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1.DISTRIBUTED DIGITAL CONTROL October 23, 2008

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2.00.00 DISTRIBUTED DIGITAL CONTROL, MONITORING AND   

        INFORMATION SYSTEM (DDCMIS)

 

 

         The  microprocessor based distributed  digital  control,

 

         monitoring   &   information   system(DDCMIS)shall    be 

 

         provided for the safe and efficient operation of SG, TG,

 

         balance  of plant and all auxiliaries in all regimes  of

 

         Operation.

 

The following standards shall be followed for design, manufacturing, installation and commissioning of the Distributed Control System:

 

a) ANSI/ISA84.01 1996 – Application of Safety Instrumented 

   System.

b) IEC – 61151 – Functional Safety- Safety Instrumented 

   System for Process Sector.

c) IEEE – 1046 – IEEE Application guide for Distributed  

   Digital Control Monitoring for Power Plant.

d) ANSI/ ISA – 77.13.01 – Fossil Fuel Power Plant Steam

   Turbine By-pass System.

e) NUREG – 700 – Human- System Interface Design Review

   Guidelines.

      f) ANSI/ISA-18.1-Annunciation Sequence and Specification.

 

2.01.00  GENERAL REQUIREMENTS

        

2.01.01  The   requirements  for  distributed   digital   control

 

         monitoring and information system(DDCMIS) are  indicated

 

         on functional basis in this specification. Bidder  shall

 

         be responsible for engineering, selection and connection

 

         of  all  components and sub-systems to form  a  complete

 

         system   whose   performance  is  in   accordance   with

 

         functional, hardware, parametric and other  requirements

 

         of this specifications.  It is not the intent or purpose

 

         of this specifications to specify all individual  system

 

         components since the bidder has full responsibility  for

 

         engineering and  furnishing of a complete system.

 

2.01.02  SYSTEM CONFIGURATION

        

         DDCMIS  shall  basically consist of  control  system  of

 

         boiler, turbine & balance of plant (namely SG-C&I,TG-C&I

 

         &   BOP-C&I  including  their   respective   measurement

 

         system);  Man-machine  interface and  plant  information

 

         system(MMIPIS);   system  programming  &   documentation 

 

         facility;   data  communication   system(DCS);integrated

 

         sequence of events recording system(SERS);  Annunciation

 

         system,  and  master & slave  clock system. 

 

         The basic configuration of DDCMIS shall be as  indicated

 

         in the  DDCMIS configuration drawing No.CED/STP/I/821,822,

 

         823.

 

2.01.03  SYSTEM EXPANDABILITY

 

         Modular  system  design shall be adopted  to  facilitate

 

         easy  system  expansion.   The  system  shall  have  the

 

         capability  and  facility  for  expansion  through   the

 

         addition  of   controller modules,  process  I/O  cards,

 

         drive  control modules, hand/auto stations, and push button

 

         stations, peripherals like CRT/ Keyboards, printers etc.

 

         while  the  existing system is fully  operational.   The 

 

         system shall have the capability to add any new  control

 

         loops  groups/ sub-groups, in control system  while  the

 

         existing system is fully operational.

 

 

2.01.04  ON LINE MAINTENANCE

 

         It shall be possible to remove/ replace on line  various

 

         modules(like  I/O module)from its slot  for  maintenance

 

         purpose  without  switching  off  power  supply  to  the

 

         corresponding  rack.   System design shall  ensure  that

 

         while doing so, undefined signaling and releases do not

 

         occur  and  controller  operation  in  any  way  is  not

 

         affected(including  controller  trip  to  manual,   etc)

 

         except that information related to removed module is not

 

         available  to  controller.  Further, it  shall  also  be 

 

         possible  to  remove/  replace  any  of  the   redundant

 

         controller  module without switching off the   power  to

 

         the  corresponding  rack  and this will  not  result  in

 

         system  disturbance or loss of any controller  functions

 

         for main controller.  The on line removal/ insertion  of

 

         controller, I/O modules etc. shall in no way  jeopardize

 

         safety of plant and personnel.

 

2.01.05  FAULT DIAGNOSTICS

 

         The  DDCMIS  shall  include on  line  self  surveillance,

 

         monitoring  and diagnostic facility so that  a  failure/

 

         malfunction can be  diagnosed automatically down to  the

 

         level  of  individual  channels of  modules  giving  the

 

         details  of  the fault on the   programmer  station  CRT

 

         displays  supplies, sensor fault, any channel  fault  in

 

         2V3 channels etc. These faults on CRTs as well as  local

 

         indication   on   the  faulty  channel/module   and   on

 

         corresponding  rack/  cubicle shall be  available.   The

 

         diagnostic  system  shall  ensure that  the  faults  are

 

         detected before any significant change in any controller

 

         output  has taken place.  Failure  of any  I/O  modules,

 

         controller etc.shall be suitably grouped and annunciated

 

         to annunciation facia and to OWS(Operator work Station).

 

 

2.02.06  FAULT TOLERANCE

 

         The DDCMIS shall provide safe operation under all  plant

 

         disturbances  and on component failure so that under  no

 

         condition the safety of plant, personnel or equipment is

 

         jeopardized. Control system shall be designed to prevent

 

         abnormal  swings  due to loss of  control  system  power

 

         supply,  failure of any control system  component,  open

 

         circuits/ short circuits, instrument air supply  failure

 

         etc.   On   any  of  these   failures   the   controlled

 

         equipment/parameter shall either remain in last position

 

         before  failure  or shall come to fully  Open/ Close  or

 

         ON/OFF  state  as  required for  the  safety  of  plant/

 

         personnel/  equipment and as finalised  during  detailed

 

         engineering.

 

2.01.07  DDCMIS  shall  meet all  requirements  stipulated  under

 

         other   sub-sections/sections  of   the    specification

 

         including   general   technical   conditions.    General

 

         technical  requirements, quality  assurance,  parametric

 

         requirements etc.

 

2.01.08  SIGNAL EXCHANGE

 

         All  the  signal exchange   between  various  functional

 

         groups of each control group ( i.e. within SG, TG & BOP

 

         C&I) shall be implemented through redundant main  system

 

         bus  (The  main bus connecting  various  sub-systems)and

 

         local  system  bus  within  a  sub-system  as  per   the 

 

         standard  practice of the bidder.  It shall  be  ensured

 

         that any single failure in electronics involved for such

 

         communication,   e.g.  communication  controllers,   bus

 

         interface  modules, physical communication  media,  etc.

 

         does  not  result in loss of such signal  exchange   and

 

         there  in no deterioration in specified system  response

 

         and   system   parametric  requirements.   In   case   a

 

         controller utilizes some inputs generated/ processed  by

 

         any   other   controllers/functional   group   and   the 

 

         requirement of controller response time as specified  in

 

         Clause   2.04.02   is   not  met   due   to   inadequate

 

         communication  rate/ procedure, then the   bidder  shall

 

         provide  hardwired  signal  exchange  for  such  inputs. 

 

         Bidder  shall furnish documentary evidence  through  its

 

         standard  catalogues and drawings explaining as  to  how

 

         this  requirement  is being met by them.   Bidder  shall

 

         also  furnish  along with the above documents,  list   of

 

         coal  fired thermal power stations where  the   proposed

 

         scheme  for  such signal exchange  is  already  working. 

 

         Further,  bidder  to  note that if  his  offered  system

 

         cannot  meet  the  above  requirement  of  communication

 

         redundancy  and specified system response  &  parametric

 

         requirements  then  all the  signal exchange,  analog  as

 

         well as binary among various functional groups shall  be

 

         carried out through hardwiring only and not through  bus

 

         system.

 

         However,  if  in  the opinion of the   employer,  a  few

 

         signal  exchanges are found required  to  be  hardwired,

 

         the  same shall be  provided by the bidder.   Control  &

 

         protection signal exchange between control systems of SG,

 

         TG  and  BOP C&I shall be  hardwired  only.   Protection

 

         signals  like MFT/Turbine/Generator or tripping of unit             

                  

         shall  necessarily   be  hardwired and  redundant  even

         for exchange within  the  same  sub-system, as stipulated

         in NFPA 85. Signal to or from BOP shall be galvanized or  

         optically isolated. 

2.01.09  No  single failure either of equipment or  power  source

         shall  be  capable of rendering  any  part/  system/sub-

 

         system of DDCMIS in operative to any degree.

 

2.01.10 SYSTEM SPARE CAPACITY

 

         Over and above the equipment and accessories required to

 

         meet  the fully implemented system as per  specification

 

         requirements.   DDCMIS  shall have  spare  capacity  and

 

         necessary   hardware/  equipment/accessories   to   meet

 

         following requirement for future expansion at site.

 

2.01.10.01   10%  spare  channels in each  of  the   input/output

 

         modules, fully wired up to marshalling cabinets.

