run back due to loss of one FD/ PA/SA/ID fan or boiler feed pump or any other emergency. In addition Bidder shall indicate the capability of the unit with respect to fast change of load. 2.2

INTERLOCK, PROTECTION AND SEQUENTIAL CONTROL SYSTEM The BIDDER shall guarantee the proper functioning of interlock, protection and sequential control system as specified in Section-D 5.3 and D 5.4 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 5.3 of specification shall also be guaranteed.

2.4

HUMAN-MACHINE INTERFACING SYSTEM The BIDDER shall guarantee the proper functioning of HMI system & Control Engineer’s interfacing equipment as specified in Section-D 5.3 & D 5.4 of specification.

2.5

MAINTENANCE ENGINEER'S EQUIPMENT (MEE) The BIDDER shall guarantee the proper functioning of Maintenance Engineer's Equipment as specified in Section- D 5.3 & D 5.4 of specification.

2.6

SEQUENCE OF EVENTS RECORDING AND ANNUNCIATION SYSTEM The BIDDER shall guarantee the proper functioning of Sequence of Events Recording as specified in Section-D 5.3 & D 5.4 of specification.

3.0

FAIL-SAFE TYPE SG INTEGRAL CONTROL SYSTEM The BIDDER shall guarantee the proper functioning of Fail- safe type SG Integral control system for BMS/Boiler protection system as specified in Section-D 5.3 & D 5.4 of specification.

4.0

FAIL-SAFE TYPE TG INTEGRAL CONTROL SYSTEM The BIDDER shall guarantee the proper functioning of Fail- safe type TG Integral control system for Turbine Governing & Protection system as specified in Section-D 5.3 & D 5.4 of specification.

5.0

PLC BASED CONTROL SYSTEM(S) ISSUE

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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. 6.0

SOFTWARE PACKAGES The BIDDER shall guarantee the proper implementation and functioning of all Software packages required for different control systems namely, DCS, PLC type control system etc. included in the scope.

7.0

TURBOVISORY SYSTEM The BIDDER shall guarantee the proper functioning of Turbo-Supervisory System as specified in Section-D 5.3 of specification.

8.0

MASTER CLOCK (TIME SYNCHRONISATION) SYSTEM The BIDDER shall guarantee the proper functioning of Time Synchronisation system equipment including GPS receiver, Antenna, Master Clock and Slave Clocks etc. as specified in Section-D 5.4 of specification.

9.0

AUXILIARY POWER SUPPLY SYSTEM (APSS) The BIDDER shall guarantee the proper functioning of auxiliary power supply system as specified in Section-D 5.2 of specification.

10.0

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, hardwired alarm annunciation system etc. and final control elements like control valves / control dampers, de-superheaters etc., shall be guaranteed for proper functioning within an accuracy as specified.

11.0

LARGE VIDEO SCREEN / VDU MONITORS All equipment shall be guaranteed for proper functioning as specified in Section-D 5.4 of specification.

12.0

STEAM & WATER ANALYSIS SYSTEM (SWAS) The BIDDER shall guarantee the proper functioning of Steam and water system (SWAS) as specified in Section-D 5.4 of specification.

13.0

GAS ANALYSERS The BIDDER shall guarantee the proper functioning of all Gas Analysers as specified ISSUE

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in Section-D 5.4 of specification. 14.0

BOILER TUBE LEAK DETECTION SYSTEM The BIDDER shall guarantee the proper functioning of Boiler Tube Leak Detection System as specified in Section-D 5.4 of specification.

15.0

SMART TRANSMITTER MAINTENANCE FACILITY The BIDDER shall guarantee the proper functioning of Smart Transmitter Maintenance Facility as specified in Section-D 5.4 of specification.

16.0

VIBRATION MONITORING AND ANALYSIS SYSTEM (CMS) The BIDDER shall guarantee the proper functioning of the Vibration monitoring & Analysis system as specified in Section-D 5.4 of specification.

17.0

FURNACE FLAME MONITORING AND ANALYSIS SYSTEM The BIDDER shall guarantee the proper functioning of Furnace flame monitoring & Analysis System as specified in Section-D 5.4 of specification.

18.0

PERFORMANCE ANALYSIS, DIAGNOSTIC AND OPTIMISATION (PADO) SYSTEM The BIDDER shall guarantee the proper functioning of Performance Analysis, Diagnostic & Optimisation System as specified in Section-D 5, TABLE-20 of specification.

19.0

MANAGEMENT INFORMATION SYSTEM (MIS) & STATION LAN The BIDDER shall guarantee the proper functioning of Management Information System as specified in Section-D 5, TABLE-22 of specification.

20.0

COMMUNICATION LINKS Bidder shall note and confirm to the successful implementation of all the specified communication links amoung different Control & Monitoring systems like DCS, PLC Controls, PADO, MIS etc. under the scope of this specification. All the links shall be redundant and Bi-directional and shall be implemented through Fibre Optic cables and run in two physically separate conduits.

21.0

TOTAL SYSTEM AVAILABILITY

21.1

The BIDDER shall guarantee the availability of DCS / SG / TG Integral Control system / PLC Based Control systems etc. for minimum 99.7% on an annual basis and demonstrating the same.

21.2

The method of calculating the total system availability shall be as specified in SectionD 5.5 of specification. ISSUE

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22.0

Volume – V


SHEET 5 OF 5

PERFORMANCE The BIDDER shall guarantee that the goods furnished by him shall be in full accordance with the requirements of the enquiry specifications.

23.0

QUALITY

23.1

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.

23.2

Bidder shall guarantee the specified requirements for microprocessor based systems supplied by him.

ISSUE

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Spec No.

SECTION: D5

TCE.5657A-C-500-001

Sl. no.

Volume – V

INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM - TABLE 1 – TERMINAL POINTS

Package / Activity

SHEET 1 OF 5

Design / Engineering

Supply

Erection

Commissioning

1.0

Coal handling system

1.1

All field devices & instruments

BOP

BOP

BOP

BOP

1.2

PLC system for CHS (With 1nos. Of operator station & 1no. Of Engineering station)

BOP

BOP

BOP

BOP

1.3

Remote I/Os at main CHP substation, wagon tippler substation, bunker floor PMCC room and air compressors.

BOP

BOP

BOP

BOP

1.4

Redundant fiber optic cables between PLC and remote I/O

BOP

BOP

BOP

BOP

1.5

Control desk in CHP control room and wagon tippler control room.

BOP

BOP

BOP

BOP

1.6

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.

BOP

BOP

BOP

BOP

1.7

Equipment mounted PLC based control systems for wagon tippler & side arm charger and stacker / reclaimer

BOP

BOP

BOP

BOP

1.8

Redundant communication link between a) PLCs of stacker reclaimers and CHP main PLC b) PLC wagon tippler, side arm charger and main CHP PLC

BOP

BOP

BOP

BOP

1.9

Bunker level indicator signals to DCS - cabling to DCS

BTG

BTG

BTG

BTG

1.10

Cabling for master clock signal from master clock to PLC system

BTG

BTG

BTG

BTG

1.11

UPS for complete I&C system

BOP

BOP

BOP

BOP

1.12

Communication link between DCS and PLC system

BTG

BTG

BTG

BTG

1.13

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.

BTG

BTG

BTG

BTG

1.14

I&C cabling for entire CHS package including JBs, cable trays, etc.

BOP

BOP

BOP

BOP

ISSUE

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Spec No.

SECTION: D5

TCE.5657A-C-500-001

Sl. no.

Volume – V


Package / Activity

SHEET 2 OF 5


Supply

Erection

Commissioning

BOP

BOP

BOP

BOP

1.15

Cabling between CHS MCC to PLC

2.0

DM Water plant & Effluent treatment plant

2.1

Complete filed instrumentation and final control elements

BOP

BOP

BOP

BOP

2.2

Installation hardware for instrumentation equipment

BOP

BOP

BOP

BOP

2.3

PLC System with 1 nos. operator station and 1 no. of engineering station based local control panel

BOP

BOP

BOP

BOP

2.4

Programming station for the PLC station

BOP

BOP

BOP

BOP

2.5

Control desk DM control room

BOP

BOP

BOP

BOP

2.6

Complete I&C cabling including JB's, Cable trays, etc. for the DM plant

BOP

BOP

BOP

BOP

2.7

UPS for DM water plant & Effluent treatment plant PLC based I&C system

BOP

BOP

BOP

BOP

2.8

Cabling for master clock signal from master clock system to PLC

BTG

BTG

BTG

BTG

2.9

Cabling between DM Plant MCC to PLC

BTG

BTG

BTG

BTG

3.0

RESERVOIR INTAKE WATER SYSTEM

3.1


BOP

BOP

BOP

BOP

3.2


BOP

BOP

BOP

BOP

3.3

PLC based local control panel LCD keypad operated

BOP

BOP

BOP

BOP

3.4

Complete I&C cabling including JB's, Cable trays, etc.

BOP

BOP

BOP

BOP

3.5

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

BOP

BOP

BOP

BOP

3.6

UPS for Reservoir intake water PLC based I&C system

BOP

BOP

BOP

BOP

3.7

Cabling between Reservoir intake MCC to PLC

BOP

BOP

BOP

BOP

ISSUE

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TCE FORM NO. 120R2


Spec No.

SECTION: D5

TCE.5657A-C-500-001

Sl. no.

Volume – V


Package / Activity

SHEET 3 OF 5


Supply

Erection

Commissioning

4.0

Raw water & pre-treatment system

4.1


BOP

BOP

BOP

BOP

4.2


BOP

BOP

BOP

BOP

4.3

PLC based local control panel LCD keypad operated

BOP

BOP

BOP

BOP

4.4

Complete I&C cabling including JB's, Cable trays, etc.

BOP

BOP

BOP

BOP

4.5

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

BOP

BOP

BOP

BOP

4.6

UPS for Reservoir intake water PLC based I&C system

BOP

BOP

BOP

BOP

4.7

Cabling between Raw water MCC to PLC

BOP

BOP

BOP

BOP

5.0

Circulating water / auxiliary cooling water

5.1

Field instruments and associated instrument installation hardware except CW header

BTG

BTG

BTG

BTG

5.2

Field instruments and associated instrument installation hardware for CW header

BTG

BTG

BTG

BTG

5.3

DCS operator station and I/O modules in CW / ACW pump house

BTG

BTG

BTG

BTG

5.4

I&C cabling where both ends are BTG equipment (eg. Field instruments)

BTG

BTG

BTG

BTG

5.5

I&C cabling where at least one end of cable connects to BTG equipment (MCC, hardwired annunciation system and CW header instruments)

BTG

BTG

BTG

BTG

5.6


BTG

BTG

BTG

BTG

6.0

Ash handling system ISSUE

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Spec No.

SECTION: D5

TCE.5657A-C-500-001

Sl. no.

Volume – V


Package / Activity

SHEET 4 OF 5


Supply

Erection

Commissioning

6.1

All field devices & instruments along with Installation hardware

BOP

BOP

BOP

BOP

6.2

AHS PLC (With 1 nos. Of operator station & 1no. Of Engineering station)

BOP

BOP

BOP

BOP

6.3

Slurry system PLC

BOP

BOP

BOP

BOP

6.4

LCPs for Bottom ash handling system

BOP

BOP

BOP

BOP

6.5

LCPs of bottom ash handling system

BOP

BOP

BOP

BOP

6.6

Local control panel for Silo unloading system

BOP

BOP

BOP

BOP

6.7

Local control panel for Coarse ash handling system

BOP

BOP

BOP

BOP

6.8

Remote I/O as required

BOP

BOP

BOP

BOP

6.9

Control desk in AHS control room

BOP

BOP

BOP

BOP

6.10

Redundant serial link between ash water & slurry PLC to AHS PLC

BOP

BOP

BOP

BOP

6.11

Bus cabling between remote I/Os and ash handling system PLC

BOP

BOP

BOP

BOP

6.12

UPS for PLC based I&C systems

BOP

BOP

BOP

BOP

6.13

Complete I&C cabling including JBs, cable trays, etc.

BOP

BOP

BOP

BOP

6.14

Communication link between DCS and PLC system

BTG

BTG

BTG

BTG

6.15

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.

BTG

BTG

BTG

BTG

6.16


BTG

BTG

BTG

BTG

6.17

PLC / microprocessor based control system for air compressor

BOP

BOP

BOP

BOP

6.18

Communication link between air compressor PLC and AHS PLC system

BOP

BOP

BOP

BOP

7.0

GENERAL

ISSUE

R0


TCE FORM NO. 120R2


Spec No.

Volume – V SECTION: D5

TCE.5657A-C-500-001


SHEET 5 OF 5


Supply

Erection

Commissioning

7.1

Cable link between the slave clocks and the PLC system across the plant [BTG & BOP PLC's] including master and slave clock

BTG

BTG

BTG

BTG

7.2

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.

BTG

BTG

BTG

BTG

7.3

Hardwired signal exchange from BOP to BTG DCS cabling

BTG

BTG

BTG

BTG

7.4

I&C cabling where at least one end of cable connects to BTG equipment (MCC, etc)

BTG

BTG

BTG

BTG

Sl. no.

Package / Activity

ISSUE

R0


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM –TABLE 2

Sl. No.

System / Equipment

1

Air & Flue Gas

2

Eletro-Static Precipitator

3

Coal & Fuel Oil

Control System Hardware

Interfacing with Plant DCS

DCS DCS / PLC Based Control System

Remarks Per unit basis

Note 1

DCS DCS / PLC Based Control System (Note 2)

SHEET 1 OF 2

Per unit basis Per unit basis

4

Mill Reject System

5

Steam

DCS

Per unit basis

6

Feed Water

DCS

Per unit basis

7

Condensate

DCS

Per unit basis

8

Condensate Polishing System

9

CW/ACW

DCS

Plant common

10

Turbine Integral System

DCS

Per unit basis

11

Turbo-supervisory Instrumentation

DCS

12

Make up water System

DCS

Plant common

13

Generator Auxiliary Systems

DCS

Per unit basis

14

Chemical Dozing

DCS

Plant common

DCS

Plant common

15 16 17

Service /Potable Water System Reservoir intake Water System - # Raw Water & PreTreatment Plant - #

18

Compressed Air Plant

19

Coal Handling Plant - #

20

Ash Handling Plant - #

21

DM Water /Effluent Treatment Plant - #

22

DG Set

23

Other Utility Plants - #

24

Fire Protection System

PLC Based Control System

PLC Based Control System PLC Based Control System PLC Based Control System PLC Based Control System PLC Based Control System PLC Based Control System PLC Based Control System PLC Based Control System PLC Based Control System

Note 1

Note 1

Note 1

Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note 1 Note1 Note 1

Per unit basis

Per unit basis

Per unit basis

Plant common Plant common Plant common Plant common Plant common Plant common Per unit basis Plant common Plant common

ISSUE

R0


TCE FORM NO. 120R2


Spec No.

SECTION: D5

TCE.5657A-C-500-001


Sl. No.