 

2.01.10.02  Wired in space for 20% modules in each of the  system

 

         cabinets  for   mounting electronic modules  wired  up to

 

         corresponding   spare terminals in marshalling  cabinets

 

         such that implementation of any additional control loop/

 

         logic  can  be achieved only by insertion  of  necessary

 

         electronic modules(s) in system cabinets,  configuration

 

         of   corresponding   controller   and   connection    of

 

         inputs/outputs  at  field end of  marshalling  cabinets/

 

         logic cabinets as applicable.

 

2.01.10.03  MMIPIS shall be provided with capacity to handle  25%

 

         or   at least    1  No.of  each   type   of   peripherals

 

         additionally, like CRTs, keyboards, printers, PCs etc.,

 

         over and above already specified, without any additional

 

         hardware or software.

 

2.01.10.04   each  controller shall have  30%  spare  functional

 

         capacity  to implement additional function blocks,  over

 

         and   above  implemented  logics/loops,   further   each

 

         controller  shall have spare capacity to handle  minimum

 

         20%  additional  inputs/outputs of  each  type(including

 

         2.01.10.01  &  02  above), over  and  above  implemented

 

         capacity.   Each  of  the  corresponding   communication

 

         controller  shall also have same spare capacity as  that

 

         of controller.

 

 

2.01.10.05  The data communication system (including main  system

 

         bus  and  other bus system)shall have  the  capacity  to

 

         handle the additions mentioned in clause  Nos.2.01.10.01

 

         to  2.01.10.05.  This will be in addition to  50%  spare

 

         capacity specified under this clause.

 

2.01.10.06  20% spare relays of each type and rating, mounted and

 

         wired in relays cabinets.  All contacts of relays  shall

 

         be  terminated in terminal blocks of relay cabinets.  In

 

         each  of  the relay cabinets 20% spares terminal  blocks

 

         shall  be  provided  so that additional  relays  can  be

 

         mounted and wired.

 

2.01.11  the spare capacity as specified above shall be uniformly

 

         distributed throughout all cubicles.  The system  design

 

         shall  ensure that above mentioned additions  shall  not

 

         require any additional controller/ processor/ peripheral

 

         drivers  Power   supply  module, software  etc.  in  the

 

         system  delivered  at  site.  Further,  these  additions

 

         shall  not  deteriorate the  system  response  time/duty

 

         cycle etc.from those stipulated in the specification.

 

2.01.12  DDCMIS  shall  meet system  performance  and  parametric

 

         requirements as stipulated under specification.

 

 

2.DDC-SYSTEM DESCRIPTION

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2.02.00  SYSTEM  DESCRIPTION

 

         The  DDCMIS  shall include following  main  systems/sub-

 

         systems.  The  DDCMIS shall work in full  integration  &

 

         conjunction  with  field equipments/drives  like  pumps,

 

         motors,  valves, actuators, dampers,  hydraulic  control

 

         systems(eg.for  HP/LP bypass etc.)and field  instruments

 

         to   be   provided   by   the   Bidder.    The    DDCMIS

 

         hardware(controllers,   modules/  cards  etc.)shall   be

 

         housed   in  cabinets  located  in   control   equipment

 

         room(CER) except for operation interfaces located in UCD

 

         & UCP in unit control room.

 

2.02.01  CONTROL  SYSTEM

 

         The  control  system along with its  measurement  system,

 

         shall perform functions of closed loop control, sequence

 

         control, interlock & protection of SG TG and auxiliaries

 

         in all regimes of Unit operation.

 

         The  measurement system of control system shall  perform

 

         the  functions of signal acquisition,  conditioning  and

 

         signal  distribution of various types of  inputs/outputs

 

         like analog (4-20 mA DC, thermocouple, RTD)binary  pulse

 

         etc. The inputs, which are required for only  information

 

         & monitoring  purposes shall be distributed suitably  in

 

         various groups of the measurement system.

 

2.02.02  MAN-MACHINE   INTERFACE  &  PLANT  INFORMATION   SYSTEM

         (MMIPIS)

 

         The MMIPIS shall perform control, monitoring & operation

 

         of SG,TG & auxiliaries in all regimes of unit operation,

 

         interacting  with the control system.  For  this  MMIPIS 

        

         shall primarily perform following functions.

 

         i)  Operator interface for control system.

 

         ii)  Plant  Supervisory functions like  displays,  alarm

 

         monitoring  &  reporting(reports &  logs,  calculations,

 

         trend recording, historical and long term data storage &

 

         retrieval etc.).

 

2.02.03  SYSTEM PROGRAMMING & DOCUMENTATION FACILITY

 

         The  programmer  stations shall be provided for –

 

      i) On line configuration & tuning of control system.

 

     ii) On line program development/ modifications in MMIPIS.

 

         In addition, latest state of the art workstation  based

 

         system documentation for the complete plant.

 

2.02.04  DATA COMMUNICATION SYSTEM (DCS)

 

         The  data  communication system shall be   provided  for

 

         communication   between   control   system   &    MMIPIS

 

         communication   &   signal  exchange   between   various

 

         functional  groups  as  well  as  communication  between

 

         various units & off site/ off line systems.

 

2.02.05  SEQUENCE OF EVENTS RECORDING SYSTEM(SERS)

 

         The DDCMIS shall be  capable of carrying out sequence of

 

         event recording function to  scan & record events in the 

 

         sequence of occurrence within a resolution of 1 milli sec.

 

2.02.06  MASTER AND SLAVE CLOCK SYSTEM

 

         Master & slave clock system shall be  provided to ensure

 

         uniform  time  indication throughout the  various  plants

 

         facilities  and  time  synchronization  between  controls

 

         system,  MMIPIS, switchyard disturbance recorder,  PLC’s

 

         etc.

 

2.02.07  ANNUNCIATION SYSTEM

 

         A facia annunciation system shall be provided with  lamp

 

         boxes in the unit control room.  The annunciation  logic

 

         will  be  implemented as a part of DDCMIS through  which

 

         the  lamp  boxes shall be driven.   However,  additional

 

         facility  to drive stand-alone printer in case of  total

 

         MMIPIS & system bus failure shall be provided.

 

3.MEASUREMENT FUNCTIONS OF CONTROL SYSTEM

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2.03.00  MEASUREMENT FUNCTIONS OF CONTROL SYSTEM

 

2.03.01  All  the signals coming into/going out of  the   control

 

         system  shall  be  connected either directly  or  routed

 

         through  marshalling cabinets. The input/output  modules

 

         employed  in the  control system shall be separate  from

 

         controller hardware.

 

2.03.02  ANALOG SIGNAL CONDITIONING & PROCESSING

 

2.03.02.1  the  conditioning  and  processing  functions  to  be 

 

         performed as a minimum for the  analog input coming  for 

 

         control & information purposes are :-

 

         i)  Galvanic isolation of input & output signals wherever

             required.

 

         ii) Transmitter  power  supply  with  per  point   fuse

             protection  or  current limiting  and  power  supply

             monitoring.

 

         iii)Transducer/transmitter signal output limit check.

 

         iv) Implementation of multiple measurement schemes.

 

         v)  Square root extraction

         vi) Pressure & temp.compensation.

         vii)On line ADC gain & drift monitoring & correction  at

             periodic intervals.

 

        viii)Linearisation of thermocouple signals.

 

         ix) Reasonability check for all analog inputs.

 

2.03.02.2 all  analog  signals  for  control  purpose  shall   be

 

         acquired, validated, processed and their respective data

 

         base  updated  at  a  maximum  interval  of  250   milli

 

         secs.except for some fast acting control loops for which

 

         the  above-referred  time  shall  be   as  per  process

 

         requirement.  For signals required for information only,

 

         the above functions shall be performed at an interval of

 

         1  sec. The validated analog inputs shall be   converted

 

         into engineering units on a per point basis.

 

2.03.02.3  The 4-20 mA input analog cards shall be  suitable  for

 

         interfacing  transmitters giving 4-20 mA  analog  signal

 

         along with super imposed HART interface signals. 4-20  mA

 

         DC signal will only be used for control purpose &  super

 

         imposed  HART  signal will be  used  for  configuration,

 

         maintenance  diagnostic  & record keeping  facility  for

 

         electronic  transmitters  & analyzers etc. 

 

2.03.03  BINARY SIGNAL CONDITIONING & PROCESSING

 

2.03.03.1  The  changeover type contacts (i.e.NC +  NO  together)

 

         shall be wired to the control system for all the  binary

 

         inputs  required for control purposes, except for  input

 

         from MCC/SWGR, actuators and inputs related to hardwired

 

         signal exchange among various functional groups for which

 

         non-changeover type contract(NC or NO)shall be wired  to

 

         the  control  system.  The  binary  input  required  for

 

         information  purposes  only shall be  wired  to  control

 

         system in the form of non-changeover type contacts.