System / Equipment

25

Fire Detection system

26

A/C and Ventilation

27

Station Electrical System Switchyard Electrical System (SCADA)

28

Volume – V

29

UPS

30

Condenser online tube cleaning system & self cleaning filter

Control System Hardware Micro-processor based PLC Based Control System DCS PLC Based Control System PLC Based Control System

Interfacing with Plant DCS

PLC Based Control System

SHEET 2 OF 2

Remarks

Note 3

Plant common

Note 1

Plant common Plant common

Note 1 Note 1

Plant common Per unit basis

Note 1 Per unit basis

NOTES: 1

Communication link between DCS & PLC control is redundant bi- directional OPC communication link with TCP-I/P protocol.

2

Bidder Has the option of implementing the control for the system/ equipment in a separate PLC based control system duly interfaced with DCS in place of DCS based control.

3

Serial link applicable for microprocessor based system.

4

Thus “#” marked utility packages are provided by other vendors.

ISSUE

R0


TCE FORM NO. 120R2

Volume – V


Spec No.

SECTION: D5

TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 3

SHEET 1 OF 1

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 Annunciator sequences and spec. 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 Air Purge System 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 18.1 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 ISA S 12.4 / NFPA 496 ISO 5167 ANSI MC 96.1 / IEC 751 IEC 529 IEC IEC IEC 62443

ISSUE

R0


TCE FORM NO. 120R2

Spec No. TCE.5657A-C-500-001




SHEET 1 OF 2

TABLE-4: I&C DATA TO BE FURNISHED WITH THE BID The following documents shall be furnished along with Bid for Complete I & C system (Main Plant I & C system). 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. user’s certificate for the DCS system configuration offered.

2.0

Control philosophy / operation philosophy / Design philosophy / Redundancy philosophy for Plant DCS controls.

3.0

Grouping philosophy of control loops in controllers

4.0

DCS/ PLC configuration drawing / system architecture drawings including MMI.

5.0

Control room layout

6.0

P&ID (Process and Instrumentation drawings) indicating primary and secondary Instruments and the destination/functionality of the signals for main Plant.

7.0

Clause wise confirmation / deviation list with respect to I & C requirements specified in sections.

8.0

Duly signed schedule of performance guarantees.

9.0

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.

10.0

List of software included for Plant DCS controls.

11.0

Confirmation certificate for the latest version of software and hardware offered.

12.0

Codes and applicable standards followed for the project. List of closed loop controls included. Redundancy concept for CLCS controls with details. Redundancy concept for Boiler controls and Turbine controls (EHTC). List of open loop controls included. Redundancy concept for OLCS controls with details of Boiler Protection system and Turbine Protection system.

13.0 14.0

15.0 16.0

Evidence that the offered DCS system is upgradable and evolutionary in both hardware and software Letter confirming support of spares for 15 years for the DCS/PLC system

ISSUE


TCE FORM NO. 120R2

Spec No. TCE.5657A-C-500-001




SHEET 2 OF 2

SL. NO

DATA TO BE FURNISHED supplied.

17.0

Details of Historical Storage and Retrieval (HSR) System

18.0

Details of Management Information System (MIS) system.

19.0

Details of Computerised Maintenance Management System

20.0

Details of Performance Analysis, Diagnostics & Optimisation System

21.0

Details of Management Information System

22.0

Details of Vibration Monitoring and Analysis system

ISSUE


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 5 TABLE- 5: ESSENTIAL SPARES

SHEET 1 OF 4

SL. NO.

ITEM/DESCRIPTION

QUANTITY / UNIT

1.0

Field Instruments (Gauges, Switches, transmitters), Solenoid Valves

10% for each type and range but minimum 2 nos.

2.0

DCS System

2.1

Power Supply modules/Cards

2.2

Network Cards

5% for each type and range but minimum 1 no 5% for each type and range but minimum 1 no

2.3

Communication Interface Cards

5% for each type and range but minimum 1 no

2.4

All other electronic modules


2.5

I/O Cards (Each Type)

2.6

SER Cards

5% for each type and range but minimum 2 nos each 5% for each type and range but minimum 1 no

2.7

Controller card

5 nos.

2.8

Optical Disk Drive

1 no

2.9

Optical Disk

5 nos

2.10

Compact Disks (R&W)

50 nos

2.11

Printer Cartriges

5 nos of each type

2.12

Data Bus Cable

1 no- full length

2.13

1 no

2.15

Data Bus Controller Fibre Optic Cable Conver/Deconverter Unit (applicable if remote I/O module is supplied) Keyboard & Mouse/Track Ball

2.16

Interposing Relay

10% of total quantity

3.0

PLC CONTROL SYSTEM (Each)

3.1

Power Supply modules/Cards

3.2

Network Cards

5% for each type and range but minimum 1 no 5% for each type and range but minimum 1 no

3.3

Communication Interface Cards


3.4

All other electronic modules


3.5

I/O Cards (Each Type)

3.6

SER Cards

5% for each type and range but minimum 2 nos each 5% for each type and range but minimum 1 no

3.7

Controller card

2 nos.

3.8

Interposing Relay

10% of total quantity

2.14

2nos 2 nos of each type

ISSUE


TCE FORM NO. 120R2


Spec No.

SECTION: D5

TCE.5657A-C-500-001


SL. NO.

ITEM/DESCRIPTION

4.0

Panels, local panels, system /marshalling cabinets for Main Plant

4.1

Fuses of each type and rating

50 nos

4.2

MCB of each type and rating

10 nos

4.3

MCB of each type Male/female parts of pre-fabricated cables

10 nos

4.4

6 nos. of each type

5.1

1 no. of each type

5.2

seat ring

1 no. of each type

5.3

packing and gaskets

1 no. of each type

5.4

pilot relay

1 no. of each type

5.5

actuator diaphragm

1 no. of each type

5.6

O-rings Control valves (Electrical operated- if supplied) – Interfacing modules

2 no. of each size

5.7

6.0

Solenoid Valve

6.1

Solenoid Valve Coil

7.0

Turbine Supervisory Instruments

7.1

For all instruments.

8.0

Time Synchronisation EquipmentMaster Clock System:

8.1

Each type of card

8.2

9.0

SHEET 2 OF 4

QUANTITY / UNIT

Control valves and Pneumatic Block valves (for each valve): For main Plant Plug and steam assembly

5.0

Volume – V

1 no. or 10% of total qty. whichever is higher.

Minimum 01 no. or 10% of each rating of total quantity whichever is higher.

Min. 1no. or 10% of total quantity whichever is higher.

10 % of total quantity or 01 no whichever is higher.

Slave Clocks

5 Nos. with necessary cables /connectors.

Vibration Monitoring and Analysis System

ISSUE


TCE FORM NO. 120R2

Volume – V


Spec No.

SECTION: D5

TCE.5657A-C-500-001


SHEET 3 OF 4

SL. NO.

ITEM/DESCRIPTION

QUANTITY / UNIT

9.1

Vibration pickups with cable

1 no. or 10% of total quantity whichever is higher for each type and range.

10.0

Steam tube leakage detection system

10.1

Sensor

10.2

Any other items

11.0

Large Video Screen

11.1

Lamps & Fuses

10% of total quantity for each type

11.2

Other Spare parts

As per the manufacturer’s recommendation.

2 nos. or 10% of total quantity whichever is higher for each type and range. As per the manufacturer’s recommendation.

12.1

Flue Gas analysers (For each Analyser) Sensing element

12.2

complete probe assembly

1no 1no

12.3

PCB of each type,

1no

12.4

set of gaskets and O-ring

1no

12.5

heater element and filter for proble

2 nos

12.6

standard gas for calibration

2 cylinders with regulator and connector

12.7

Fuses Sampling accessories like diaphragm pump, peristatic pump, refrigerated gas coolers, ejectors, temp guages, Nox/NO convertors etc.

5 nos. of each type and rating

12.0

12.8

1 no of each type

13.0

SWAS Analyser

13.1

Electronic cards

1no for each type and range

13.2

Conductivity cells/ pH cells & electrodes

1no for each type and range

13.3

Chemical Reagents

Suitable for 6 charges/usages

13.4

2 nos

13.6

Resin Column Dissolved O2 Analyser-sensor with compensating element Hydrazine Analyser-sensor

13.7

Sampling system Accessories

13.7.1

Sample coolers

13.5

1 no 1 no Minimum 1 no or 10% of total quantity whichever is higher for each type ISSUE


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001


SL. NO.

ITEM/DESCRIPTION

13.7.2

Pressure Control valve,

SHEET 4 OF 4

QUANTITY / UNIT 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

Thermometer, Temperature switch, 13.7.3 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 manufacturer’s recommendation.

ISSUE


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 1 OF 8 SYSTEM – TABLE 6 TABLE-6: LABORATORY AND TEST INSTRUMENTS

SL. No.

Instrument

Qty

Specification

1

Manometer

1 Set

Ranges: 0-10 mbar To 0-765 (Vertical) mbar with different indicating liquids; Scale: Black graduations on white back-ground with zero adjustment facility. Accuracy: Better than +/-0.25% of Reading.

2

Manometer

1

Range: (-) 250 mm To (+) 250 mmWC; Scale with black graduations on white back-ground with zero adjustment facility. Accuracy: +/0.25% of Reading.

(Inclined tube) 3

Manometer (U tube)

1

Range: 0-1000 mmWC; Scale: 0-100 cm with zero adjustment facility; Borosilicate glass tube in AL box; Five valve manifold; Aspirator

4

Test Manometer

1

Range: 0-10 cm; Scale: 0-100 mmWC with zero adjustment facility; Borosilicate glass tube in AL box; Five valve manifold; Aspirator.

5

Master Gauge

1 Set

250mm dial size; +/- 0.1% FSD accuracy; 1/2" BSP (M) conn; direct bottom conn; knife edge, micrometer pointer with -1 to 0, 0-25, 0-160, 0-250, 0-600 kg/cm.Sq ranges.

6

Air Set

1

Primary Pressure Range: (-) 760 mmHg to 0, 0-10 Bar; Secondary 2 pressure: 0-2.1 Kg/Cm . Filter element: 5 micron sintered bronze filter element. Accuracy: +/- 1.6% FS; Accessory- Input / Output Gauge, suitable regulator; Connection ¼ inch NPT (F) .

7

Pressure Comparator (Portable)

1

Range of 8157 to 19999 mmwc;1 mmwc vacuum and pressure resolution ; +/-0.1% accuracy; 4 1/2 digit calibrator LCD read out; built in relief valve; zero adjustment.

8

Integrated CalibratorElectronic and Pneumatic Instruments (Portable)

1

Checking and calibration for Electronic display.

(i) (ii)

(iii) (iv)

9

Pressure

INSTRUMENT DP transmitters, Draft Gauge, DP Indicators DP transmitters, Draft Gauge, DP Indicators, Pressure Transmitter, P/I & I/P converters Pressure Gauges, Pressure Switches, Pressure Transmitters I/P & P/I Converters DP / Pressure Transmitters

Integrated CalibratorElectronic and Pneumatic Instruments

1

the following with 4 1/2 digit LCD

RANGE -2000 mmwc to +2000 mmwc

ACCURACY +/-0.25% F.S

-0.8 bar to + 10 bar

+/-0.15% To

0-700 bar

+/-0.35% F.S

0-20mA/ -200mV

0.01mA / 0.01mV

F.S

Checking and calibration for the following with 4 1/2 digit LCD Electronic display.

ISSUE


TCE FORM NO. 120R2

Volume – V


Spec No.

SECTION: D5

TCE.5657A-C-500-001


(Table Mounted) INSTRUMENT (i) DP transmitters, Draft Gauge, DP Indicators (ii) DP transmitters, Draft Gauge, DP Indicators, Pressure Transmitter, P/I & I/P converters (iii) Pressure Gauges, Pressure Switches, Pressure Transmitters (iv) I/P & P/I Converters DP / Pressure Transmitters

RANGE -2000 mmwc to +2000 mmwc

ACCURACY +/-0.25% F.S

-0.8 bar to + 10 bar

+/-0.15% To

0-700 bar

+/-0.35% F.S

0-20mA/ -200mV

0.01mA / 0.01mV

F.S

10

Vacuum Calibrator (Poratble)

1

Range: (-)1 to (+) 1 Bar; Accuracy: +/- 0.025% FS; Power Supply; External charger / chargeable battery

11

Vacuum Calibrator (Table top mounted)

1

Range: (-)1 to (+) 1 Bar; Accuracy: +/- 0.025% FS; Power Supply-230 V AC.

12

Vacuum Pump/ Compressor

1

Max. flow capacity of 6 SC FM & max. vacuum of 0.005 mbar; max. pressure upto 60 psi; power supply 115 V 220V AC, 50/Hz.

13

Dead Weight Tester

1

Range: 0.3 -300 kg/cm2; Accuracy: +/- 0.1% of reading; Adapter set with 1/4" to 1/2" size NPT input connector; Accessories: Weight set & tool box.

14

Vacuum Tester

1

Motorised; Range: 0.1-1000 mBar; Accuracy: 0.025% of Reading; Adapter set with 1/4" to 1/2" size NPT input connector; Accessories: SS weights & AL for low weight set, tool box. Power supply-230 V AC.

2

Diaphragm operated, range: -0.95 bar to +6.5 Bar, sensitivity of Pressure and vacuum 0.03 bar, flow capacity: 15 Litres/min. Nickel plated brass or SS body material and Beryllium copper diaphragm material, max drift of 0.015% of setting in 30 minutes

15

High Precision Regulators for pressure and vacuum

o

o

o

o

o

16

Precision Set Thermometers (Mercury in Glass)

1

Ranges of -38 to 2 C, -8 to 32 C, 25-55 C , 50 to 80 C, 75-105 C, o o o o 95- 155 C, 145-205 C, 195-305 C, 295- 405 C; Ice point auxiliary scale cushioned carrying case.

17

Test Thermocouple

2

K type; upto temperatures of 950 C; inconel sheath; extension wires with teflon insulation; sheath dimensions suitable for calibrator.

o

o

18

Test RTDs

2

PT-100 OHM with 0.1 C stability, SS316 outer sheath, insulation resistance of more than 500 MOhm at 500 V DC;for temperatures o upto 500 C, (3/4)" wire to suit the calibrator; calibration to be traceable to national standard; sheath dimensions suitable for calibrator.

19

Temperature Calibrator (Portable)

1

Microprocessor based programmable for different temperatures and slope rates suitable for RTDs, thermocouples, switches, etc. with self-diagnostic capability, 4 1/2 digit displays, low battery

ISSUE


TCE FORM NO. 120R2

Volume – V


Spec No.

SECTION: D5

TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 3 OF 8 SYSTEM – TABLE 6 TABLE-6: LABORATORY AND TEST INSTRUMENTS o

o

o

indication & ranges of -50 to 123 C at 0.1 C resolution, +/-0.3 C o o o accuracy, +/-0.05 C stability; 50 to 650 C at 0.1 C resolution, +/-0.5 o o o o C accuracy +/-0.05 C stability; 200 to 1204 C at 1 C resolution, +/o o 2 C accuracy, +/-0.5 C stability. Accessories : Calibration software, RS-232C interface. 20

mV calibrator (Portable))

1

Measurement of mili-volt / thermocouple signals and generator of mili-volt signals. Built in electronic null detector and standard cell. Manual / automatic reference junction compensation facility. Power supply- re-chargeable power pack with charger.

21

Temperature Calibrator (Table Top Mounted)

1

Microprocessor based programmable for different temperatures and slope rates suitable for RTDs, thermocouples, switches, etc. with self-diagnostic capability, 4 1/2 digit displays, low battery o o o indication & ranges of -50 to 123 C at 0.1 C resolution, +/-0.3 C o o o accuracy, +/-0.05 C stability; 50 to 650 C at 0.1 C resolution, +/-0.5 o o o o C accuracy +/-0.05 C stability; 200 to 1204 C at 1 C resolution, +/o o 2 C accuracy, +/-0.5 C stability. Accessories : Calibration software, RS-232C interface.

22

mV calibrator (Table Mounted)

1

Measurement of mili-volt / thermocouple signals and generator of mili-volt signals. Built in electronic null detector and standard cell. Manual / automatic reference junction compensation facility. Power supply- re-chargeable power pack with charger.

23

Temperature Calibration Bath (oil)

1

Checking and Calibration for the following with 4 1/2 digit LED display

(i) (ii)

(iii) (iv)

INSTRUMENT T/C, RTD, Thermometers Temp. Switch & Thermister RTD, Thermisters Cold/ Ref. Junction of T/Cs

RANGE Ambient to 600 degree C o -50 C from ambient to o +75 C

T/C, RTD, Temp. Indicator, controllers Voltage indicators

-200 to 1370 C and 0-24mA 0-120V

24

Laboratory Furnace

1

25

Portable Field Electronic ICE Bath

1

26

Sling Psychrometer

1

o

transmitter, Temp.

ACCURACY +/-0.1% F.S +/-0.25%

+/-0.3oC and +/-0.05% +/-0.05%

o

Range Amb to 1200 C with digital temperature control for normal operation; K type thermocouple temperature sensoring, blind temperature control for safety and door limit switch for cut off supply when the door is opened. o

o

Accuracy of +/-0.1 C; stability .03 C Ice point reference; 1 o Cresolution; ambient to 600 C ; digital display, analog O/P; mains operated. o

o

Two matched thermometers with scale ranges of 0 to 100 F and o 0.5 F resolution, metal channel mounting frame with swivel handle, accuracy of 1%. Accessories: wick, psychrometric tables.

ISSUE


TCE FORM NO. 120R2

Volume – V


Spec No.

SECTION: D5

TCE.5657A-C-500-001


27

Digital Infrared Pyrometer

1

-50 to 1000 C range; spectral response 8 to 14 µ ; thermopile o detector; +/- 0.8% accuracy; RS 232C interface; 1 C repeatability; o analog output 0-1 V or 1 mV/ C; response 2 readings/sec; battery operated; 5 1/2 digit LCD display

28

mA Calibrator (Portable)

1

Output: 4-20 mA; Power supply- 230 V AC mains with battery & battery charger

29

mA Calibrator (Table Top Mounted)

1

Output: 4-20 mA; Power supply- 230 V AC mains.

30

Multi function Calibrator

1

Microprocessor based multi function calibrator suitable for measurement of transmitters, RTDs, T/Cs and act as a source for calibration of secondary instruments and system inputs. Digital LCD display simultaneously for input measured value and output signal. Data entry through numeric function keys.Built in diagnostics and auto calibration facility and shall be capable of measuring of voltage, current, Mv, RTD, frequency and simulation of corresponding primaries including 2 wire transmitter. Power supply- 230 V AC mains, battery with battery charger

31

Digital Multimeter (Portable)

3

4 1/2 digit, DC voltage ranges of 1 V to 1000 V with 100 micro V to 0.1 V resolution and accuracy of +/-0.04% to+/-0.1% of reading; AC RMS voltage of 1 V to 1000 V with resolution of 100 micro V to 0.1 V and accuracy of +/-0.3%to +/-10% of reading over the frequencies of 40 Hz to 100 KHz; dc current ranges of 20mA to 10A with resolution of 10 micro A to10 mA and accuracy of +/-0.4% of reading; AC current TRMS voltage ranges of 20mA to 10 A with 10 micro A to 10 mA resolution and accuracy of +/-0.6% of reading over the frequencies of 40 Hz to 400 Hz; resistance ranges of 1 K Ohm to 100 M Ohm with resolution of 100 mOhm to 10 K Ohm and accuracy of +/-0.15% to +/-5% of the reading; frequency ranges of 20 KHz to 200 KHz with 1 Hz to 10 Hz resolution and accuracy of +/o o o 0.1% of reading; temperature ranges of -60 to 200 C with 0.1 C o resolution and accuracy of 1 C: dB (for ac) ranges of -51 dB to 43 dB with 0.1dB to 1 dB resolutions and accuracy of +/-0.3% ; dB (for dc) ranges of -47 dB to 53.8 dB with 0.1 dB to 1 dB resolution and accuracy of +/-0.1 dB to +/-1 dB; diode and continuity testing facilities.

32

Digital (Table type)

3

4 1/2 digit, DC voltage ranges of 1 V to 1000 V with 100 micro V to 0.1 V resolution and accuracy of +/-0.04% to+/-0.1% of reading; AC RMS voltage of 1 V to 1000 V with resolution of 100 micro V to 0.1 V and accuracy of +/-0.3%to +/-10% of reading over the frequencies of 40 Hz to 100 KHz; dc current ranges of 20mA to 10A with resolution of 10 micro A to10 mA and accuracy of +/-0.4% of reading; AC current TRMS voltage ranges of 20mA to 10 A with 10 micro A to 10 mA resolution and accuracy of +/-0.6% of reading over the frequencies of 40 Hz to 400 Hz; resistance ranges of 1 K Ohm to 100 M Ohm with resolution of 100 mOhm to 10 K Ohm and accuracy of +/-0.15% to +/-5% of the reading; frequency ranges of 20 KHz to 200 KHz with 1 Hz to 10 Hz resolution and accuracy of +/-

Multimeter mounting

ISSUE


TCE FORM NO. 120R2

Volume – V


Spec No.

SECTION: D5

TCE.5657A-C-500-001


o

o

0.1% of reading; temperature ranges of -60 to 200 C with 0.1 C o resolution and accuracy of 1 C: dB (for ac) ranges of -51 dB to 43 dB with 0.1dB to 1 dB resolutions and accuracy of +/-0.3% ; dB (for dc) ranges of -47 dB to 53.8 dB with 0.1 dB to 1 dB resolution and accuracy of +/-0.1 dB to +/-1 dB; diode and continuity testing facilities. 33

Function Generator

1

Sine, Square, Triangle, Ramp or Pulse O/P; built in frequency counter; line frequency read out; Input range upto 10 MHz and O/P range of 1 Hz to 1 MHz; Digital display variable amplitude and offset.

34

High Resolution Timer/Count

1

Measurement of frequency, period, frequency ratio, totalise pulses, time interval and RPM; high resolution reciprocal counting; frequency range of 0.1 Hz to 120 MHz with an accuracy of +/- 1 count period measurement of 8 ns to 200,000,000 sec; Ratio measurement A/B time interval A-B; Totalise A.

35

Dual Trace Digital Storage Oscilloscope

1

Dual channel; Band width upto 20 MHz; transient wave form capture; component tester; sampling rate of 5 MHz; digital time base of 2 µs; X-Y plotter interface; battery back up; 2 mv sensitivity; inversion, addition, subtraction; Z modulation; 2-level calibrator.

36

DC Regulated Power Supply

1

VDC O/P voltage; 0-10A O/P current; 1 MV rms noise ripple; voltcurrent analog display; over load and short circuit protection, line regulation of +/- 0.05% for +/- 10% change in mains voltage; load regulation of +/- 0.05%

37

DC Battery Chargers

2

Accept cartridges and instruments, pack standby charger for upto four cartridges/instruments; operate from either 115 or 230VAC, 50 Hz Line Power.

38

Adjustable AC Power Supply

1

O/P voltage of 0-150 VAC; O/P current of 0-10A; power of 1300 VA

39

Digital Tong Tester

1

Auto ranging; 3 1/2 digit LCD display; AC volts with an accuracy of +/-1.0%; AC current upto 1000A with an accuracy of +/- 1.2%; resistance upto 2000 ohms with an accuracy of +/-0.7%

40

Single Phase Auto Transformer

1

20 A rated current,30A max current; 240VAC single phase input; 0270 V AC output voltage.

41

Decade Resistance Box

1

Range 0.01 ohms to 111.11111 K ohms; Total 8 decades; accuracy of +/-2% for 0.01 decade, +/-0.3% for 0.1 decade, +/0.05% for 1,10, 100, 1K, 10K decades and +/-0.5% for 100K decade, manganin resistance coils; non - inductivity wound and aged resistors; low temp coefficient; low contact resistance steps.

42

Portable Wheat stone Bridge

1

Range 0.001 ohms to 11.11 M ohms; 4 decades in steps of 1000, 100,10 and 1 ohms; ratio arms of bridge select multiplying arms of 0.001, 0.01, 0.1, 10, 100, 1000 for conductive resistance measurement for VARLEY loop test and 10,100, 1000 for Murray test; accuracy of adjustment of coils +/- 0.05% or 1 M ohms ISSUE


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 6 OF 8 SYSTEM – TABLE 6 TABLE-6: LABORATORY AND TEST INSTRUMENTS whichever is greater.

43

Portable RCL Bridge

1

Range: 2000 µH-100 H Inductance, Capacitance 2000.0 pF – 2000.0 µF, Resistance 20.0 ohm to 20.0 M Ohm; DF(with C): 0-9.9999; Q: 09999; Test frequency 120 kHz & 1 Khz. Features required: Simultaneous display of primary parameter 9L, C,R) with secondary parameters Q, D,R. Max./Min./Av. Recording, auto power off, auto blown fuse indication, hi/low limit setting, Series or parallel equivalent circuit.

44

Rheostat

1

Wire wound continuously variable rheostat/potentiometer type. Sliding part & brush rated to with stand flowing current. Insulation resistance > 5 M ohms at 500 V DC between terminal and case. Qty. one 91) no for each of the following range: 12A/3W, 5A/18A, 2A/47W, 2A/100A, 1A/470W

45

Insulation (Meggar)

3

Measurement upto 100 Meg. ohm at 1000 V.

46

Soldering & Desoldering Station

1

Multi digital controlled soldering/ de-soldering station with built in pump for vacuum suction. Accessories includes soldering / desoldering pencil / iron, support rack, cleaning sponge, spare nozzles, de-soldering pump, 15/25/40 watt soldering irons.

47

Soldering iron with bits

3

Standard item.

48

Solder Sucker

3

Standard item.

Digital Vibration Meter (Portable)

1

Acceleration range of 0.1 to 199.9 m/s sq peak, velocity range of 0.01 19.99 cm/s RMS, displacement range of 0.001 to 1.999 mm P-P; frequency range 10 to 1000 Hz and 1000-15000 Hz; AC signal O/P, digital display; accuracy of +/- 5% of reading value.

49

Vibration /Shock Pulse Analyser

1

Frequency range: DC & 21 CPM (0.36 Hz) to 1,500,000 CPM (25K Hz); Acceleration Input: 21 to 1,500,000 CPM & 120-1,500,000 CPM; Velocity Input: 21 to 1,500,000 CPM & 120-1,500,000 CPM; Displacement Input: 21 to 1,500,000 CPM, 1,500-1500,000 & 1201,500,000 CPM; Voltage Input 30V DC /5V DC; Power supply Battery operated power pack with charger; Output RS 232C port with HART protocol for communication; Splash resistant, sealed case.

50

Digital Tachometer

1

Combined contact and photo type, range: 10-99999 rpm for optical, 10-25000 rpm for contact and 6-1000 metres per minute for linear of reading, integral non contact photo electric pickup with adapter for contact pickup. Non-contact pick up range 1-25 inches from target, 5 digit LCD/LED display and battery operated.

Tester

Accessories: contact adapter, surface speed wheel, interchangeable tips-concave, convex, linear, reflective tape (100 strips), Batteries, carrying case. 51

Digital Stop Watch

2

Accuracy: of +/- 0.5 sec per day in time display mode; 2/100th of a sec per timing of one hour in stop 500-002 clock mode; 1/100th of a ISSUE


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 7 OF 8 SYSTEM – TABLE 6 TABLE-6: LABORATORY AND TEST INSTRUMENTS sec for timing of 30 mts in stop clock mode; 0.00035 sec. for timing up to one inute in stop clock mode; Quartz controlled with LCD display; operating voltage from 1. 35V to 1.85V by commonly available G-13 type 1.5V silver oxide battery.

52

Barometers

1

Sea level to 10,000 feet; double scale 20 to 3.1" and 508 to 794 o o mm, double scale thermometer in C and F.

53

Aneroid Barometer

1

Range: 660-800 mmHg; Dial diameter: 4/6 inch.

54

Wet & Dry Bulb Hygrometer

2

Range: Humidity 0-95%, Temperature (-) 20 to 60 degree C; Accuracy:+/- 3%, +/- 0.8 degree C; Resolution: 0.1%, 0.1 degree C; Display Counts- 2000 count LCD, Wet and Dry calibration adjustments

55

Ph Meter (Portable)

1

0-14, Battery pack with charger & 230 V AC operated with digital display.

56

Conductivity (Portable)

Meter

1

20-200 Simens, Battery pack with charger & 230 V AC operated digital display.

57

Flue Gas Analyser (Portable)

1

Manually operated portable flue gas analyser for field determination of content of following gases in flue gas. Accuracy: +/- 2%; CO: 01000 ppm, O2: 0-25% by Vol., NO: 0-2000 ppm: NO2: 0-100 ppm; SO2: 0-1000ppm; HC: 0-100%LEL; Power supply: 230 V AC and battery pack with charger. Interface: RS 232C, galvanically isolated.

58

Sound level Monitor

2

Range: 50-100 dB, 80-130 dB. Frequency range 20-8 KHz

59

Ultrasonic Flow meter (Portable)

1

Dual transmitting / receiving clamp-on for pipe sizes 50 mm to 1000 mm. Display: Backlit LCD / LED for flow in m3/literhr. Velocity in m/sec. Totaliser: 8 digits; Power supply: Both 230 V AC external supply and battery pack with charger. Output: 4-20 mA DC. Internal data logger for data storage. Operating temperature (-) 20 degree C to 125 degree C.

60

Grinding Wheel

1

Standard item.

61

Torsimitor

2

Standard item.

62

AC Power meter

1

Standard item.

63

Logic Analyser

1

Standard item.

64

Logic Probe

1

Standard item.

65

Electronic Bench

Test

1

Standard test bench for calibration of electronic equipments complete with all facilities.

66

Pneumatic Bench

Test

1

Standard test bench for calibration of pneumatic equipment complete with all facilities.