 

2.03.03.2  The  conditioning  and  processing  functions  to   be

 

         performed  as a minimum for the binary input coming  for

 

         control & information purposes are :-

 

      i) 24  V DC power supply for contact interrogation  for    

 

         all  potential  free contacts with  per  point  fuse    

 

         protection   or  suitable  current  limit   feature/    

 

         isolation  through optocoupler.

 

     ii) Contact  bounce filtering delay time of 15 milli secs.

 

    iii) Facility  for  pegging the binary  signal  to  logic             

 

         one/zero or last correct value in case of failure of    

 

         binary input module.

 

     iv) Binary  signal distribution to different user  shall    

 

         be in such a way so as to ensure that a short/ground    

 

         fault  on  one user is not reflected  to  the  other     

           

         user.

 

      v) Implementation  of multiple measurement schemes  for    

 

         signals for control purpose.

 

     vi) All  binary  signals  shall  be  acquired  validated    

 

         processed, alarm checked and their database updated    

 

         within  1  sec.  In addition  to  this  requirement,    

 

         binary  signals  required  for  SOE  shall  have   a    

 

          resolution of 1 milli sec.

 

      vii)Checking for excessive No.of status changes for  all   

 

          binary/contact inputs.

 

     viii)Facility to delete any binary input from scan or  to     

 

          return to scan on operator demand.

 

      ix) The  non-coincidence monitoring shall  be   provided     

 

          for  binary  inputs  for  all  changeover   signals,     

 

          namely   process  actuated  switches  required   for     

 

          control purpose.

 

       x) All relay contacts shall be hermitically sealed.

         

 

2.03.04       Two out of Three Measurement

 

       a)Triple  measurement scheme for analog  inputs  employing

 

         three  independent  transmitters connected  to  separate

 

         tapping points shall be  employed for the most  critical

 

         measurements used in analog control functions  including

 

         the  following  but not limited to furnace  draft,  feed

 

         water  flow,  throttle  pressure,  turbine  first  stage

 

         pressure,  drum level, drum pressure,  deaerator  level,

 

         turbine  speed.  Turbine control valve  position,  power

 

         measuring  device  LP  &  HP  Heater  Level,  PA  Header

 

         pressure etc.

 

      b) The three signals shall be auctioneered to determine the

 

         median/average  value , which will be  used  for  control

 

         purpose.   In  case  one  transmitter  fails  or   shows

 

         excessive  deviation with respect to others, it will  be

 

         removed from computation of medium/ average value &  the

 

         average  of the other two transmitter outputs  shall  be 

 

         used  for  controls.   The control loop  shall  trip  to

 

         manual  when  any two of the three  transmitter  outputs

 

         shall be used for controls. The control loop shall  trip

 

         to manual when any two of the three  transmitter signals

 

         fail.   The operator shall be able to select any of  the 

 

         transmitters  or   the  median/average  value  from  the

 

         control desk.  The outputs of the transmitters shall  be 

 

         continuously  monitored  for excessive  deviation  which

 

         shall  be   displayed, logged &  alarmed.

    

c)    For MFT/ Turbine/Generator/Unit tripping;Triple Sensor shall

 

   be  provided.

 

d)    For auto starting of pumps, pump tripping due to  very Low

 

   level of water, Triple Sensor shall be provided.

   

2.03.05       One Out of Two Measurement

 

      a) Dual measurement scheme for analog inputs  employing two

 

         independent transmitters, connected to separate tapping

 

         points/  temp.  element  shall  be   employed  for   the 

 

         remaining measurements used for analog control functions.

 

         The  output  of  the  redundant  transmitters  shall  be

 

         continuously monitored for excessive deviation.  In case

 

         the deviation is within limits, the mean value shall  be

 

         used  for the control loop.  If the   deviation  becomes

 

         high  (with  both transmitters remaining  healthy),  the

 

         other  transmitter remains healthy, then the  output  of

 

         the  healthy transmitter shall be used for control.   If

 

         the  other  transmitter also fails, loop shall  trip  to

 

         manual.   The  outputs  of  the  transmitters  shall  be

 

         continuously  monitored  for extensive  operation  which

 

         shall be displayed and logged and alarmed.

 

         Individual transmitter signal, their status and selected

 

         value for control/measurement shall be available on OWS.

 

      b) All sensor other than MFT(Boiler)Tripping,Turbine Tripping,

 

         Generator Tripping etc. for  safety interlock.

 

c)    All pressure/ Temperature/Level Switches in Control loop.

 

d)    All Water/ oil Tank level alarm for Very low.

 

e)    All non critical Measurement for Control loops.

 

f)    Any other service recommended by equipment manufacture or

 

IEC/ISA/ASME/Standard/ code .

 

2.03.06  For  Binary  and  analog inputs required  in  furnace  &

 

         turbine  protection  triple  sensing  devices  shall  be 

 

         provided.  Binary and analog inputs which  are  required 

 

         for  protection of more than one equipment  (e.g.  flame

 

         failure,  deaerator  level very low, etc.)  as  well  as

 

         protection  signals  for  MDBFP,  triple   sensing

 

         devices  shall be provided.  For other  critical  binary

 

         and analog inputs required for protection and  interlock

 

         purpose  of  other  equipment,  dual  sensors  shall  be

 

         provided.

 

2.03.07  Wiring  scheme for inputs to control system shall be  as

 

         follows :-

 

2.03.07.1  Each  of  the dual triple redundant  binary  &  analog

 

         inputs  shall  be wired to separate input  modules.   In

 

         addition,  for functions employing 2V3 controllers  like

 

         BMS/Turbine  protection, each of the redundant binary  &

 

         analog signals shall be  wired to separate input modules

 

         associated   with   each   controller   in   line   with

 

         configuration drawing of BMS & TPS & meeting requirement 

 

         stipulated  under  clauses  2.04.01  of  this   section.

 

         Similarly  each  of the dual redundant binary  &  analog

 

         inputs shall be  wired to separate input modules.  These 

 

         redundant  modules shall be placed in  different  racks,

 

         which   will   have  separately  fused   power    supply

 

         distribution.   Implementation of  multiple  measurements

 

         scheme  of  these  inputs  will  be  performed  in   the

 

         redundant  hardware loss of one input modules shall  not

 

         affect the signal to other module and also other channels

 

         of these modules can be used by other inputs of the same

 

         functional group.

 

2.03.07.2  the single binary & analog signal required for control

 

         purposes shall be wired as follows :-

 

      i) The  limit  &  torque  switches  and  the   MCC / SWGR

 

         check backs  shall  be  wired to  drive  control  modules

 

         wherever  provided.  For the drives where  DCM  are  not

 

         provided,  these  signals shall be  connected  to  input

 

         module only.

 

     ii) Other  single analog & binary inputs shall be  wired  to

 

         single input modules.

 

2.03.08  The binary and analog outputs from one sub-system of the

 

         control  system  to other which are  required  in  these

 

         systems  for  control purposes shall be  made  available

 

         from  triple/dual  redundant binary  and  analog  output

 

         modules.  However, redundancy in binary & analog outputs

 

         to  indicators/ recorders, SERS and  Annunciation  facia

 

         lamps are not required.

 

2.03.09  The   signal   conditioning  functions   like   multiple

 

         measurement  schemes  square root  extraction  for  flow

 

         signals,  pressure  &  temperature  compensation,  limit

 

         value  computation  can  be   performed  either  in  the 

 

         controllers  or in signal conditioning   and  processing

 

         hardware outside  controllers.

 

2.03.10  The  maximum No.of inputs/outputs to be   connected  to

 

         each type of module shall be as follows:-

 

         1.  Analog input module                16

 

         2.  Analog output module               16

 

         3.  Binary input module                32

 

         4.  Binary output module               32

 

         5.  Analog input & output(combined)-    16           

 

         6.  Binary input & output(combined)-    32 

 

             (Note:- For Binary inputs, one changeover contact is

                     counted as 2 inputs)

         Further,  minimum 10% spare channels shall be kept in

    

         each of the input/output modules.

 

2.03.11  The following requirements shall be met :

 

2.03.11.1 Input filters to attenuate noise shall be provided.

 

2.03.11.2  All analog/ binary   input  shall   be   capable   of

 

         withstanding  500 V DC common mode and 500 V AC peak  to

 

         peak.  All analog outputs shall be short circuit  proof.

 

2.03.11.3  Common  mode noise rejection for analog inputs  shall

 

         be  minimum 120 db at 50 Hz.

 

2.03.11.4  Normal  mode  noise rejection for  all  analog  inputs

 

         shall be 60 db at 50 Hz.

 

2.03.11.5  Surge Switch stand as per IEEE 472.

 

2.03.11.6  Any single sensor/transducer/transmitter failure alarm

 

         shall  be provided on I&C maintenance or  program  CRTs

 

         for  all  sensors/transducers/transmitters.    Similarly

 

         sensor break alarm for thermocouples etc. shall also  be

 

         displayed on the CRTs.