ISSUE


TCE FORM NO. 120R2

Spec No. TCE.5657A-C-500-001




NOTE: 1. The necessary furniture required to set up the I&C maintenance laboratory which to be located in the station building shall be supplied along with the laboratory instruments are to be provided. 2. Steel almirah and lockable racks to be provided. 3. Additional spare charger / battery / leads for the instruments if any as applicable shall be provided.

ISSUE


TCE FORM NO. 120R2

Volume – V


Spec No.

SECTION: D5

TCE.5657A-C-500-001


SHEET 1 OF 6

TABLE-7: SIZE, MATERIAL & RATING FOR IMPULSE PIPES / T UBES & FITTINGS N S E E L M V A I U L R R A E T V T S S A N I T M

S G N I T T I F D N A E B U T / E P I P E S L U P M I R O F G N I T A R & L A I R E T A M , E Z I S A

L A E S G I R L N E U E I T P N T T A I I M I L F M L E A S I L R U E E T P P A I M I P M

G I N I S T N A A R

2 2 - F A - r G M T 2 S 8 A 1

S S A L C . 0 L 0 P 5 2 S

2 2 - F A - r G M T 2 S 8 A 1

G N I I S T N A A R

2 2 - F A - r G M T 2 S 8 A 1

. S B L 0 0 0 9

2 2 - F A - r G M T 2 S 8 A 1

. O N . L S . F E ) R ( 2

. I ) L O N N E A . 1 I . S R L L E . O U E F N . P B T A E ) H U R M I T M ( 1 S

5 3 2 ) Y L 3 - 2 O E A L E - P T M r L T G A ( S S A

S B L 0 0 5 1

5 0 1 A M I T I r S G A -

S B L 0 0 4

- B A - r G M T 5 S 0 A 1

S B L 0 0 0 3

A M - I T 5 I r S 0 A 1 G

S B L 0 0 0 3

S A B L M I 0 I T 5 - 0 S 0 r 0 A 1 G 9

5 3 2 ) Y L 3 - 2 O E A L E - P T M r L T G A ( S S A

S B L 0 0 5 2

2 6 - E S A - Z B N Y M L T O D 0 S R O 5 A B B 1 5 0 1 M I T I r S A G

6 0 N ) 1 - B O L E A - r B E R G A T M T C S S ( A

6 0 N ) 1 - B O L E A - r B E R M G A T T C S S ( A

6 0 N ) 1 - B O L E A - r B E R M G A T T C S S ( A

6 1 3 S S

6 1 3 S S

6 1 3 S S

6 1 3 S S

6 1 3 S S

E B U T

5 6 . 1 X K 0 H 0 T m M m M 7 . 2 1

5 6 . 1 X K 0 H 0 T m M m M 7 . 2 1

5 6 . 1 X K 0 H 0 T m M m M 7 . 2 1

5 6 . 1 X K 0 H 0 T m M m M 7 . 2 1

5 6 . 1 X K 0 H 0 T m M m M 7 . 2 1

E P I P

S m X m X . 4 D H 3 . O C 1 S 2

0 m 8 . m H 4 D C 3 . O S 1 2

0 m 8 . m H 4 D C 3 . O S 1 2

0 6 4 D 1 . 3 . O H 1 m C 2 m S

0 m 8 . m H 4 D C 3 . O S 1 2

/ M D A E E T T A . S R M A N I U T A A E T M S S

/ T N A O E I H T E C R A T R T H O X O P H E T H

N T N D E O O E I A E G E / T H C F R T C / / S R A M A A M P H E I E D E R A N T L H T E A L I M C S S O E X T R R O U I Y C R E S E D B P D S

R M E E T T A S Y W S

. 1

. 2

. 3

. 5

E Z I S

E C I V R E S . L S . N O

S B L 0 0 0 3

. 4

ISSUE


TCE FORM NO. 120R2

Volume – V


Spec No.

SECTION: D5

TCE.5657A-C-500-001


SHEET 2 OF 6

B. SIZE, MATERIAL & RATING FOR IMPULSE PIPES / TUBES & FITTINGS N S E E L A M I U V L R R A E T V T S S A N I T M


E S G L N U E I P N T I I T M I L F

G N I I S T N A A R

- I I A - r M G T 5 S 0 A 1

S B L 0 5 1

G I N I S T N A A R

I - I A - r M G T 5 S 0 A 1

. S B L 0 0 0 3

L A E I S R L U E E T P P A I M I P M

. O 6 N 0 . L 1 - B S A r M G . F T E S R ( 2 A

L A E I S R . L E U B E T F P A E U M I T M R

6 1 3 S S

_

E P I P

0 D 8 . 3 . O H 1 m C 2 S m

E Z I S

. L S . N O

- I I A - r G M T 5 S 0 A 1

S B L 0 5 1

S B L 0 0 0 3

9 Y S 3 V S 2 A A 1 E L S I H C

D E S I N ) A V L A G (

6 1 3 S S

E B U T

E C I V R E S

2 6 B M I T I r S A G

m m 5 6 . 1 x K D H O T M M 7 . 2 1 - ) 0 m G E 4 . m P U T I O U H 3 O . C 1 P S 2 ( H T H

- I I A - r M G T 5 S 0 A 1

- I I A - r M G T 5 S 0 A 1

S B L 0 5 1

- I I A - r G M T 5 S 0 A 1

S B L 0 5 1

S B L 0 0 0 3

5 0 1 A M I T I r S A G

S B L 0 0 0 3

9 Y S 3 V S 2 A A 1 E L S I H C

6 1 3 S S

) K C A L B (

6 0 1 - B A - r M G T S A

N ) O L B E R E A T S C (

6 1 3 S S

m m 5 6 . 1 x K D H O T M M 7 . 2 1 0 m 4 . m D H 3 . C 1 O S 2

2 E G ) 0 m P I U T 8 . m P O U ( O H 3 . D R C 1 S O H T H

E ; L I M O M M M E E U E R T E T T T O S B S S R S D Y U Y N T I Y L S L S I N A S

E M C I E V T R R S E I Y S A S

I M R R E E E A / T L I U S S O L A Y B F G S

. 6

. 8

. 9

. 7

ISSUE


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001


SHEET 3 OF 6

C. SIZE, MATERIAL & RATING FOR IMPULSE PIPES / TUBES & FITTINGS

G I N I S T N A A R

5 0 1 A M I T I r S A G

L A E S G I G R L N N I E I U E T T S I P N T A N T A I I M I L F M A R

I - I A - r G M T 5 S 0 A 1

N S E E L A M I U V L R R A E T V T S S A N I T M


E P I P E S L U P M I

L A I R E T A M

E S L U E P B U M I T

2 . O N . L S . F E R (

) 1 . O N . H S N I

1 . O N . L S . F E R (

L A I R E T A M

E B U T E Z I S E P I P C I V R E S . S L N O .

) 1 . O N . H S N I

S B L 0 5 1

2 8 1 A - a 6 M T F r S A G

S B L 0 5 1

. S B L 0 0 0 3

a 6 - F I A - r G M T 2 S 8 A 1

. S B L 0 0 0 3

6 0 N ) 1 - B O L E A r B - R E G A T M T C S S ( A

2 S 1 S ) 3 L - 6 1 E L E A 3 - - N E P I T M A T T T S S S A (

O . T R 2 E E 1 L D B N O A U T C I E 1 . L C O P I N P V . A R E L S S S A

2 S 1 S ) 3 L - 6 1 E L E A 3 - - N E P I T M A T T T S S S A (

6 1 3 S S

6 1 3 S S

m m m 5 K m 6 . H 7 . 1 2 X T 1 D 0

m m m 5 K m 6 . H 7 . 1 2 X T 1 D 0

0 m 4 . m D H 3 . 0 C 1 S 2

0 m 4 . m D H 3 . 0 C 1 S 2

K E G ) M 7 7 P . I U T M 2 H T P O U 3 . x M ( R O 1 D H 2 0 M H T

U U C M A V

E E R T K P E T M A U A S Y M W S

I L E P G T M N S M A Y S S

. 1 1

. 1 2

. 1 0

6 1 3 S S

*

NOTES: 1.0 IMPULSE PIPE THICKNESS SHALL BE SELECTED AS PER ANSI B 36.10 BASED ON THE SCHEDULE INDICATED AGAINST EACH SERVICE. * - There are 4 samples; minimum 150mts tube(½”) to be considered for each sample

ISSUE


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001


SHEET 4 OF 6

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 ½ 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 ½ INCH.

1.0

BULK HEAD FITTING SOCKET WELDED TYPE TO BE PROVIDED AT INSTRUMENT RACK/ ENCLOSURE. ALL INSTRUMENT IMPULSE TUBE SIZE SHOULD BE ½” 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

3.2

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.

4.0

DRAIN

4.1

DRAIN SHALL BE PROVIDED FOR ALL WATER/STEAM AND NONINFLAMMABLE / NON-CORROSIVE FLUIDS ONLY.

5.0

DRAIN VALVE

5.1 5.2

5.3

6.0

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

ISSUE


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001

6.1


SHEET 5 OF 6

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

THE SIZE OF THE DRAIN HEADER SHALL BE 1”.

6.3

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.

7.0

INSTRUMENT

7.1

TYPE OF THE VALVE SHALL BE NEEDLE VALVE WITH BUILT IN DRAIN VALVE.

7.2

SIZING OF THE VALVE SHALL BE ½”.

8.0

RIGHT/LEFT THREADED FITTINGS :

8.1

THIS SHALL BE PROVIDED FOR INSTALLATION/REMOVAL OF INSTRUMENTS WITHOUT DISTURBING THE TUBING/PIPING.

9.0

A SUITABLE ADAPTER SHALL BE PROVIDED TO INSTALL THE INSTRUMENTS ON ½” RIGHT-LEFT THREADED FITTING

10.0

A ½” VENT LINE WITH A ½” 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.

11.0

FOR AIR/FLUE GAS MEASUREMENT A DRAIN POT WITH PLUG SHALL BE PROVIDED IN PLACE OF DRAIN VALVES

12.0

PURGING SYSTEM

12.1

THIS SHALL BE PROVIDED FOR FLUE GAS MEASUREMENTS

12.2

INSTRUMENT AIR CONNECTION SHALL BE PROVIDED AT EACH INSTRUMENT FOR AIR & FLUE SERVICE FOR CONTINUOUS PURGING.

ISSUE


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001


SHEET 6 OF 6

12.3

ONE AIR FILTER REGULATOR, PURGE ROTAMETER AND A BLOW DOWN DEVICE PER INSTRUMENT SHALL BE PROVIDED IN THE TRANSMITTER RACK.

12.4

THE PURGE LINE SHALL BE CONNECTED TO EACH INSTRUMENT THROUGH A ½” ISOLATING VALVE.

ISSUE


TCE FORM NO. 120R2

TCE Consulting Engineers Limited Spec No.


TCE.5657A-C-500-001


SHEET 1 OF 23

TABLE 8: 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

1.2

Pressure indicators shall be provided for (a)

Suction and discharge lines of pumps, including on header section, if two or more pumps are employed for the same service.

(b)

Suction and discharge lines of fans, including on header section if 2 or more fans are employed for the same service.

(c)

All input and output lines of process equipment.

(d)

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.

(b)

For all permissive conditions governed by safety operation of the equipment. e.g. pr. adequate, conditions.

(c)

For all interlock conditions which governs starting of standby equipment or subsequent equipment for safety operation of the system.

. (d) 1.3

1.4

Inlet and outlet of filters/strainers.

Differential Pressure Switches (Indicating type) shall be provided (a)

Across filters/strainers for remote monitoring

(b)

Across condenser for remote monitoring and interlocks

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.

ISSUE

R0


TCE FORM 329 R3



TCE.5657A-C-500-001

1.5


SHEET 2 OF 23

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)

On all process lines where local indication is warranted by the system either for monitoring or testing.

(b)

On the inlet/outlet equipment such as desuper-heaters, Heat Exchangers & Coolers for both the fluid media.

(c)

Differential temperature indicator shall be provided across BFP suction and discharge service

(d )

Capillary type temperature indicators shall be used in vibration prone areas. Thermowell shall be provided for all temperature indicators.

(e ) 1.7

Temperature Elements :. Thermowells shall be provided for mounting of all temperature elements. (a)

All thermocouples and RTDs as required for implementation of control & monitoring shall be supplied

(b)

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.

(c)

All temperature elements shall be supplied with associated junction box

(d)

Compensating cable shall be provided with all thermocouples (i) From T/C to field junction box and to system cabinets.

(e)

Six nos. ( 2 nos. per phase) Resistance temperature detectors (RTD’s) 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.

(f)

1 no. duplex k-type thermocouple shall be provided for each bearing of HT equipment.

(g)

For all alarm and Trip application, a LVM of temperature element shall be used. Temperature switches are not acceptable. ISSUE

R0


TCE FORM 329 R3



TCE.5657A-C-500-001

(h)


SHEET 3 OF 23

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.

1.9

Level switches : The instrument shall be provided : (a)

On all equipments (storage vessel) where parameter status has to be communicated to the operator in the control room.

(b)

All permissive, and interlock conditions governed by the safety operation of the equipment. .

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).

ISSUE

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TCE.5657A-C-500-001


SHEET 4 OF 23

(b)

The instrument shall be rotary type with glass mounted for indication.

(c)

Upto 6 inch on-line flow glasses shall be supplied and above 6 inch bypass type flow glasses shall be provided.

1.12

Speed Measurement shall be provided, where variable speed drives are to be controlled from remote (e.g. BFPs, feeders, Conveyors, ID fans etc).

1.13

Flow elements shall be provided as detailed in Table-9.

1.14

Digital Display Unit(DDU) shall be provided for main steam pressure, temperature, fuel flow, MW Export, MW Target, MVAR and frequency, vacuum, and instrument air pressure.

1.15

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 .

1.16

1.17

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.

(b)

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.

(c )

Four (4) way solenoid valve shall be provided for operating double acting cylinders. If applicable. E.g.: Pneumatically operated on-off type dampers.

(d)

Dual coil Solenoid valves shall be supplied for equipment trips and single coil for balance.

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. ISSUE

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INSTRUMENTATION INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 8

SHEET 5 OF 23

1.18

Electro-Pneumatic Converters shall be provided for all pneumatically operated control valves, valves, power cylinders etc., for converting converting controller output output of 4-20 mA to 3-15 PSI for interfacing with pneumatic actuators.

1.19

Air Filter Regulators along with gauges shall be provided in each of the

1.20

(a)

Air supply line to valve positioners /power cylinders

(b)

Air supply line to electric to pneumatic converters

(c )

Air supply line to pneumatic interlocked interlocked block valves

Interposing relay (To be mounted in IPR panel panel located at Control Control room) room) for interface to the following: LTMCC including including Soot blower – Relays with contact rating of 0.2Amps (two (t wo 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 valve (two relays per valve) - Relays with contact rating of 2Amps. DC Starter(two relays per drive) - Relays with contact rating of 0.2Amps. 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 shall be provided. provided.