 

 

4.CONTROL SYSTEM REQUIREMENTS

Filed under: Uncategorized — shivajichoudhury @ 7:44 am
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2.04.00  CONTROL SYSTEM REQUIREMENTS

 

2.04.00.1  The  control system shall be broadly divided  into  SG

 

         C&I, TG C&I and BOP C&I as already elaborated in  clause

 

         2.01.02.

 

2.04.00.2   The SG C&I system shall perform the following :-

 

         i)   Burner  Management System(BMS)including  control  &

 

              protection of coal mills, fuel oil system etc.

 

         ii)  Analog  control functions pertaining  to  secondary

 

              air    damper   control,   Aux.PRDS   pressure    &

 

              temp.control etc.

 

         iii) Soot Blower Control.

        

2.04.00.3  The  TG  C&I  system  shall  perform   the   following

           functions.

 

         i) Turbine Protection System function(TPS)

        ii) Turbine Governing System for main Turbine

 

       iii) Turbine Stress Control System (TSCS)

 

        iv) Automatic Turbine Testing (ATT)

 

         v) Automatic Turbine Run up System (ATRS)

 

        vi) HP/LP Bypass Control System

 

       vii) Turbine Generator Control System

         

2.04.00.4  The  balance  of plant C&I system  shall  perform  the

 

         following functions:

 

      i) Analog control functions performing to the  other plant

 

         areas  like coordinated master control,  furnace  draft

 

         control, FW flow control etc.

 

     ii) Binary  control  functions  pertaining  to  other  plant

 

         auxiliaries  like FD/ID/PA/APH/BFP etc.  and  electrical

 

         breakers etc.

 

2.04.00.5  The No.of Functional groups(FGs)shown in elsewhere  in

 

         the  specification,  these    are  the   minimum

 

         required.  However, splitting of any functional group in

 

         more  than  one FGs due to any  limitation  in  bidder’s

 

         system  shall  be  acceptable,  subject  to   employer’s

 

         approval.  For  each  of  the  FGs,  separate  sets   of

 

         controllers,  I/O  modules,  communication  controllers,

 

         power  packs/modules etc. shall be provided.  Mixing  of

 

         hardware  of  two or more FGs shall not  be  acceptable.

 

         2.04.00.6  The minimum functions to be  realized in each

 

         of the above-mentioned controls systems shall be  as per

 

         requirements specified  under subsequent clauses of this

 

         specifications.    The   bidder   shall   provide    all

 

         hardware/software, whether or not specifically indicated

 

         in   this  specification  to  fully  meet   operational/

 

         maintenance/  safety requirement as well  as  statutory/

 

         international standard and proven practices.

 

2.04.00.7  The  control system shall function reliably under  the

 

         environmental  conditions  as  specified  under   Part-C

 

         “General  Technical Requirement” of this  specification. 

 

         It shall be immune from the interferences resulting  from

 

         disturbances  in  power  supply  feeders  signal  lines,

 

         inputs,  outputs  etc. as experienced in  a  coal  fired

 

         power station.

 

2.04.00.8  The  control system shall have  on line  simulation  &

 

         testing  facility.  Further, it shall be possible to  on

 

         line configure & tune controllers through  configuration

 

         & tuning station for control system.

 

2.04.00.9  The  system  shall have  the  flexibility  to  easily

 

         reconfigure any controller at any time without requiring

 

         additional  hardware or system wiring changes &  without

 

         disabling  other  devices from  their  normal  operation

 

         mode.   Modifications  shall not require  switching  off

 

         power to any part of the system.

 

 

2.04.00.10  The remote manual operation from   hardwired  back-up

 

         A/M   stations   &   push    button(PB)stations(wherever

 

         provided)shall   be  independent  of   availability   of

 

         controllers & power supply to controllers.

 

2.04.00.11   The executive  programs for the  controller  modules

 

         shall be  firmware based, which shall be non-volatile  &

 

         shall  not be alterable except by replacement of  parts. 

 

         The application programs for the  functional controllers

 

         shall  be   software based which  shall  be   maintained

 

         through  power supply failure.  The application  program

 

         shall be  alterable through the configuration and tuning

 

         station  for  all configuration and   strategy  changes,

 

         etc.   and   through  the  operator’s  console  for  set

 

         point/  bias  changes,  device  selection,  etc.   Parts

 

         replacement  or parts removal shall not be  required  in

 

         order  to  accomplish changes  in  application  programs

 

         including system tuning.

 

2.04.00.12  All the 100% hot/redundant  back-up controllers shall

 

         be identical in hardware and software implementation  to

 

         their corresponding main controllers & shall be  able to

 

         perform  all  its tasks. The  back-up  controller  shall

 

         track its corresponding main controller.  There shall be

 

         an  automatic  and  bump less switchover  from  the  main

 

         controller  to its corresponding back-up  controller  in

 

         case  of main controller failure and vice versa  without 

 

         resulting  in any change in control status.  In case  of 

 

         switchover from main controller to the 100% hot  back up

 

         controller,  the  back-up controller shall work  as  the

 

         main controller.

 

         Facility  shall also be provided for  manual  switchover

 

         from main to 100% hot back-up controller and vice  versa

 

         from the programmer’s console.

 

2.04.00.13  The control system hardware design shall be such that

 

         it is able to withstand power line disturbances.

 

2.04.00.14  The  control system for  SH/RH  Attemp.  Temp.control

 

         shall be  state controller with observer.

 

2.04.00.15 The hardware design shall be such that  it is able to  

         withstand power line disturbance.The system shall conform

         to ANSI/IEEE C 62.4 (Immunity to power supply line disturbance). 

 

2.04.01  BURNER MANAGEMENT SYSTEM (BMS)

 

2.04.01.1  Fully  proven microprocessor based system,  based   on

 

         hardware  and software specifically designed and  proven

 

         for  Burner  Management application for the  same  being

 

         offered  for  shall be provided to  achieve  the  Boiler

 

         protection action e.g.master fuel trip(MFT), control  of

 

         mills  &  fuel  oil  systems etc.  BMS  shall  meet  all

 

         applicable  relevant safety requirement including  those 

 

         stipulated in NFPA- 8502.

 

2.04.01.2  The   BMS  shall  be  provided  with  automatic   self

 

         monitoring  facility.  All modules to be  used  in  this

 

         system  shall be of fail-safe design.  Any single  fault

 

         in  either  primary sensor, I/O  modules,  multifunction

 

         controllers  etc.  should not result in loss  of  safety

 

         function.   All  faults  should be  annunciated  to  the

 

         operator  right  at the of its occurrence  and  also  for

 

         alarm annunciation facia.

 

2.04.01.3  The MFT  functions shall be  implemented  in  a  fault

 

         tolerant 2 out of 3 triple redundant configuration. Each

 

         of  the  three independent channels shall have  its  own

 

         dedicated    processors,   multifunction    controllers,

 

         communication  controllers, I/O modules, interface  etc.

 

         All  safety related process inputs shall be fed to  each

 

         of   the  3  channels.  All  the  primary  sensors   for

 

         unit/boiler  protection shall be  triple  redundant.

        

2.04.01.4 The  acquisition and conditioning of binary and  analog

 

         protection criteria signals for MFT shall be carried out

 

         in  each of the three triple redundant  channels.   Each

 

         channel  shall compute  the 2 out of 3 voting logic  and 

 

         issue  a  trip command.  The trip signals of  the  three

 

         channels  shall  be  fed  to a fail 2  out  of  3  relay

 

         tripping  unit for each drive. The  protection  criteria

 

         for tripping shall be executed by a  program which shall

 

         be  identical in each of the triple  redundant  channel. 

 

         The  check back contact signals of each relay of  the  2

 

         out of 3 relays tripping unit shall be  fed back to  each

 

         of   the   triple   redundant  channels   &   shall   be 

 

         continuously monitored for equivalence in each of them.

 

2.04.01.5  The functionality of operation of mills. oil etc.shall

 

         be  similar to that of OLCS described in clause  2.04.03

 

         below.

 

2.04.02  TURBINE PROTECTION SYSTEM (TPS) FUNCTIONS

 

2.04.02.1 Fully  proven  microprocessor based  system,  based  on

 

         hardware and software specifically designed for  Turbine 

 

         protection  application  for  the  same  turbine   being

 

         offered  for this project, shall be provided to  achieve

 

         the turbine protection action.

 

2.04.02.2  The   Turbine   protection  system  shall   meet   all

 

         applicable safety standards/requirements including those

 

         stipulated.

 

         The system design shall be such that safety function  of

 

         the  total system must not be jeopardized on  occurrence

 

         of  fault.  Any single fault in either  primary  sensor,

 

         input/ output modules, controller  module etc. shall  in

 

         no  way  jeopardized  the safety of  the  turbine.   All

 

         modules to be used in this system shall be of fail  safe

 

         design.

 

2.04.02.3       Bidder  shall provide two independent  trip  channels,

           each having  its  dedicated  processing   module with 

           hot back up. Two out  of  three  voting  logic   will 

 

           be  implemented  in  each  of  the  channels  and  the

 

           output of each channel to be  fed  to each of the  two

 

           turbine trip relays.

 

        

2.04.02.4  All  the  input signals (trip signals  etc.  from  the 

 

         field  devices)  shall  be fed in parallel  to  all  the

 

         three/ both the redundant channels of protection  system

 

         as   mentioned  above  via  signal  conditioning   cards

 

         designed for such application.  Further, the computation

 

         of field input voting logics i.e. 2 out of  3 etc. shall

 

         also  be performed in the controllers of all the  three/

 

         two  channels  of  protection  system , which  will  then

 

         perform  the  computation of field input  voting  logics

 

         i.e.  2  out  of 3 etc.shall also be  performed  in  the 

 

         controllers of all the three/two channels of  protection

 

         system, which will then perform the computation of 2  out

 

         of 3 voting logic independently.

 

 

2.04.02.5  Bidder shall provide all the required primary  sensors

 

         etc. required for protection system as per his  standard

 

         and   proven practices.  All trip signal input  required

 

         for the safety of the turbine shall be be based on 2 out

 

         of 3 logics.

 

2.04.02.6  The  system  shall include  turbine  lock-out  relays,

 

         redundant turbine trip solenoids and  necessary hardware

 

         required for testing.

 

         The tripping devices shall be designed to operate on  DC

 

         supply.  The trip coils shall be monitored  continuously

 

         for healthiness and failure  shall be alarmed.

 

2.04.02.7 Turbine  Protection  System shall meet  all  applicable

 

         relevant safety  requirement including those  stipulated

 

         in ASME- TDP-1, VDE 0116, Sec8.7; VDE 0160 etc.

 

2.04.02.8  TURBINE STRESS CONTROL SYSTEM (TSCS)

 

         Bidder   shall provide a proven Turbine  Stress  Control

 

         system  which  will  work in  conjunction  with  turbine

 

         governing  system  and ATRS and  achieve  the  following

 

         functional requirements.

 

      a) Continuous  on-line monitoring of thermal stress  levels

 

         in  all critical parts of the turbine such as main  stop

 

         valves, control valves, HP casing, HP shaft and IP shaft

 

         etc.

 

       b) Continuous  on  line  computation  of  stress   margins

 

         available for the above mentioned critical components of

 

         the  turbine  during various regimes of  operation  i.e.

 

         run-up,  synchronization,  loading,  load   maneuvering,

 

         normal operation, run backs, unloading, shutdown etc.

 

       c) Computation  of  the limits of speed and  load  changes

 

         allowable    at    any   particular    instant    before

 

         synchronization and after synchronization respectively.

 

       d) Carry   out  a  fatigue  analysis  for   all   affected

 

         components  of  the  turbine and also  to   compute  the

 

         percentage service life consumption of the turbine.

 

       e) Display the stress margins etc. on a separate dedicated

 

         colour  VDU/  Printer  as well as on  OWS  for  operator

 

         guidance   and  storage  of  necessary  data   such   as

 

         percentage service life consumption etc.

 

       f) Store  long  term  data  &  carry  out  Residual   Life

 

         Analysis.

 

         The   system  shall  be  complete  including   measuring

 

         transducers  for generator load and wall temp.  measured

 

         value    processing   modules,   microprocessor    based

 

         controllers  for  stress calculations and  turbine  life

 

         calculations etc. dedicated colour  CRT monitor etc.

 

 

2.04.03  BINARY CONTROLS/OPEN LOOP CONTROL SYSTEM(OLCS)FUNCTION

 

2.04.03.1  The  OLCS shall include sequence control, interlock  &

 

         protection   for  various  plant  auxiliaries/   valves/

 

         dampers/ drives etc.  The sequence control shall provide

 

         safe and  automatic  startup and shutdown of plant   and

 

         of  plant  items  associated with a  plant  group.   The

 

         interlock  and  protection  system  shall  ensure   safe 

 

         operation  of  plant/ plant items at all times  &  shall

 

         automatically  shut down plant/ plant items when  unsafe

 

         conditions arise.

 

2.04.03.2  The  OLCS  shall  be  arranged  in  the   hierarchical

 

         control structure consisting of unit level group  level,

 

         subgroup level & drive level(as applicable).

 

         It shall be possible to perform automatic unit startup &

 

         shutdown by issuing minimum No.of command from the  OWS.

 

         Thus,  the  unit  level shall control  all  the  control

 

         system  blocks and issue appropriate startup &  shutdown

 

         commands to various blocks of control system.

 

         The  group level shall control a set of functional  sub-

 

         groups  of  drives. Appropriate start-up and  shut  down

 

         commands  shall  be issued to the  sub-group  control  &

 

         various check backs shall be received from  sub-groups or

 

         drives.   Each  sub-group shall execute  the  sequential

 

         start-up   and  shut  down  programme  of  a   set   of

 

         inter-related  drives  along with system  interlocks  and

 

         protections  associated with that sub-group as  well  as

 

         basic  interlocks  & protections related  to  individual

 

         drive  falling  under that sub-group.  The  drive  level

 

         shall accept commands from the sub-groups, push  buttons

 

         etc.  &  transmit them to the  respective  drive,  after

 

         taking into account various interlocks & protections and

 

         the safety of that particular drive.

 

2.04.03.3  Sequence Control

 

2.04.03.3.1   A sequence shall be  used to move a set of  groups, 

 

         sub-groups  from an initial steady state  (for  instance

 

         `OFF’) to a final steady state (for instance `ON’).  The

 

         sequence  initiating command for the  unit & group level

 

         shall be issued from CRT/KBD.

 

2.04.03.3.2  A sequence shall be  made of steps. The steps  shall

 

         be  executed in predetermined order according  to  logic

 

         criteria and monitoring time consisting of the interlock

 

         & protection requirements and check back of previous step

 

         which  shall act as preconditions before  the  sequence 

 

         control   can  execute  the  command  for   that   step.

 

2.04.03.3.3  Each step shall have a “waiting time” implying  that

 

         the  subsequent  step would not be executed  unless  the

 

         specified time elapses.  A monitoring time shall also be 

 

         defined as  the maximum time required  in executing  the

 

         commands   of  any  step  and  the  time  required   for

 

         appearance of checks backs signals.  In case, this is  not

 

         completed within the  specified time, a message shall be 

 

         displayed and program will not proceed further.

 

2.04.03.3.4   Manual intervention shall be possible at any  stage

 

         of operation and the sequence  control shall be able  to

 

         continue at the correct point in the  program on  return

 

         to  automatic control.  Protection commands  shall  have 

 

         priority over manual commands, and manual commands shall

 

         prevail over auto commands.

 

2.04.03.3.5  Open or close priority shall be  selectable for each

 

             drive.

 

2.04.03.3.6   The  sequence  start-up  mode  shall  be  of   the 

 

              following types.

 

      i) Automatic Mode

 

         In this mode of operation, the  sequence  shall progress

 

         without  involving  any action from the  operator.   The

 

         sequence  start/stop command shall be  issued  from  the 

 

         CRT/KBDs.

 

     ii) Semi-Automatic Mode

 

         In  this  mode  of   operation,  once  the  sequence  is

 

         initialized,  the  step progressing shall be   displayed

 

         on  the  CRT.  But the step execution command  shall  be

 

         prevented  and  shall be  sent by the operator  via  the

 

         keyboards.   It  shall  be possible to  bypass  and/  or 

 

         simulate  one or more criteria to enable the program  to

 

         proceed.   This facility shall allow the program  to  be 

 

         executed even if some criteria are not fulfilled because

 

         of  defective  switching device, etc. while   the  plant

 

         condition is satisfactory. It shall be  possible to  put

 

         the system on the Auto-mode after operating it on  semi-

 

         automatic  mode  for some steps or  vice-versa,  without

 

         disturbance to the  sequence operation.

 

    iii) Operator Test Mode

 

         It shall be  possible top use the sequential control in

 

         operator guide mode/ test mode i.e. the complete  system

 

         runs   &  receives  input  from  the   plant   and   the 

 

         individual   push  button  stations  (where   provided)/

 

         keyboards  but its command output is blocked. the  whole

 

         program,  in this case shall run in manual  mode.   This

 

         mode  shall  allow  the  operator  to  practice   manual

 

         operation  using  step and  criteria  indications.   The

 

         actual  protection should remain valid during this  mode

 

         of operation also.

 

2.04.03.4  The sequence shall be  started by putting the sequence

 

         on `Auto’ and on receipt of `Start’ command from the OWS

 

         or  from  a  higher level group/  protection  action  as

 

         defined.   The sequence shall then progress as  per  the 

 

         defined  logics.   It  should  be  possible  to   select

 

         alternative operation in the same sequence depending  on

 

         certain process/ equipment condition.  Some step can  be 

 

         automatically  bypassed also based on  certain  process/

 

         equipment  condition.  When the expected results of  the 

 

         sequence is reached the sequence is considered as ‘End’.