1.22

Vibration Measurements: Measurements: Complete vibration measurement system (microprocessor based) for TG shaft vibration and all bearings on both X-Y directions, shall be provided. provided. The vibration sensors sensors in horizontal and vertical 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 Unit DCS for monitoring and protection purpose. Vibration pads shall be provided on all HT equipment for mounting the vibration sensors.

1.23

Junction Box (JB) /Field Termination cabinets (FTC)

1.23.1 Junction Boxes Boxes shall be provided provided for ISSUE

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a) b) c) d) e) f) g)


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Shall be Double door type and not of double leaf type with cable entry from bottom. Termination of all sensors located equipment equipment wise. Termination of Duplex thermocouples/RTDS. Termination of limit switch, torque switch, position transmitter and control demand, independently 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 cables and Prefabricated Cables termination guidelines (i)

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.

(ii)

To connect limit switches, torque switches and position transmitters to their respective field junction boxes.

(iii)

Compensating cable shall be supplied for connection between the element and the respective junction boxes / system cabinets as per per guidelines.

(iv)

Prefabricated cable cable for connecting between system cabinets, marshalling cabinet to system cabinet, system cabinet to Relay Rack, etc.

(v)

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.

(vi)

1.25

Auxiliary Power Supply System (APSS) The power supply system shall confirm to the requirements indicated in Electrical portion of this specification. The power requirements of the systems shall be estimated and the power power supply requirement requirement shall worked out. Based on ISSUE

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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 f acility or diode auctioning. 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 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

1.28

Impulse pipes/tubes & fittings (a)

Impulse pipes, pipes, fittings and and air supply and signal piping/tubing shall be supplied for all the instruments under the scope of this specification. The general specification specification is given given in Table-7. Table-7.

(b)

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.

(c )

Gunmetal valves are not allowed for any instrumentation applications. applications.

(d)

All instrumentation Isolation valve should have drain facility.

Selection of Ranges for Instruments The ranges of the instruments shall be selected based on the following philosophy philosophy indicated below: (a)

For pressure and vacuum measurements, the maximum maximum operating pressure will will be within within 70 to 80% of the maximum scale range. All pump pump suction measurement will will cover cover the negative pressure range also and all vacuum measurements measurements will cover cover the negative pressure as well as the positive pressure as the case may be.

(b) (c)

For temperature measurement, the maximum operating temperature will be within 80 80 to 90% of the maximum scale scale range. For pressure switches and temperature switches, the set points shall fall within 40% to 70% of the scale range selected.

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1.29


SHEET 8 OF 23

(d)

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.

(e)

For flow measurement, the maximum range shall be fixed at about 10 to 15% above the maximum operating flow.

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)

1.30

Volume – V

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

(b)

Pressure test points shall be complete with root valves and shall terminate with a nipple.

(c)

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 Contractor’s 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.

ISSUE

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SHEET 9 OF 23

All the control room cabinets , field JB’s etc. shall have bottom cable entry. 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

SPECIFICATIONS FOR INSTRUMENTS TO BE SUPPLIED ARE AS FOLLOWS.

2.1

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 PC based calibration system .

2.4

Differential Pressure Indicators ISSUE

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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 PC based calibration system.

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 ISSUE

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(name plates, mounting brackets, etc.) will be SS. IP 65 or equivalent degree of 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%.

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RTDs shall be ungrounded. RTD shall be supplied as an assembly complete with thermowell meeting ANSI 19.3-1994 (latest) requirements. 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. Electronic Water Level Indicator (EWLI) Two (2) systems per boiler drum operating on the principle of resistivity; single pressure vessel at each end; 4-nos. isolating valves with limit switches per vessel & 2 nos. blow down valves with limit switches per vessel shall be provided. Thermal equilibrium shall be established with boiler drum. Vessel material shall be forged carbon steel of ANSI rating 2500. The size of the tapings at the drum & the isolating valves shall be the same. These tapings shall not be shared for any other instruments. No. of electrodes per vessel shall be such as probe to probe distance not to exceed 50 mm. Material of electrode-tip shall be titanium; body SS 316, insulation high purity ceramic, gasket monel-silver. Electrodes shall be arranged in 2 different rows staggered to provide maximum resolution. Solid state/micro processor based detector system and control unit with independent power supply for each unit; bicolour type display unit of 4 nos., two (2) nos. display shall provided at the control room and two (2) nos. display units at detector unit. Range of display to cover HH & LL trip levels. One set of alarm for high and low conditions and trip contacts for high high and low low conditions with adjustable settings. Self diagnostic features included. All the cables 10% of electrodes as spare and torque wrench shall be provided by the Bidder. Alarm and trip contacts shall be fail-safe type.

2.12

The detector unit shall house redundant power supply units and electronic cards connected to electrodes for measurement of boiler drum level. Alarm contacts (SPDT) rated for 0.2A, 220 V DC shall be provided low and high water level. For each pressure vessel, alarm settings shall be adjustable. The power supply shall be independent for each unit. A green lamp is illuminated for water and a red lamp for steam. The lamp rating is of 0.5 W. Each window shall have two lamps connected in parallel. Two (2) numbers display units shall be provided at the control room. Each drum shall have both fault lamp with reset push button and lamp test switch. The other two (2) number display units provided at the detector unit. Each shall have only lamp test switch. Bidder to supply EWLI of Owner / Project Manager approved make. Level Switches

ISSUE

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SHEET 13 OF 23

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 Purchaser’s 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.

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 ISSUE

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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 VDUs, 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

Digital Display Unit To display the digital value of any analog process parameter with sign and decimal point of any analog input assigned though operator. Accuracy shall be ï0.25% of reading; shall be of size 2”. type of display – LED; Seven segment or dot matrix type; five digits, sign and decimal point; digit size shall be minimum of 50mm; colour of display shall be Red ; enclosure shall be IP32 or equal; all DDUs shall be mounted on the Unit Control Panel. For outdoor applications, the size shall be 6”. DDU used outside control room shall be of Dot matrix type.

ISSUE

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2.20


SHEET 15 OF 23

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 Purchaser’s 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) 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 ISSUE

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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; 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 ISSUE

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SHEET 17 OF 23

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 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.

ISSUE

R0


TCE FORM 329 R3


SECTION: D5

TCE.5657A-C-500-001

2.27

Volume – V


SHEET 18 OF 23

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 OW NER/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 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. ISSUE

R0


TCE FORM 329 R3



TCE.5657A-C-500-001


SHEET 19 OF 23

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 OW NER/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, 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

ISSUE

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TCE FORM 329 R3



TCE.5657A-C-500-001


SHEET 20 OF 23

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 : 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.

ISSUE

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TCE FORM 329 R3



TCE.5657A-C-500-001


SHEET 21 OF 23

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 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

ISSUE

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TCE FORM 329 R3



TCE.5657A-C-500-001


SHEET 22 OF 23

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 OW NER / 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. 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 f low.

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 ISSUE

R0


TCE FORM 329 R3



TCE.5657A-C-500-001


SHEET 23 OF 23

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 ( ½” 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 Purchaser’s 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.

ISSUE

R0


TCE FORM 329 R3

Spec No. TCE.5657A-C-500-001

SL. NO

TYPE OF FLOW ELEMENT

1

ORIFICE PLATE

Volume – V


SECTION: D5

INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 1 OF 1 SYSTEM – TABLE 9 TABLE-9: GUIDE LINES FOR SELECTION OF FLOW ELEMENTS

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

2

ORIFICE PLATE

WATER

PR.>+30 Kg/Cm2 TEMP .>100°C

ALL PIPE SIZES

i)SH/ RH SPRAY WATER FLOW ii) HP/LP BYPASS SPRAY

BW

3

ORIFICE PLATE

STEAM

FOR ANY CONDITION

< 3 INCH

SOOT BLOWING STEAM FLOW

BW

4

FLOW NOZZLE

WATER

PR. >=30 Kg/cm2 OR TEMP >100°C

FOR ALL PIPE SIZES EXCEPT VERY LARGE DIA PIPE

i)

BW

5

FLOW NOZZLE

STEAM

PR..>30Kg/cm 2 OR TEMP >100°C

BFP SUCTION FLOW (FOR ONE EACH BFP) ii) FW FLOW

BW i)

6

ORIFICE

WATER (CW)

PR. <=30 Kg/cm2 & TEMP <=100°C



FOR ALL PIPES

7

AIR FOIL/ VENTURY

AIR

PR.<=30 Kg/cm2 AND TEMP.<=100°C

ALL DUCT SIZES

HP BYPASS STEAM FLOW ii) AUX. STEAM FLOW

BW

CONDENSER COOLING WATER TO ASH COOLERS

FLANGE

i) PRIMARY AIR ii) SECONDARY AIR FLOW

BW BW

BW

ISSUE


TCE FORM NO. 120R2

Volume – V


Spec No.

SECTION: D5

TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 1 OF 1 SYSTEM – TABLE 10 TABLE 10: 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.

MAIN STEAM SERVICES

CS

P

2.

FEED WATER SERVICES

WC6

P

3.

HEATER DRAIN SERVICE

WC5

P

4.

LP BYPASS SERVICES

WCB

H

5.

CONDESATE WATER SERVICES

WCB

P

6.

DM WATER SERVICES

SS316

P

7.

AUX. PRDS PR. CONTROL

CS

P

8.

AUX. PRDS TEMP. CONT VLV

WCB

P

9.

AUX. STEAM SERVICES

WCB

P

10.

GLAND STEAM SERVICES

WCB

P

11.

AIR SERVICES

WCB

P

12.

FLUE GAS SERVICES

WCB

P

13.

LUBE/CONTROL OIL/FUEL OIL SERVICES

WCB

P

14.

HP BYPASS SERVICES P – PNEUMATIC H - HYDRAULIC

F22

H

15.

ANY OTHER SERVICES AS REQUIRED

*

P

16.

CONTROL DAMPERS/VALVES FOR AIR AND FLUE GAS SERVICES

WCB

P

* MATERIAL IS SUBJECT TO PURCHASER’S APPROVAL DURING DETAIL ENGINEERING.

ISSUE

R0


TCE FORM NO. 120R2




Spec No.

SHEET 1 OF 1

TCE.5657A-C-500-001

TABLE 11: GUIDELINE FOR PROVISION OF ANALYTICAL MEASUREMENTS SL NO 1

STREAM Make Up Water

ANALYSER Specific Conductivity Cation Conductivity

2

Hotwell

Specific Conductivity (Both sides) Cation Conductivity (Both sides)

3

CEP Discharge

pH Specific Conductivity Cation Conductivity Sodium Dissolved Oxygen

4

Condensate Polisher Outlet

pH Specific Conductivity Cation Conductivity Sodium Dissolved Oxygen Silica

5

Deaerator Outlet

Dissolved Oxygen

6

Feed Water At Economiser Inlet

pH Specific Conductivity Cation Conductivity Hydrazine Silica Turbidity

7

Separator Outlet Steam At LTSH Inlet

Specific Conductivity Cation Conductivity Hydrazine Silica

8

Main Steam Outlet

pH Specific Conductivity Cation Conductivity Sodium Silica

9

Reheated Steam

Cation Conductivity

10

Condenser Cooling Water

pH Specific Conductivity

ISSUE

R0


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 1 OF 4 SYSTEM – TABLE 12 TABLE-12: TESTS TO BE PERFORMED FOR DCS/PLC / PROGRAMMABLE CONTROL SYSTEM

DCS SYSTEM EQUIPMENT / PLC / PROGRAMMABLE CONTROL SYSTEM 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 ISSUE

R0


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 2 OF 4 SYSTEM – TABLE 12 TABLE-12: TESTS TO BE PERFORMED FOR DCS/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 (VDU) Functional tests Test for capabilities of VDU 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

ISSUE

R0


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 3 OF 4 SYSTEM – TABLE 12 TABLE-12: TESTS TO BE PERFORMED FOR DCS/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.

9.0

Marshalling Cabinets Verification of degree of protection / Electrical tests as detailed under “Wiring, Terminations & Accessories”/Type tests & routine tests as per relevant Indian standards.

10.0

System cabinets Verification of degree of protection / Electrical tests as detailed under “Wiring, Terminations & Accessories”/Type tests & routine tests as per relevant Indian standards.

11.0

Wiring Termination and Accessories

11.1

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.

11.2

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

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

12.0

Tests For Auxiliary Plant Monitoring Systems

12.1

Vibration Monitoring & Analysis System

(a)

Simulated Functional test (Note-1)

(b)

Tests for Server, VDU, Printer, Keyboard

ISSUE

R0


TCE FORM NO. 120R2


Spec No.

SECTION: D5

TCE.5657A-C-500-001

12.2

Volume – V

INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 4 OF 4 SYSTEM – TABLE 12 TABLE-12: TESTS TO BE PERFORMED FOR DCS/PLC / PROGRAMMABLE CONTROL SYSTEM Note-1: Test to be witnessed by Owner or Owner’s representative.

Flame Monitoring & Analysis System

(a)


(b)


Note-1: Test to be witnessed by Owner or Owner’s representative. 12.3

PADO System

(a)


(b)



CMMS System

(a)


(b)



MIS System

(a)


(b)


Note-1: Test to be witnessed by Owner or Owner’s representative.

ISSUE

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TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001


SHEET 1 OF 2

TABLE 13: FACTORY ACCEPTANCE TESTS FOR DCS/PLCs L A R E N E G

1 2 3 4 5 6

S 7 T N 8 E 9 M R I 10 U 11 Q E 12 R 13 T S 14 E T 15

FACTORY ACCEPTENCE TEST (FAT) :REF NOTE-1 FACTORY ACCEPTENCE TEST (FAT) PROCEDURE:REF.NOTE -2



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.