 

2.04.03.5  If  during   sequence   initialization   or   sequence

 

         progressing  or  during normal running of the  drive,  a

 

         shutdown  criteria  is present, the  sequence  shall  be

 

         stopped and the shutdown sequence initiated.    

 

2.04.03.6  For  the drives, the command shall be provided  through

 

         redundant O/P module and inputs (Status, SWGR & process)

 

         shall  be acquired through input modules.  The inputs  &

 

         output  modules used in relation to drives shall not  be 

 

         mixed   with   inputs  &  output  modules   for    other

 

         applications.   The drive logic shall be implemented  in

 

         the  redundant controller.

 

         The  status  of the HT drives and some  other  important

 

         drives(total approximately 40 Nos. per unit)shall  also

 

         be wired in parallel to redundant input modules so  that

 

         on failure of the single input modules, the  information

 

         regarding   the  status of the  affected  drive  remains

 

         available in OLCS.

 

2.04.03.7  The  output  modules  shall  have  the   feature  that 

 

         ensures  that  in case of failure, all the  outputs  are

 

         driven  to zero.  The 24 V DC command outputs to  drives

 

         for   ON/  OPEN,  OFF/  CLOSE  shall  be  separate   and

 

         independent   and   inverted  outputs   shall   not   be 

 

         employed.   For   inching  type  of   drives,   position

 

         transmitter  power  supply and  monitoring  of  position

 

         transmitter  signal  shall be provided.

 

 

2.04.03.8  The termination for OPEN/ CLOSE command for the  drive 

 

         actuator  shall be performed in the actuators  specified

 

         elsewhere  in the specification.  However,  OPEN/  CLOSE

 

         and disturbance status as a minimum shall be   monitored

 

         in OLCS.

 

2.04.03.9  The sequence interlock & protection requirements shall

 

         be  finalised during detailed engineering and the   same

 

         shall be subject to employer’s approval.

 

2.04.03.10    The  OLCS  shall  also  include  the   control   of

 

         electrical  systems  in addition to the  auxiliaries  of

 

         boiler  &  turbine performing functions such  as   OPEN/

 

         CLOSE or ON/ OFF etc. of various electrical systems such

 

         as  breakers and isolators, raise/ lower  for  equipment

 

         like transformers tap changer, synchronization of  unit,

 

         etc. All the features and specification requirements  as

 

         specified above shall also be applicable for  electrical

 

         system.    Control  and  all  the  operation  shall   be 

 

         performed  through  CRT/KBDs  of  OWS.   However,   100%

 

         hardwired  backup  miniaturized switches shall  also  be

 

         provided on UCP for electrical systems.

 

2.04.03.11       Operator Interface for SIS & Sequence Control

 

         Following status information shall be available to operator 

         on OWS or Console.

      i) Where the process is in its sequence.

     ii) Indication that SIS protective action has occurred.

    iii) Indication that protective action is bypassed.

     iv) Status of sensors, final drive, diagnostic  features etc.

 

2.04.04 ANALOG CONTROLS/ CLOSED LOOP CONTROL SYSTEM(CLCS)FUNCTIONS

 

2.04.04.1  The CLCS shall continuously act on valves, dampers  or

 

         other  mechanical  devices such as  hydraulic  couplings

 

         etc.which  alter  the plant operation  conditions.   The

 

         system  shall be designed to give stable control  action

 

         in steady state condition and for load changes in  step/

 

         ramp  over  the  load  range of 60%  to  100%  MCR  with

 

         variation or parameters within permissible limits to  be 

 

         finalised during detailed engineering state.  The system

 

         shall have  the following minimum features.

 

2.04.04.2  The  loop reaction time (from change of output of  the 

 

         sensor  of the transmitter/ temperature element to   the 

 

         corresponding  control command output) shall  be  within

 

         500  m/secs.   However, for faster loops  such  as  feed

 

         water,  furnace draft, P A header pressure control  loop

 

         etc.  the  same  shall  be   based  on  actual   process

 

         requirement but shall not be more than 250 milli secs. The loop response time shall be as per IEEE-1046.

 

2.04.04.3 The control system shall be bumplessly transferred  to

 

         manual on the  following conditions as a minimum and  as 

 

         a minimum and as finalised during detailed engineering.

 

         Control  power  supply  failure,  failure  of  redundant 

 

         controllers,  field input signal  not available,  analog

 

         input exceeding preset value etc.

 

2.04.04.4  Any  switch over from auto to manual, manual  to  auto

 

         and  switchover  from  CRT  operation  to  H/A   Station

 

         operation  and  vice versa shall be bumpless  &  without

 

         resulting  in any change in the  plant  regulations  and

 

         the  same shall be reported to the operator.

 

2.04.04.5  Buffered  analog output of 4-20mA DC shall be  provide 

 

         from   CLCS  to  the  respective  E/P  converters.   For

 

         electrical   actuators,  type  output(bound   less

 

         control)  shall be preferred.  CLCS shall  also  provide

 

         all the necessary outputs for indicators& recorders with

 

         output  loop resistance of 500 Ohms for each channel  of

 

         the  output module.

 

         For  the drives, the command shall be  provided  through

 

         redundant  O/P  module and inputs(position feed  back  &

 

         process)  shall be acquired through input modules.   The

 

         inputs & output modules used in relation to drives shall

 

         not  be  mixed with inputs & output  modules  for  other

 

         applications.   The drive logic shall be implemented  in

 

         the redundant  controller.

 

2.04.04.6  The functional requirement of the CLCS loops as well as 

 

         the detailed schemes shall be finalised during  detailed

 

         engineering  stage and shall be  subject  to  employer’s

 

         approval.

 

2.04.04.7  The  system  being supplied shall be  such  that  when

 

         permissible limits are exceeded, an automatic switchover

 

         from an operation governed by maximum efficiency, to  an

 

         operation   governed  by  safety  and  availability   is 

 

         effected.

 

2.04.04.8  For safety reasons, switchover logics associated  with

 

         the  modulating control loops, shall be performed within

 

         the closed loop control equipment.

 

2.04.04.9  Where  the  equipments are controlled by  a  group  of

 

         regulators  acting  in parallel, the  relative  position

 

         of  individual  actuator associated with them  shall  be

 

         capable  of being adjusted with respect to  one  another

 

         and to the common automatic signal.

 

2.04.04.10   Time  supervision  facility  shall  be  provided  to

 

         monitor the final control element.

 

2.04.04.11  It shall be possible to block the  controller  output

 

         on a pre-programmed basis.

 

2.04.04.12   All  controllers shall be freely  configurable  with

 

         respect  to requisite control algorithms.

 

2.04.04.13   Whenever,  alternate measurement is available  for  a

 

         control  input the alternate measurement value  will  be 

 

         automatically  substituted in the  control loop in  case 

 

         of  loss of control input.  All necessary  software  for

 

         switching  and reconfiguration shall be   provided.   In

 

         addition,  such  substitution shall be  balance less  and

 

         bumpless and shall be reported to the operator.

 

2.04.05  HP/LP BYPASS SYSTEM

 

2.04.05.1  LP BYPASS CONTROL SYSTEM

 

         The  LP  Bypass control system shall consists  of  steam

 

         pressure control loop and steam temp.control loop.   The

 

         LP Bypass control shall be implemented through a set  of

 

         redundant  controller modules, I/O modules etc.  The  LP

 

         Bypass  control shall suitably interface with  other  TG 

 

         control  like  HP  Bypass, EHG  etc.  Further  condenser

 

         exhaust  hood spray valve shall be  interlocked to  open

 

         whenever LP Bypass comes into operation.

 

2.04.05.2  HP BYPASS CONTROL SYSTEM

 

      a) The  system  shall consists of steam  pressure   control

 

         loop & steam temp.control loop.  HP Bypass system  shall

 

         be   implemented through  a set of redundant  controller

 

         modules, I/O modules etc.  The system shall be  supplied

 

         with redundant 2 out of 3, primary sensor & suitably

 

         interface  with other TG C&I controls like LP Bypass, EHG

         etc.

 

      b) HP Bypass system shall conform to ANSI/ISA 77.13.01.

 

2.04.05.3  OTHER SG C&I FUNCTIONS

 

         The SG control functions shall also consist of Secondary

 

         Air  Damper Control soot blower control, Auxiliary  PRDs

 

         etc.  in  addition to the burner Management  system  and

 

         described above.

2.04.05.4  OTHER T G C&I FUNCTIONS

 

         The TG control functions shall also, consist of  Turbine

 

         Generator  control system like seal oil, primary  water,

 

         hydrogen system etc. interlock & protection.