    

16 17 18 TOTAL SYSTEM CONFIGARATION DRAWINGS 19 FAT PROCEDURE CONSITING OF : S 20 (i) TEST EQUIPMENT T (ii) TEST ENVIRONMENT N 21 E (iii) TEST CONFIGURATION M 22 U 23 (iv) TEST PROCEDURE C 24 (v) TEST SCHEDULE O D 25 (vi) TEST VENUE T (vii) TEST REPORTS- SPECIMEN COPIES S 26 E FUNCTION DESIGN SPECIFICATION FOR EACH EQIPMENT / SYSTEM T 27 28 29 GENERAL APPEARENCE CHECK & BILL OF MATEIRALS CHECK Y 30 R 31 CONSTRUCTION CHECK AS PER OVER ALL GENERAL ARRANGEMENT DRAWINGS A N DIMENSTIONAL CHECK I 32 M LABELLING , TERMINAL ARRANGEMENT AND EQUIPMENT IDENTIFICATION CHECK I 33 L POWER SUPPLY VOLTAGE LEVEL CHECK & POWER 'LEDs -ON CHECK E 34 R 35 COOLING FAN OPERATION CHECK P P 36 GROUNDING NETWORK CHECK 1. THE INTENT OF T HE 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



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ISSUE R0


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001


SHEET 2 OF 2

TABLE 13: FACTORY ACCEPTANCE TESTS FOR DCS/PLCs 1 2 M3 E 4 T S 5 Y S 6 7 8 9 10 11 12 13 14 15 16 R 17 E 18 E N I 19 G 20 N E 21 R 22 E L 23 L O 24 R T 25 N O 26 C 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 ,

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CLOSED LOOP CONTROL SIMULATION CHECK OPEN LOOP CONTROL SIMULATION CHECK CONTROL LOOP RESPONSE CHECK BUMPLESS AUTO MANUAL TRANSFER CHECK VDU – GRAPHIC OVERVIEW CHECK VDU- TREND CHECK VDU- REAL TIME TREND CHECK VDU- MIMICS CHECK VDU- CHECK FOR OPERATING CONTROL DIRECTLY FROM MIMICS VDU- FUNCTION KEYS CHECK VDU- ANALOG CONTROL DISPLAY CHECK VDU- SEQUENCE CONTROL DISPLAY CHECK VDU- OPERATOR GUIDENCE MESSAGE CHECK VDU/ BACKPANEL ‘OPERATION PRIORITY’ CHECK VDU- ALARM MANAGEMENT FUNCTION CHECK VDU LOGGING FUNCTION CHECK VDU / RESPONSE / UPDATING CHECK KEYBOARD LOCK FUNCTION CHECK VDU INTERCHANGEBILITY & ASSIGNABILITY CHECK PRINTER ASSIGNABILITY & BACK-UP FUNCTION CHECK FLOPPY DISK/ STD / OPTICAL DISK UNIT STORAGE & RETRIEVAL CHECK VDU ASSIGNABILITY CHECK FOR HARD COPIER FUNCTION PLANT PERFORMANCE CALCULATION CHECK COMMUNICATION INTERFACE TO OTHER’S SYSTEM SIMULATION CHECK SER INTERFACE DATA DUMP FUNCTION CHECK DATA BUS DISTANCE BUILDING CHECK (REFER NOTE- 3)

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35 GRAPHIC DISPLAY BUILDING FUNCTION CHECK 36 CLOSED LOOP CONTROL SYSTEM MODIFICATION CHECK E 37 OPEN LOOP CONTROL SYSTEM MODIFICATION CHECK C N 38 ALARM DISPLAY PRIORITISATION CHECK A SYSTEM SECURITY CHECK N 39 E 40 SYSTEM ALARM CHECK T N I 41 SYSTEM DIAGNOSTIC FUNCTION CHECK A 42 POINT DETAIL CONFIGURATION CHECK M 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. S 4. DURATION OF FAT SHALL BE MINIMUM THREE(3) WEEKS. THE FAT PROCEDURE SHALL BE SUBJECT TO E T PURCHASER’S APPROVAL. O N 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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ISSUE R0


TCE FORM NO. 120R2

Spec No. TCE.5657A-C-500-001




SHEET 1 OF 3

TABLE-14 TESTS TO BE PERFORMED FOR INSTRUMENTS

1.

Pressure indicators Calibration Hydro test (1.5 times max. Pr.)

2.

Pressure switches Calibration test/Hydro test/Contact rating test/Accuracy test/Repeatability

3.

Pressure Transmitters Calibration test/Hydro test/Leak test/Over range test/Accuracy test/Repeatability test.

4.

Differential Pressure Indicators Calibration test/Hydro test/Leak test/Over range test/Accuracy test/Repeatability test.

5.

Differential Pressure Switches Calibration test/Hydro test/Leak test/Over range test/Accuracy test/Repeatability test.

6.

Differential Pressure Transmitters Calibration test/Hydro test/Leak test/Over range test/Accuracy test/Repeatability test.

7.

Thermometers Calibration test/Material test//Accuracy test/Bore concentricity : ±5% of wall thick/Hydrostatic test for TW (1.5 times max. pr.).

8.

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.

9.

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.

10.

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

11.

Temperature transmitters Calibration test/Accuracy test/Ambient temperature error test

12.

Thermowells Material test/Bore concentricity : ±5% of wall thick/Hydrostatic test for TW (1.5 times max.pr)

13.

Interposing relay Functional test/temperature rise test/high voltage test/limits of operation ISSUE R0


TCE FORM NO. 120R2

Spec No. TCE.5657A-C-500-001




SHEET 2 OF 3


test/insulation test. 14.

Level gauges Hydrostatic test/Material test/Seat leakage test/Ball check test

15.

Level switches (magnetic) Material test/Contact rating test/Hydro test/Calibration test

16.

Level gauges (Probe) Material test/Contact rating test/ Hydro test/Calibration test

17.

Flow switch Material test/Hydro test/ (1.5 time max. pr)/function test

18.

Flow glasses Material test/Hydro test/ (1.5 time max. pr)/function test

19.

Variable are flow metes Calibration test/Material test/Hydrostatic test (1.5 time max. pr)

20.

Flow element 100% Radiography test/Hydro test/Calibration test/IBR certificate

21.

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 < 400 0C Calibration and Hysteresis test (Refer note-1) Note-1: These tests shall be witnessed by PURCHASER / CONSULTANT

22.

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

23.

Pressure Regulating Valves: a) IBR certificate : Form IIIC as applicable b) Hydrostatic test : ANSI B 16.34 ISSUE R0


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SHEET 3 OF 3


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.

Position transmitters Calibration/hysteresis and Accuracy test

25.

Electro Pneumatic converters Calibration test/Accuracy

26.

Solenoid valves Hydro test/Seat leakage test/CV test/coil insulation test

27.

Air filter regulators Calibration test/Accuracy test

28.

Junction boxes Test for degree of protection/Material test

29.

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

30.

Transmitter racks Verification of degree or protection. Test for enclosure type, Type tests & routine tests as per relevant Indian standards.

31.

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.

ISSUE R0


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 1 OF 5 SYSTEM – TABLE 15 TABLE 15: 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 CD’s in addition to hard printout for each revision. Finally CONTRACTOR shall submit as installed and commissioned drawings / documents. SL. NO

TYPE OF DOCUMENTS

DETAILS OF FIELDS

1.

Drive List

1,

Sl. no. (*), TCE tag number.

2.

General Data

3.

4.

(a)

Bidder : Motor (Bidder’s name) (*), drive equipment (*).

(b)

Type / Form : Type (Refer electrical data sheet M4-203-01) (*), reference standard (*), manufacturer’s dwg. No.

(c)

Mounting, coupling method (*).

(d)

Motor Equipment Location : Layout dwg. No. co-ordinates, elevation.

Data required for electrical engineering : (a)

Rating : Output (kW) (*), full load speed (RPM) (*), voltage.

(b)

Enclosure, Indoor / Outdoor, starting method, direction of rotation, winding insulation class, Integral starter, Integral starter wiring diagram no.

(c)

Space Heater : Number provided, Rating (kW)

(d)

Performance at rated volts & Hz : Rated current (IFL) Amps (*) starting % IFL (*), starting current %IFL (*), power factor (*), starting torque %IFL, pull out torque..

(e)

Terminal box : Cable size (mm2), cable OD(mm), location.

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. ISSUE R0


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 2 OF 5 SYSTEM – TABLE 15 TABLE 15: FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES) 5.

Solenoid Valve Data (*) (a)

Sl. no. Service, fluid (*), quantity (*)

(b)

Type : 2 way, 3 way, 4 way.

(c)

Size : Pipe, Body, Orifice

(d)

Operating conditions : Pressure – (kg/cm2)

(e)

CV : Selected, Rated/

(f)

Action : Coil # 1, (E/DE), Coil # 2 (E/DE)

(g)

Coil : Single coil

(h)

Voltage “ 110V AC, 220V DC.

(i)

VA : Normal, Inrush.

2.

Inputs to Bidder from Purchaser’s System

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 BIDDER’s system, purpose, reference dwg. No. Remarks.

3.

Outputs from BIDDER’s System to PURCHASER’s System

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 BIDDER’s system, purpose, Reference dwg. No., contact rating, Remarks.

4.

Junction Box Schedule

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,

5.

Terminal Details – Analog

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.

6.

Terminal details – Digital

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

7.

Schedule of Instruments with Settings

(a)

Sl. no., (Service Status condition to be indicated for contact signals), Scope, Instrument type, (Indicator / Switch / Transmitter, etc.)

(b)

General Data ISSUE R0


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 3 OF 5 SYSTEM – TABLE 15 TABLE 15: 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.

(ii)

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.

(iii)

Flow : Fluid, pipe size, velocity (mts/sec), viscosity, maximum pressure loss, normal flow (m 3 /hr), maximum flow (m3 /hr), design flow (m3 /hr), DP at maximum flow (mmwcl).

(iv)

Level : Normal level, maximum level, instrument range, engineering units.

(v)

Accessories, body rating (ANSI), remarks (redundancy of instruments to be indicated here).

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.

9.

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.

10.

List of bearing vibration measurement (to be furnished for all HT drives in BIDDER’s scope).

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.).

ISSUE R0


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 4 OF 5 SYSTEM – TABLE 15 TABLE 15: FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES)

11.

Equipment List

Equipment, equipment code, equipment location, remarks.

12.

Cable List (For all cables in BIDDER’s scope)

Cable scope, cable no., cable type, source, source location, destination, destination location, signal tag no., service description, remarks, cable length in metres.

13.

Loop Drawings

Loop Drawings shall be submitted for all signals between the field instruments & system cabinet / local panels in BIDDER’s 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., VDU / CPU indicator / to PURCHASER’s 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 BIDDER’s system.

A.

NOTES : APPLICABLE TO ALL THE DOCUMENTS LISTED ABOVE :

1.0

Wherever ‘*’ is indicated, information shall be furnished along with the bid, Balance information shall be furnished during detailed engineering.

2.0

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.

3.0

The field width for all the field of dbases, will be given by PURCHASER during detailed engineering.

4.0

There shall be no duplication of VENDOR tag nos. The VENDOR tag number shall match exactly with VENDOR flow diagrams.

5.0

TCE tag no., will be furnished at the detailed engineering stage.

6.0

Data called for in each field of the engineering documents shall be explicitly filled & not referring to some other drawing.

B.

NOTES : APPLICABLE TO ‘DRIVE LIST’

1.0

This drive list shall comprise of the following equipment in BIDDER’s scope. (i)

All motor operated unidirectional and bi-directional drives.

(ii)

All control valves / control dampers.

(iii)

Solenoid valves / Pneumatic block valves.

2.0

All drives shall have the facility for manual operation.

3.0

The information to be furnished under ‘Data required for Electrical Engineering’ is required for : (i)

Electrical Auxiliary system finalisation by PURCHASER. ISSUE R0


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 5 OF 5 SYSTEM – TABLE 15 TABLE 15: FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES) (ii)

MCC procurement / finalisation by PURCHASER.

Hence, the information marked * shall be furnished with the bid, positively. 4.0

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.

5.0

Three (3) nos., cable glands shall be provided for each Actuator for PURCHASER’s control & instrumentation cables, in addition to cable gland for power cable.

6.0

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.

7.0

Drives shall be listed in the order of the process flow path.

8.0

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..

C.

NOTES APPLICABLE TO ‘TERMINAL DETAILS ANALOG / DIGITAL’

1.0

All terminals including spares shall be listed.

2.0

For each source equipment, terminal details, the following details shall be added :

3.0

(a)

Valve actuator make

(b)

Valve actuator model

The specified format is applicable for the following : -

DC Starter

-

Valve actuators

-

Local Panels

-

Motor terminal boxes for winding

-

Any other service as applicable.

ISSUE R0


TCE FORM NO. 120R2

Volume – V


Spec No.

SECTION: D5

TCE.5657A-C-500-001


SHEET 1 OF 1

TABLE-16: TRAINING TO BE PROVIDED FOR OWNER’S PERSONNEL SL. NO.

1.0

TYPE OF TRAINING

NO. OF PERSONS

DURATION OF TRAINING

PLANT OPERATION TRAINING

1.1

Main Plant through DCS OS- Training for Control Engineers

12

8 Weeks each

1.2

Each Type Of Plant auxiliary through PLC OS-Training for Control Engineers

12

4 Weeks each

2.0

SYSTEM MAINTENANCE TRAINING

2.1

I&C Engineers In DCS Hardware & Software

6

8 Weeks Each

2.2

I&C Engineers In PLC System Hardware & Software

6

2 Weeks Each

2.5

Maintenance Engineers In CMMS System Functioning & Maintenance

8

2 Weeks Each

2.6

I&C Engineers In MIS System Hardware & Software

2

1 Week Each

2.7

I&C Engineers In SWAS System Hardware & Software

2

1 Week Each

2.8

I&C Engineers In Gas Analyser - Hardware & Software

2

1 Week Each

2.10

I&C Engineers In PADO System Hardware & Software

2

1 Week Each

2.11

I&C Engineers In Vibration Monitoring And Analysis System- Hardware, Software & Analysis

4

2 Weeks Each

2.12

For All Other Instruments/ Systems

4

Adequate Training

ISSUE P0R0


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001


SHEET 1 OF 6

TABLE-17: 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.

1.2

The Bidder shall get prior approval as per approved quality assurance plan of the Purchaser / Purchaser’s Representative before any installation work starts. If any work is carried out by the Bidder before prior approval from Purchaser / Purchaser’s Representative and modification is sought by Purchaser / Purchaser’s Representative later, then the work shall be redone by Bidder without any cost / material implications to the Purchaser / Purchaser’s Representative.

1.3

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.

1.4

All the panels, desk, cabinets supplied by the Bidder shall be welded or bolted to the floor channel. TESTING REQUIREMENTS

2.0 2.1

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.

2.2

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.

2.3

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.

ISSUE R0


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TCE.5657A-C-500-001


SHEET 2 OF 6


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 f ixed / differential settings.

2.6

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 set up required shall be arranged by the Bidder. All the conductivity conductivity type probes probes and switches switches shall be tested for performance before installation.

2.7

Air leak tests shall be performed on all flue gas impulse / sample lines, air supply and pneumatic lines. Necessary Necessary equipment such as portable compressor, compressor, connecting connecting pipes, materials, cables and test gauges shall be provided by the Bidder.

2.8

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 f ill 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.

2.9

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 inching applications applications shall also be calibrated.

2.10

Pneumatic actuators shall be calibrated at site.

3.0

COMMISSIONING REQUIREMENTS REQUIREMENTS

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.

3.2

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.

3.3

Pre-commissioning Pre-commissioning checks, individuals individuals loop checks, power initialisation, initialisation, verification of system functioning, trouble shooting final solutions to application and / or instrument problems, etc., is Bidder’s responsibility. responsibility. All the required software software and hardware changes shall be incorporated as required for successful commissioning to Purchaser’s satisfaction.

3.4

Any other tests as may be directed by the Purchaser/Purchaser’s Purchaser/Purchaser’s Representative. Representative. ISSUE R0


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Spec No.


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SHEET 3 OF 6


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 manufacturer’s manufacturer’s recommendations. 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 manufacturer’s 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.

4.0

SPECIFIC REQUIREMENTS REQUIREMENTS FOR ERECTION, TESTING, CALIBRATION CALIBRATION AND COMMISSIONING

4.1

The erection of instrumentation 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.

4.2

SCOPE OF WORK FOR ERECTION

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.

4.2.2

The Bidder shall provide all supervisory, 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.