 

5. Man Machine Interface

Filed under: Uncategorized — shivajichoudhury @ 5:48 am
Tags: , , ,

2.05.00  MAN-MACHINE INTERFACE SYSTEM AND PLANT INFORMATION  

         SYSTEM (MMIPIS) REQUIREMENTS

 

 

2.05.01  Man-Machine  interface  system  shall  be  designed  and 

 

         engineered for safe, efficient, reliable and  convenient

 

         operation.   MMIPIS shall employ high-performance,  non-

 

         proprietary  architecture  to ensure   fast  access  and 

 

         response  time  and  compatibility  with  other  system. 

 

         MMIPIS  shall  be  used  primarily  for  the   following

 

         functions.

 

      a) As operator interface for control operation of the plant

 

         or  accepting data from and issuing commands to SG  C&I,

 

         TG C&I and Station C&I system etc.

 

      b) To perform plant supervisory, monitoring and information

 

         functions.  The plant data pertaining to are unit  shall

 

         be available in the MMIPIS of the  respective unit. Data

 

         from common system shall be available in the  MMIPIS  of

 

         both units.

 

2.05.02  OPERATOR INTERFACE TO THE CONTROL SYSTEM

 

2.05.02.1  The operator interface of the MMIPIS shall consist  of

 

         21 inch colour TFT Monitor/KBDs of OWS (Operator Work

 

         Station), colour Laser Printers, large video screen(LVS), 

 

         console etc. Each Operator  workstation (OWS) shall include

 

         one  TFT Monitor, one keyboard and touch screen or mouse for 

 

         ease of operation. The TFT Monitor operation  shall  employ 

 

         powerful menu-driven  and window supported input facilities 

 

         for operational ease and comfort.

 

         No   single  failure  in  MMIPIS  shall  lead   to   non

 

         availability of more than one OWS and two printers.   In

 

         such  an  event  i.e., single  failure  leading  to  non

 

         availability of any OWS, it shall be possible to operate

 

         the  entire plant in all regimes of operation  including

 

         emergency  conditions from each of the  other  available

 

         OWS. 

 

         Operator functions displays, structure of the   keyboard

 

         assembly  and key assignment shall be  finalised  during

 

         detailed  engineering.   Further all  frequently  called

 

         important functions including major control loop display

 

         shall  be  assigned to dedicated function keys  for  the

 

         convenience of the operator.

 

2.05.02.2  (a) Operator Functions

 

         The operator functions for control on each OWS shall  as

 

         a   minimum  include  control  system  operation,  alarm

 

         acknowledge, call control displays, demand/ printout  of

 

         various displays, logs, summaries etc.

 

         The display selection process shall be optimized so that 

 

         the  desired display can be  selected with  the   barest

 

         minimum  No.of key strokes/ steps by the  operator. 

 

         The  control  related  display on the  CRT/ TFT Monitor 

 

         shall  as  a  minimum include mimic displays, overview

 

         displays, area displays,  individual loop/ drive display, 

 

         closed  loop control displays, open loop control displays

 

         etc. Operator’s   function   allowed   the    control of

 

         drives/equipments,  viewing  of all  displays,  changing

 

         certain  pre-selected parameters like set  points,  bias

 

         etc. printing of report.

 

         However   following   functions  are    prohibited   for

 

         operator.

 

     (i) Modification  of  control  parameters.  Modification  of

 

         logic/loops/  data  base/ MMI or software.

 

    (ii) Changing of assignments of logs & trend etc.

 

     (b) Programmer Functions

 

         The programmer (Administrator) functions allows  viewing

 

         of  all display, changing of all set  points, bias  etc.

 

         printing  of  all report, modification of   all  control

 

         loops/logic/data  base  and  values.   Modification   of

 

         MMIPIS software.

 

2.05.03  PLANT SUPERVISORY, MONITORING & INFORMATION  FUNCTIONS

         OF MMIPIS 

 

         The MMIPIS shall be designed as an on line system  which

 

         shall  process, display & store information  to  provide

 

         the  operator,  either automatically or on  demand,  the 

 

         relevant information as indicated in subsequent clauses.

 

         The following functions shall be performed by MMIPIS  as

 

         a minimum.

 

2.05.03.1  BASIC CALCULATIONS           

 

          All  the  algebraic/logical  calculations  related   to

 

         analog  points(e.g.   sum/difference/average/integration

 

         etc.) digital point, transformations, flow calculations,

 

         time   projection  or  rate  of   change   calculations,

 

         frequency  etc.shall  be provided.  All  the  calculated

 

         values of the plant shall be available in the database.

 

2.05.03.2  PERFORMANCE CALCULATIONS

 

      a) The  performance  calculations  shall  use  FORTRAN   or

 

         equivalent  high-level language.  An extensive  set  of

 

         steam  property  sub-routines based on 1967  ASME  steam

 

         tables   shall   be   included  in  the   system.    The

 

         calculation  shall  be carried out at 30% unit  load  or

 

         higher. The calculation frequency shall be selectable at

 

         site  from  10  minutes to 1 hour, with  a  step  of  10

 

         minutes.  The performance calculations shall be  broadly 

 

         subdivided into two classes.

 

         Class I : Equipment protection calculations

 

         Class II: Plant/ equipment efficiency calculation.

 

     b)  The Class I calculations are generally for the   purpose

 

         of detecting & alarming unit malfunctions. 

 

         These  shall  include  cold  reheat  steam  approach  to

 

         saturation  temp.SH spray outlet approach to  saturation

 

         temp.  turbine  steam metal temp.  differences,  turbine

 

         metal temp. rates of change, feed water heater  terminal

 

         temp.difference,   feed   water  heater   drain   cooler

 

         approach and LMTD,excess air deviation from standard, feed 

 

         water heater temp. deviation  from  standard,  drum   water

 

         saturation  temp.rate of change, metal temp.  difference

 

         for SH `Y’ and RH `Y’ piece etc.

 

      c) The   class-II   performance   calculations   shall   be 

 

         performed  to  determine the performance  of  individual

 

         items   of  equipment  and  the   overall   unit.    The

 

         periodicity  of this calculation shall  be   selectable

 

         from  10  minutes  to 60 minutes  in  increments  of  10

 

         minutes.   These shall include calculations  for  Boiler

 

         efficiency,  Gross  turbine generator heat  rate,  gross

 

         unit  heat  rate, net unit heat rate,  operating  hours,

 

         plant   load/availability  factors,   HP/IP/LP   turbine

 

         enthalpy drop efficiency, condenser/deaerator/economizer

 

         performance,  air heater performance, unit  availability

 

         calculations, deviation from expected  values  for  each

 

         calculation  shall  also  be computed.  The performance

 

         calculation shall be  as  per following ASME code or BS

 

         standard.

 

      i) Boiler  Efficiency  – BS-2885(By Heat  Loss Method)  

     ii) Steam Turbine       – ASME  PTC-6

    iii) Air Pre- Heater     – ASME  PTC-4.3

     iv) Feed Water Heater   – ASME  PTC-12.1

      v) Deaerator           – ASME  PTC-12.3

     vi) Condenser           – ASME  PTC-12.2

 

2.05.03.3 All the primary  instruments, cable, hardware,  software

 

         whatever    required   for    efficiency/    performance

 

         calculations shall be in the Bidder’s scope.   

 

2.05.03.4 Other Calculations

 

         Variable alarm limit calculations, heat rate deviations

 

         and  revenue  calculations,  frequency  excursion   time

 

         integration etc.shall also be provided.

 

 

2.05.03.5  Alarm Monitoring and Reporting

 

         The   system   shall  display  history  of   alarms   in

 

         chronological order of occurrence on any of the OWS.   The

 

         MMIPIS  shall have the capability to store a minimum  of

 

         1000  alarms pages, each with paging  features  allowing

 

         the  operator to view any page.  The OWS keyboard  shall

 

         have all alarm functions and related function keys  like

 

         alarm acknowledge, reset, paging, summaries etc.   Other

 

         design  features  like prioritization, set  point/  dead

 

         band  adjustments, alarm report format etc. shall be  as

 

         finalised during detailed engineering.

 

2.05.03.6  Displays    

 

         Various displays on the CRTs shall as a minimum  include

 

         P & ID displays or mimic, bar chart displays, X-Y &  X-T

 

         plot(trend)   displays,   operator   guidance    message

 

         displays,   group  displays,   plant   start-up/shutdown

 

         message displays, generator capability curves, heat rate

 

         deviation  displays, system status displays  etc.  No.of

 

         displays  and  the  exact functionality shall  be  on  a

 

         required   basis  and  as  finalised   during   detailed

 

         engineering.     

 

         Other types of displays as applicable for convenience of

 

         operation  shall  be provided by Bidder.   However,  the 

 

         minimum quantity of major types of displays shall be  as

 

         follows:-

 

         a) Control displays(group/sub-group/               500

            sequence/loop)

         b) P&ID/ mimic display                             300

         c) Bar chart                                       100

         d) X-Y/X-T Plot                                    200

         e) Operator guidance message                       100

         f) Plant starting/ shutdown guidance message       100

         g) Other Misc. Display                             100

         h) System status & other diagnostic on as required  

            basis display.