4.2.3

The Bidder shall maintain proper record of the materials at the place of storage for quick identification as and when required.

4.2.4

The Bidder shall carry out all repairs to damages that might have suffered during transit or in subsequent storage and replacement replacement of all lost parts.

4.2.5

The Bidder shall furnish a detail erection schedule, 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 PURCHASER shall be strictly adhered to by the t he Bidder.

4.2.6

The erection work shall include but not limited to the following: (a) Transportation of the tested and and calibrated calibrated equipment equipment to the place place of of installation installation without any damage. (b) Installation Installa tion of PLC equipment as per bill of material and as per relevant approved G.A and disposition disposition drawing. ISSUE R0


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Spec No.


TCE.5657A-C-500-001


SHEET 4 OF 6

TABLE-17: ERECTION, FIELD TESTING AND COMMISSIONING REQUIREMENTS (c) (d)

(e) (f) (g)

Installation of the necessary cable and racks with with posts, posts, brackets, brackets, and fasteners. Installation and termination of electrical, electrical, measuring, measuring, control, control, power 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 structural steel plates, angles, 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 separate earthing pits as as recommended recommended by the PLC system supplier, laying and connection of the earthing cables from different equipment to the respective earthing pit.

4.3

ERECTION

4.3.1

Cabinets and desk

4.3.1.1

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.

4.3.1.2

Before installation 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 Bidder’s scope of supply.

4.3.1.3

The cabinets and desks shall be cleaned by blowing air to remove dust or foreign particles.

4.3.1.4

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.

4.3.1.5

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.

4.3.2

Cables, cables trays and conduits

4.3.2.1

All electrical work shall conform to the rules and regulations of Indian Electricity Act.

4.3.2.2

All cables shall be tested for insulation level. Cable ends shall be properly cleaned.

4.3.2.3

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TABLE-17: ERECTION, FIELD TESTING AND COMMISSIONING REQUIREMENTS be no damage to the cables. 4.3.2.4

Flexible conduits shall be provided wherever necessary.

4.3.2.5

Cable in hot areas shall have proper heat protection.

4.3.2.6

A minimum distance of 400 mm shall be kept between instrument / signal cables and power cables.

4.3.2.7

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.

4.3.2.8

Instrument Cable Trays, shall be erected vertically as far as possible to avoid dust accumulation.

4.3.2.9

All the cables laid shall be tied individually to the Tray.

4.3.2.10

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.

4.3.2.11

The cabling accessories shall include cage-clamp type terminal blocks, splicing materials, crimping tools, cable support grips, insulating tapes, GI f lexible conduits, conduit fittings, GI perforated covered trays, supports, accessories, and cadmium plated trays & cable glands.

4.4

LOOP TESTING

4.4.1

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.

4.4.2

For current signals, 4 – 20 mA shall be injected and checked the loop for 0%, 25%, 50%, 75% and 100% of fullscale inputs.

4.4.3

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%.

4.4.4

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%.

4.4.5

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.

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TABLE-17: ERECTION, FIELD TESTING AND COMMISSIONING REQUIREMENTS 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.

4.5

COMMISSIONING

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.

4.5.2

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.

4.5.3

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.

4.5.4

Control loops shall be put in auto mode as per the operational requirement of different phases.

4.5.5

Bus Worst loading conditions calculation shall be proved at the time of commissioning.

4.5.6

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.

4.5.7

The performance test shall be carried out for the system offered and certificates to these effects shall be approved by the PURCHASER.

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TABLE- 18: COMPUTERISED MAINTENANCE MANAGEMENT SYSTEM (CMMS) 1.0

GENERAL

1.1

A complete integrated computerised maintenance management system (CMMS) with relevant data bases completely populated and system customised for power plant application shall be provided. The system to be provided shall include all necessary hardware, software, firmware and interfaces required for implementing a fully functional CMMS system suitable for integrated maintenance management function for a modern power generation utility. Bidder’s offered CMMS shall include but not limited to the details specified in subsequent paragraphs.

1.2

CMMS system shall be common for both the units.

2.0

CMMS FUNCTIONS CMMS shall meet following functional requirements: (a) Asset management and asset register (b) Inventory Management (c) Work Order (d) Job Plan (e) Resources (f) Scheduling (g) Preventive maintenance (h) Purchasing (i) Personnel (j) Financial (k) Other functions (l) Reporting

2.1

ASSET MANAGEMENT AND ASSET REGISTER FUNCTIONS

2.1.1

Asset management function shall facilitate the creation of an asset register which will hold the comprehensive details of each asset/ equipment. It shall have following features: (a) Building the location details and it’s hierarchy (b) Building the equipment, it’s hierarchy and specification details including drawings. (c) Creating hierarchies identifying operating locations as a part of multiple systems (d) Defining relationship between equipment, location and system (e) Building spare parts and sub-assembly catalogues of the asset/equipment (f) Tracking the equipment, movements, associated costs, histories of planned and unplanned maintenance & failures. (g) Facility to launch condition based preventive maintenance work orders based on preset equipment- wise upper and lower limits. (h) Links to inventory management and purchase functions.

2.1.2

The asset management facility shall be capable of performing the following: (a) Control the company’s list of maintainable assets through an asset register. (b) Control the accounting of assets, purchase price, depreciation rates etc. (c) Control maintenance inventory (stores management, requisition and purchasing).

2.2

INVENTORY MANAGEMENT FUNCTION

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TABLE- 18: COMPUTERISED MAINTENANCE MANAGEMENT SYSTEM (CMMS) 2.2.1

Inventory management function shall have following features: (a) Specifying attributes and then ability to search by attribute for items, equipment and locations (b) Tracking of stocked and non-stocked items through multiple stores. (c) Tracking of items, costs and balances by bin, lot and storeroom. (d) Stock replenishment when inventory falls below minimum levels (e) Automatic reorder of items through “ lights out replenishment” (f) Tracking of items by last cost, average cost or user definable standard cost. (g) Usage of ABC analysis to assign inventory item prioritising. (h) Employing just in time methodologies to generate purchase orders. (i) Identifying out of stock items and making substitutions with alternate parts, vendor and location tracking capabilities. (j) View of work order reservations for inventory items (k) Linked up with asset register.

2.3

WORK ORDER FUNCTION

2.3.1

Work order function shall have following features: (a) Viewing comprehensive and detailed planning information such as following: (i) Work Plans (ii) Schedules (Target and scheduled date tracking) (iii) Costs (iv) Labour, materials, Skill set / crafts, Special tools requirement etc. (v) Equipment (vi) Failure analysis (vii) Related documentation (b) Recording of maintenance work and closure of work orders. (c) Scheduling of work orders based on real time criticality and logistics (d) Sequencing of work orders for multiple equipment based on location and / or equipment (e) Comparision of real time budgets or estimates with actual and historical data (f) Tracking of equipment down time (g) Tracking of equipment failure history with cause and remedy. Facility for generation of micro-level failure/ cause stratification diagram

2.4

JOB PLAN FUNCTION

2.4.1

Job planning function shall have following features: (a) Tracking of costs by operation or job plan (b) Linking job plans sequentially, each with it’s own parts, labour and tool estimates. (c) Duplicate job plans for modification and use as templates.

2.5

RESOURCES Resource function shall allow to maintain detailed resource information to plan and analyze maintenance work related to company, service contract, tools etc.

2.6

SCHEDULING FUNCTION Scheduling function shall enable to forecast future preventive maintenance dates for ISSUE R0


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resource planning. 2.7

PREVENTIVE MAINTENANCE FUNCTION

2.7.1

Preventive maintenance schedule shall be capable of performing the following: (a) Allows each asset / equipment to have a defined maintenance profile (b) Helps to schedule planned preventive maintenance routines (c) Control preventive maintenance procedures (d) Control the issue and documentation of planned and un-planned maintenance work.

2.7.2

Preventive maintenance function shall have following features: (a) Generation of preventive maintenance work-orders on demand, batched or automatically. (b) Generation of preventive maintenance work-orders for planned shut downs. (c) Sequence multiple job plans and consolidate multiple procedures on one preventive maintenance schedule. (d) Facilitates clustering of PM work orders for various departments / divisions to take reduced planned equipment downtime. (e) Capable of generating PM work orders on the basis of fixed frequency intervals or run hours. (f) Reservation of inventory for scheduled PM works.

2.8

PURCHASING FUNCTION

2.8.1

Purchasing function shall have following features: (a) Creation of purchase requisitions or purchase orders either from scratch or from the inventory or work order modules (b) Create RFQs for multiple vendor bids (c) Automatic release of agreement Purchase orders (d) Creation of special orders for parts not stocked in inventory. (e) Elimination of costly “Maverick Buying” by establishment of approved vendors. (f) Direct issue of purchase orders and issue parts and services directly to work orders for the expense off items. (g) Analyzing of vendor performance before ordering of parts (h) Use of invoice matching (i) Defining multiple tax rates to budget for interstate and international purchasing (j) Autp re-order PR/PO generation for the spares, when stock falls below re-order level. (k) PR to PO consolidation to group PRs by vendor into single purchase order. (l) Line item /Purchase order status generation-Initiated (Unapproved), Approved, Partial receipt, Completion of receipt, Invoice matched, Cancelled etc.

2.9

PERSONNEL FUNCTIONS

2.9.1

Personnel function shall have following features: (a) Creation of employee details including employment and personnel information tracked. (b) Assignment details like department, preferred staff, available weekly work hours tracked. (c) Craft / salary rates-employees can be expensed to work orders by an average craft rate or actual hourly rates. ISSUE R0


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(d) (e)

Training / certifications of employees tracked by the system Security levels-each employee can be assigned access security levels for each of the functional areas in the system.

2.10

FINANCIAL

2.10.1

Financial function shall have following features: (a) Facility for supporting double entry accounting for integration with any financial system. (b) Creation of user defined financial calendars to correlate directly with accounting periods

2.11

OTHER FUNCTIONS

2.11.1

Other facilities required are as follows: (a) Interface to MS project to permit planning of work carried out in CMMS system to MS project for scheduling. Work progress can then be tracked in CMMS and used to update the project. (b) CAD / Image viewing capability to enable users to store, mark up and view drawings, scanned images, word documents etc. (c) Account code or project budgeting to enable users to set up periodical project budgets. The system will then be able to track actual and committed costs against budgeted costs.

2.12

REPORTING FUNCTIONS

2.12.1

Reporting facilities required are as follows: (a) Standard Reports-Generation of standard reports on work orders, safety plans, inventory values and other critical points about maintenance operations. (b) Report types- capabilities shall include Columnar reports, forms, Bar Charts, Pie Charts, Cross tabs etc. (c) Report generation- Crystal reports. (d) Data export capability via crystal reports to Text, Excel/Lotus, Word documents, Email, HTML, ODBC etc.

3.0

CMMS DESIGN FEATURES

3.1

CMMS system shall be based on Client- Server and relational data base environment. The system shall operate on a commonly used hardware platform and network operating system

3.2

System shall be suitable for simultaneous use by multiple users. Presently, the system supplied shall be used by 10 nos users. However, the system shall be expandable in future to accommodate additional 10 no users through additional client workstations and user licenses.

3.3

The system shall be suitable for a wide range of tagging systems and in particular KKS tagging system.

3.4

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groups and each group shall have a separate security profile. It shall be possible to provide additional personal security settings for individuals within a group. 3.5

CMMC processing shall be carried out in an independent server. The system shall be able to obtain requisite plant equipment status data from the concerned plant control system like plant DCS & Switchyard SCADA system. Further, the system shall be interfaced with MIS system server for transmission of maintenance related details for usage with MIS. To meet the above requirement, CMMS system shall be interfaced with all relevant plant control systems through redundant communication link. The MIS system server will be connected with station LAN and all user PCs will be connected with the station LAN.

3.6

CMMS user workstations will be located in different plant buildings and the same shall be connected to the CMMS server through STATION LAN network.

3.7

Where ever required same user work stations (PCs) will be used for CMMS (maintenance management system) and MIS. Together with MIS system total 35 nos user workstations shall be provided.

4.0

CMMS SYSTEM IMPLEMENTATION

4.1

System shall be delivered fully implemented and shall be user tested at site. It is the Contractor’s responsibility to fully populate the CMMS system data base and demonstrate the proper functioning of the system to User’s personnel.

4.2

It is preferred that Contractor’s implementation team will involve ultimate user’s personnel during system implementation.

5.0

CMMS HARDWARE/ SOFTWARE REQUIREMENT

5.1

CMMS shall include all hardware and software as required for proper functioning of the system including but not limited to the following: (a) One (1) no Server (With PC, VDU, Keyboard /Mouse) (b) 10 no Client workstations (Each with PC, VDU, KBD/ Mouse) for Admin building, workshops, stores and switchyard [Refer Plant instrumentation and system configuration Drwg. No: TCE-5657A-IC-SK-01. (c) CMMS Software with multiple user’s license. (d) Server & User PCs operating licenses. (e) System cables, interconnecting office LAN & Station LAN etc.

5.2


5.3

It shall be possible to upgrade the installed system with the latest available version of the software model during the plant life. DESIGN DATA

6.0

6.1

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(d) (e) (f) (g) (h)

DVD / CD ROM Drive-50X DAT Drive-Required Network Interface- Required Server Operating System-Required External Modem- Required, 56 k V.90

6.2

Video Display Unit : 21" colour TFT LCD 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 Sixteen (16) colours shall be provided. Anti-reflection feature shall be provided. The VDUs shall be of table top mounting type. All VDU's shall have dedicated keyboard. .

6.4

MIS User Workstation PC shall be of latest model with 160 GB hard disk drive, DVD/CD ROM drive and DAT drive facility. Monitors shall be 21 inch colour TFT LCD monitor with minimum 1280x1024 pixel resolution.

7.0

STATION LAN

7.1

Refer Section D 2, Table-21 for details on station LAN.

7.2

Station LAN will be common for CMMS, MIS & Security and Surveillance system.

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TABLE- 20: PERFORMANCE ANALYSIS, DIAGNOSTICS AND OPTIMISATION (PADO) SYSTEM

1.0

GENERAL

1.1

PADO system shall provide critical analysis of the plant performance and guidance for optimisation on continuous on-line basis. The system shall analyse dynamically the status of the process and the equipment of the power generating units and will automatically generate the operator guidance instructions for remedial actions for maintaining the process and the system / equipment in the plant to their optimum performance.

1.2

PADO shall incorporate the complete thermal design model of the plant and shall use the measured data from the plant control systems (DCS) acquired through a suitable interface.

1.3

The system to be provided shall include all necessary hardware, software, firmware and interfaces required for implementing a fully functional PADO system. Bidder’s offered PADO shall include but not limited to the details specified in subsequent paragraphs.

1.4

PADO system shall be independent for each unit.

2.0

FUNCTIONAL REQUIREMENT PADO system shall provide following functional requirements: (a) Performance analysis and monitoring of systems and components (b) System and performance diagnosis (c) System and performance Optimisation (d) Emission analysis and monitoring (e) Boiler performance optimisation (f) Boiler Stress Condition Analysis (g) Regenerative cycle performance Optimisation (h) Interactive water and steam chemistry management system

2.1

Performance Analysis And Monitoring Of Systems And Components

2.1.1

Performance analysis and monitoring of systems and components shall involve and facilitate the following: (a) (b) (c)

Computation of thermal performance status of the plant and efficiency of generation. Computation of all the key system performance indicators at system level such as heat rate, plant and equipment efficiency, generator output and controllable losses. Computation of all the key system performance indicators at major component. This shall include the following: (i) Assessment of boiler operation based on efficiency, excess air and cleanliness factors of superheater, reheater and economiser. (ii) Turbine performance evaluation considering efficiency, enthalpies, steam flow and gland leakage flow estimation. (iii) Air Pre-heater performance involving efficiency and pressure losses. (iv) Condenser performance based on heat duty and heat transfer co-efficient and cleanliness factors. ISSUE


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(v)

(d)

(e)

(f) (g)

Performance of re-generative heaters by computing extraction flows, drain flows, terminal temperature difference and drain cooling approach.

Analyse the impact of individual component performance on overall losses or gains in total unit generation along with computation and display of cost of individual loss/gain. Performing detailed analysis of each component including computation of key performance indicators such as efficiency, heat transfer co-efficient, TTD, DCA and fouling factor. Visualisation of individual component efficiencies and performances and display of the same. Visualisation of impact of incremental change of the major process parameters including but not limited to the following on boiler efficiency, turbine heat rate and unit heat rate etc. through ‘What If” query facility for operator: (i) Main Steam pressure (ii) Super heater Spray flow (iii) Re heater Spray flow (iv) Economiser Inlet Temperature (v) Excess Air (vi) Burner Tilt (if applicable) (vii) Coal Analysis (viii) Surface effective for super heater, re heater and economiser

2.1.2

Performance computations to be carried out at specified intervals based on time averaged data during steady state operating conditions.

2.1.3

Computations to be based on process signals, equipment status, design criteria and manual input data (where ever needed). Raw measured value for process signals shall be reconciled before usage.

2.2

System And Performance Diagnosis

2.2.1

System and performance diagnosis shall involve detection of the abnormalities and diagnosis of system and component performance degradation up to component level to pin-pointing root cause of abnormalities existing in the process and guiding the operating personnel to attend to the same.

2.2.2

Diagnosis function involves the following: (a) Equipment health diagnosis for high/ low pressure, temperature, level & vibration etc. (b) Plant performance diagnosis for boiler, turbine, condenser, feed water and regenerative heating system (c) Identifying degradation of measuring instrument for important parameters using data validation checks.

2.2.3

Diagnosis based on expert system in the form of “Fault Trees” / Neural and Bayesian belief networks. etc . Expert systems shall draw inferences based on knowledge base, on-line measured data and computed performance indices.

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Diagnosis system shall be capable to provide following helps: (a) Avoiding a possible trip (b) Maintaining process parameters within safe limits thereby enhancing the life of the equipment (c) Drawing the operator’s attention to the degradation of the equipment and instruments

2.3

System And Performance Optimisation

2.3.1

System and performance optimisation involves optimisation of set points for controllable parameters by recommending to the operator the optimum set points for optimising the given process or activity at the measured operating condition using state of the art optimisation techniques.

2.4

Emission Analysis And Monitoring

2.4.1

Emission analysis and monitoring functions involves the following: (a) Monitoring, tracking and analysing plant emissions such as SO2, NOX, CO, CO2 etc.in real time assuming sensors are available for all except CO2 which can be calculated. (b) Monitor and analyse ESP & Stack conditions such as temperature, humidity, gas flow rate and opacity. (c) Facilitate obtaining lowest emissions by recommending optimal damper position to minimise the NOX level measured at the stack while maintaining the CO value and unburnt carbon below desired permissible limits. (d) Facilitate obtaining lowest emissions while maintaining combustion efficiency. (e) Facilitate to set alarms to highlight conditions that violate pre-defined conditions.

2.5

Boiler Performance Optimisation System (BPOS)

2.5.1

BPOS shall enable operating personnel to improve boiler performance and optimise fuel consumption including optimised operation of Soot Blowing system. This system shall have following features: (a) (b)

(c)

(d)

Incorporates the complete thermal design model of the boiler capable of both forward and backward computation of complete boiler thermal performance. Boiler thermal design model calibrated to made “Site- specific” based on series of field trials of thermal performance of the boiler during start up and prior to trial operation. BPOS to function continuously taking into consideration the performance of furnace, super heater, economiser, air heater and pulveriser based on the continuous on-line measurement of the including but not limited to the following parameters: (i) Flue gas temperature at ECO I/L (ii) Flue gas oxygen content (iii) Other fluid temperature(s) entering and exiting various heat transfer surfaces (iv) Coal Characteristics BPOS shall be capable for continuous on-line calculation of the thermal ISSUE


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performance of the boiler for the operating conditions indicating performance prediction zonal absorption, metal temperature and shall have the following features: (i) Fuel switching capability (ii) “What If” query capability (iii) Selective soot blowing of furnace/Super heater based on trends of zonal absorption. 2.5.2

Expert system diagnostics for quick identification of the Root Cause of deviations from the predicted parameters

2.6

Boiler Stress Condition Analysis (BSCA)

2.6.1

BSCA monitors of thermal stresses and assess life exhaustion in thick walled components like super heater and re heater outlet headers by estimating the expended life due to low cycle fatigue and creep.

2.6.2

BSCA shall guide the operator during start- up and shut down regarding controlling of rate of heating or cooling of metal within specified limits and also guides the margins available for the rate of steam generation (for fuel firing) during start-up.

2.7

Regenerative Cycle Performance Optimisation System (RCPOS)

2.7.1

Regenerative cycle performance optimisation system shall involve the following: (a) Analysis of deviation of performance of the turbine cycle by examining the deviation of important parameters of the turbine cycle. (b) Analysis of actual efficiency of individual stages of turbine. (c) Evaluation of LPH & HPH performance by comparing current values of TTD/ DCA to the reference values. (d) Heater level evaluation

2.8

Interactive Water And Steam Chemistry Management System

2.8.1

Interactive water and steam chemistry management system shall be capable of guiding the operator for appropriate chemical dosing to maintain the chemical balance, optimal blow down and carry out further investigation as advised by the system.

2.8.2

The system shall have following features: (a) Monitoring of various steam and water parameters at certain pre-determined points in the flow cycle and warning the operator about any distinct aberration and guiding on precautionary as well as corrective actions to be taken. (b) The system shall use “Decision Trees” and “Fault Trees” or other suitable methods for each parameter to diagnose deviations in controlled parameters in order to find the root cause and advise corrective actions.

2.8.3

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(d) (e) (f)

Decline in degradation of turbine components Lessening of boiler tube scale formation Reduction in energy consumption

3.0

PADO DESIGN FEATURES

3.1

PADO system shall be based on Client- Server and expert system. The system shall operate on a commonly used hardware platform and network operating system

3.2

System shall be suitable for simultaneous use by multiple users.

3.3

The system shall be suitable for a wide range of tagging systems and in particular KKS tagging system.

3.4

The system shall be password protected. It shall be possible to organise system users into groups and each group shall have a separate security profile. It shall be possible to provide additional personal security settings for individuals within a group.

3.5

The system shall be able to obtain requisite plant system / equipment and process data from the concerned plant control systems like plant DCS. To meet the above requirement, PADO system shall be interfaced with all relevant plant control systems through redundant communication link.

3.7

PADO system is illustrated in drawing no. TCE.5657A-IC-SK-01

4.0

PADO SYSTEM IMPLEMENTATION

4.1

System shall be delivered fully implemented and shall be user tested at site. It is the Contractor’s responsibility to demonstrate the proper functioning of the system to User’s personnel.

5.0

PADO HARDWARE/ SOFTWARE/INTERFACING REQUIREMENT

5.1

PADO shall include all hardware and software as required for proper functioning of the system including but not limited to the following: (a) One (1) no Server (With PC, Video Display Unit, Keyboard /Mouse) (b) One (1) no user station (Each with PCs, Video Display Unit, Keyboard/ Mouse) (c) PADO Software with all relevant user’s license. (d) Server & User PCs operating licenses. (e) Redundant OPC communication link with all necessary hardware and software. (f) System cables, interconnecting office LAN & Station LAN etc.

5.2


5.3


6.0

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6.1

Server Unit (a) Pentium latest model & version (b) Memory-1024 MB RAM (c) Hard Disk Drive-160 GB or Higher (d) DVD / CD ROM Drive-50X (e) DAT Drive-Required (f) Network Interface- Required (g) Server Operating System-Required (h) External Modem- Required, 56 k V.90

6.2

Video Display Unit : 21" colour TFT LCD 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 Sixteen (16) colours shall be provided. Anti-reflection feature shall be provided. The VDUs shall be of table top mounting type. All VDU's shall have dedicated keyboard. .

6.5

MIS User Workstation PC shall be of latest model with 160 GB hard disk drive, DVD/CD ROM drive and DAT drive facility. Monitors shall be 21 inch colour TFT LCD monitor with minimum 1280x1024 pixel resolution.

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INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 21 TABLE- 21: STATION LAN

SHEET 1 OF 2

GENERAL A plant wide Local Area Network (LAN) encompassing the different plant buildings shall be provided. The Station LAN shall interconnect the buildings together and shall facilitate the smooth transfer of Data from one building to the other.

2.0

DESIGN AND FUNCTIONAL REQUIREMENT

2.1

The LAN shall be of the gigabit type (1000Mbps) and shall utilize standard IEEE 802.3 protocols such as Ethernet.

2.2

The Station LAN shall connect following buildings: (a) Station Building- Central Control Room (b) Service Building (c) Coal Handling Plant (d) Ash Handling Plant (e) Water Treatment Plant (f) Workshop (g) Stores (h) Switchyard Control Building (i) Any other building under the scope of this specification. (j) Admin Building (In future-by OTHERS).

2.3

The actual no of rooms where the LAN network to be provided with the actual number of user points in each building shall be decided during detailed engineering.

2.4

The various buildings shall be interconnected through the use of minimum 4 core single mode fibre and shall be connected to the main switch in the Service Building in a STAR topology.

2.5

Each building shall be provided with a 12U high wall-mountable communications cabinet complete with glass door, 6 way power distribution unit, 2 shelves and force ventilation. All units are to be supplied with cage nuts and bolts to house LAN switches.

2.6

Switches provided shall be minimum 4x fibre (1000Base-SX) 1Gbps uplink ports or 2 x STP (1000Base-T) 1Gbps uplink ports Ethernet switch, configurable via browser interface and have a 50% spare capacity for future addition of LAN points.

2.7

The LAN shall be designed in a manner such that failure of an individual switch shall not hamper the failure of the entire system.

2.8

All provisions required for extending the Station LAN to Admin. Building shall be provided in main LAN Switch. Extension of Station LAN with intra building LAN network for admin. Building will be carried out by others.

2.9

Inter building wiring shall be a minimum of Category 5E STP cable manufactured, tested and verified to ISO11801 EIA/TIA standard. Internal building wiring shall be of the structured ISSUE


TCE FORM NO. 120R2

Spec No. TCE.5657A-C-500-001



INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 21 TABLE- 21: STATION LAN

SHEET 2 OF 2

cabling type and shall incorporate patch panels on every floor or as required. A minimum of two RJ-45 ports shall be provided for each specified location. Category 5E shuttered modules shall be used in pre-assembled faceplates to save installation time. Modules shall include a slide label system. 2.11 CMMS & MIS servers together with user workstations shall reside on Station LAN.

ISSUE


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 22 TABLE- 22: MANAGEMENT INFORMATION SYSTEM

SHEET 1 OF 3

1.0

GENERAL

1.1

An integrated management information system (MIS) shall be provided for the plant. System shall be able to provide information related to the following aspects to management personnel: (a) Plant Operation Information (b) Plant Maintenance related Information (c) Environmental Information

2.0

FUNCTIONAL REQUIREMNT

2.1

MIS will provide following plant information: (a) Environmental and hazard management (b) Equipment maintenance history (c) Fault cause analysis (d) On job information report (e) Plant Operation history (f) Plant performance details (g) Any other plant operation data/ details

3.0

DESIGN REQUIREMENTS

3.1

MIS system shall be based on Client- Server and relational data base environment. The system shall operate on a commonly used hardware platform and network operating system

3.2

System shall be suitable for simultaneous use by multiple users. Presently, the system supplied shall be used by 10 nos users. However, the system shall be expandable in future to accommodate additional 10 no users through additional client workstations and user licenses.

3.3

The system shall be password protected. It shall be possible to organise system users into groups and each group shall have a separate security profile. It shall be possible to provide additional personal security settings for individuals within a group.

3.4

MIS processing shall be carried out in an independent server interfaced with the plant DCS, SCADA system, Plant analysis, diagnostics & optimisation system (PADO), Computerised Maintenance management system (CMMS) for polling of plant operational and performance data, and maintenance details. Plant environmental data shall be obtained from DCS. The MIS system server will be connected with station LAN and all user PCs will be connected with the station LAN.

3.5

MIS user workstations will be located in different plant buildings and the same shall be connected to the MIS server through STATION LAN network.

3.6

Where ever required same user work stations (PCs) and printers will be used for CMMS ISSUE


TCE FORM NO. 120R2


Spec No.


TCE.5657A-C-500-001

INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 22 TABLE- 22: MANAGEMENT INFORMATION SYSTEM

SHEET 2 OF 3

(maintenance management system) and MIS. Together with CMMS system total 10 nos user workstations shall be provided. 4.0

MIS SYSTEM IMPLEMENTATION

4.1

System shall be delivered fully implemented and shall be user tested at site. It is the Contractor’s responsibility to demonstrate the proper functioning of the system to User’s personnel.

4.2

It is preferred that Contractor’s implementation team will involve ultimate user’s personnel during system implementation.

5.0

MIS HARDWARE/ SOFTWARE REQUIREMENT

5.1

MIS shall include all hardware and software as required for proper functioning of the system including but not limited to the following: (a) One (1) no Server (With PC, Video Display Unit, Keyboard /Mouse & Colour Laser Printer) (b) 20 no Client workstations (Each with PCs, Video Display Unit, Keyboard/ Mouse and Colour Laser Printer) (c) MIS Software with multiple user’s license. (d) Server & User PCs operating licenses. (e) System cables, interconnecting office LAN & Station LAN etc.

5.2


5.3


6.0

DESIGN DATA

6.1

Server Unit (a) Pentium latest model & version (b) Memory-1024 MB RAM (c) Hard Disk Drive-80 GB or Higher (d) DVD / CD ROM Drive-50X (e) DAT Drive-Required (f) Network Interface- Required (g) Server Operating System-Required (h) External Modem- Required, 56 k V.90

6.2

Video Display Unit : 21" colour TFT LCD 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 Sixteen (16) colours shall be provided. Anti-reflection feature shall be provided. The VDUs shall be of table top mounting ISSUE


TCE FORM NO. 120R2

power plant control and Instrumentation specification

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