 

         The  system  shall have adequate  storage  capacity  for

 

         storing the last 72 Hrs.of data at scan rate 1 sec.for a

 

         minimum  500 Analog points(operator selectable  for  use

 

         in trend displays.

 

         The  system  shall have adequate  storage  capacity  for

 

         storing  the last 8 hrs.of data at scan rate  1  Min.for

 

         all  analog  points of unit and status changes  of  1000

 

         binary points.

 

2.05.03.7  Logs/ Summaries

 

         The   system  shall  generate  three  basic   types   of

 

         reports/logs  i.e. Event activated, time  activated  and 

 

         operator  demand  log & summaries.  The log  format  and

 

         point  assignment for each logs/report and other  design

 

         features  shall  be as finalised during  detailed  Engg. 

 

         The system shall have the  facility for viewing of  time

 

         activated  and  operator demand logs/ summaries  on  the

 

         MMIPIS CRT(s).

 

      a) Event Activitated

 

         The trip analysis log shall record a minimum of 30

 

         pretrip  and 30 post-trip readings for  the  pre-defined

 

         parameters  but  not less than 250  points,  sub-divided

 

         into  25  groups.  The data collection  rate  shall  be

 

         variable,  i.e. faster near the trip point and  gradually

 

         slower with time.  The exact details shall as finalised

 

         during detailed engineering.

 

         The  system shall be capable of generating and  printing

 

         SG & TG start-up shutdown logs.

 

       b) Time Activated

 

         Time  activated logs shall as a minimum include  hourly,

 

         shift  log and daily log.  Each of these  shall  provide

 

         hourly  record of a minimum 100 points sub divided  into

 

         10 groups.

 

       c) Operator Demand Log

 

         Operator demand logs shall include, as a minimum,  trend

 

         log, maintenance data log, summary log, performance logs

 

         and some special logs as decided during detailed

 

         Engineering stage.

 

         The system shall be  capable of generating and  printing

 

         trend log for a minimum  of 80 groups of 15 points each.

 

         Maintenance   data   log  shall  provide   schedule   of

 

         preventive    maintenance   and    routine    equipments

 

         inspection.

 

       d)Various  summaries  shall  include  off  scan   summary,

 

         constants  summary, point quality  summary,  substituted

 

         values summary, peripheral status summary etc.

 

       e)The  assignment of logs to any of the printers shall  be 

 

         possible  from  MMIPIS CRTs/  keyboards  and  programmer

 

         station.

 

2.05.03.8  Log Generation Utility

 

         The  Bidder  shall  offer a log  generation  utility  to

 

         generate  a log/report having following facilities as  a

 

         minimum.

 

      a) Define format of the log like header information,  time,

 

         date etc.                 

 

      b) Selection  of  any point(scanned &  calculated)from  the

 

         data base and assign it to a log group.

 

      c) Selection  of  log data  collection  process  initiating

 

         event, collection intervals(1,2,3,5,10,30 & 60 minutes)

 

         for each point of a particular log group. Facility shall

 

         also  be   provided  for selection of 100  points  at  a

 

         collection intervals of 1,2,3,5,10,20,30 seconds.

 

      d) Assignment  of log printout initiation on event or  time

 

         including,  selection  of  the   printing  interval  for

 

         particular  log  group and time  of  printing.(For  time

 

         initiated logs).

 

      e) Assignment  of  No.of samples to be collected  for  each

 

         point.

 

      f) Select  points for which minimum,  maximum  accumulation

 

         over  a  selected  period, average etc.  values  can  be

 

         printed.   Also facility shall be  provided to  tag  the

 

         time    at   which   the   parameter   passed    through

 

         maximum/minimum.

 

         It  shall  be  possible to define 100 log groups  of  15

 

         points each.  Any log group can have any point  from the 

 

         Database.  One log shall include at the maximum 10 such

 

         groups.

 

2.05.03.9  Historical Storage and Retrieval System(HSRS)

 

         The   HSRS shall collect, store and process system  data

 

         from MMIPIS database.  The data shall be saved on  line

 

         on  hard disk and automatically transferred to  erasable

 

         dual Magneto-optical disk (removable type)once in  every

 

         24 hours periodically for long-term storage.   Provision

 

         shall be made to notify the  operator when optical  disk

 

         is  certain percentage  full. 

 

         The data to be stored in the above system shall  include

 

         alarm  and  event list, periodic  plant  data,  selected 

 

         logs/report such as event activated logs, trip  analysis

 

         log,  start-up  log  etc. The data/  information  to  be 

 

         stored & frequency of storage and retrieval shall be  as 

 

         finalised during detailed engineering.

     

         The  system shall provide operator function to  retrieve

 

         the data from historical storage. The operator shall  be

 

         able to retrieve the selected data on OWS and any  other 

 

         CRT which are  connected with system  bus or printer and

 

         suitable  index files/ directories shall be provided  to

 

         facilitate the same.

 

         In  addition  to  the HSRS the system  shall  also  have

 

         facility to store & retrieve  important plant data for a

 

         very long duration(plant life) on MODs.

 

         The  System   shall have adequate  memory  capacity  for

 

         storing  the plant life data (minimum 30 years) at  scan

 

         rate  30  secs.for minimum 500 analog points  and  shall

 

         have  adequate storage capacity the last 5 year data  at

 

         the scan rate of 5 secs.for minimum 500 analog points.

 

         However these points may increase as per  recommendation

 

         of original manufacturer of equipment.

 

2.05.03.10  Quality Tag

 

         The  system  shall identity and tag the quality  of  all

 

         data  (scanned & calculated points)is a way  that  makes

 

         all  users(control,  calculations, logs  displays  etc.)

 

         aware  of its quality. Quality of data other  than  good

 

         shall  be  clearly  identified  in  all  printouts   and

 

         displays  by appending quality character to  the  value/

 

         status  of  point.  The quality  tagging  shall  include

 

         good, bad, substitute, doubtful, suspect etc.

 

2.05.03.11  a) DDCMIS shall provide fault alarm analysis  guiding

 

         the  operator  to the most likely cause of  fault.   The

 

         alarm  system  shall be designed in such a  manner  that

 

         main   auxiliaries  tripping  can  be  traced   to   the 

 

         originating cause.

 

         b)  Trend alarms shall be provided in DDCMIS for slowly

 

         varying   process  parameters,  so   that   appropriate

 

         corrective  actions  are taken in  time.   These  alarms

 

         shall  be  suitably  provided  in  OWS,  which  will  be 

 

         decided during detailed engineering stage.

 

2.05.03.12    An   integrated  unit  startup  system   shall   be

 

         implemented  in  DDCMIS  incorporating  all  operational

 

         curves for SG, TG and auxiliaries.  This shall guide the

 

         operator to take appropriate actions at appropriate time

 

         to   bring  the  rated  parameters  safely  within   the

 

         specified time.

 

2.05.04  MMIPIS  HARDWARE

 

2.05.04.1          The  MMIPIS  as specified shall be  based  on  latest

 

         state   of  the  art  work  stations  and  servers   and

 

         technology  suitable for industrial application &  power

 

         plant environment. The  quantity of peripherals, main  &

 

         bulk memory etc. as shown in the referred drawing is the

 

         minimum  the  bidder has to provide.   The  workstations

 

         other  than OWS shall be configured in such a  way  that 

 

         loss of  one workstation does not result in loss of  any

 

         function.   

 

 

         The  actual  size of the main and bulk memory  shall  be 

 

         sufficient   to  meet  the  functional  and   parametric

 

         requirements  as specified with 25%  additional  working

 

         memory  and 50% additional bulk memory over  and  above

 

         the memory capacity required for system  implementation. 

 

         The  exact system configuration and sizing shall  be  as

 

         approved by employer.

 

2.05.04.2  The   work  station/  servers  employed   for   MMIPIS

 

         implementation  shall  be  based  on  industry  standard

 

         hardware   and   software   which   will   ensure   easy

 

         connectivity  with  other  systems  and  portability  of

 

         employer developed and third party software.  These will

 

         be  64 bit machines. 

 

2.05.04.3  Redundant  sets of communication controllers shall  be

 

         provided  to  handle all the communication  between  the

 

         MMIPIS and redundant system bus and to ensure  specified

 

         system response time and parametric requirements.   Each

 

         communication  controller  shall have  message  checking

 

         facility.

 

2.05.04.4  Power Fail Auto Restart(PFAR) facility with  automatic

 

         time update shall be provided.

 

2.05.04.5  All  the  peripherals shall confirm to  the  following

 

         minimum requirement but the exact make & model shall  be

 

         as  approved  by employer during  detailed  engineering. 

 

      a) All the  monitor shall be 21” colour TFT and

 

         suitable  for  mounting in tabletop  arrangement. Processor 

 

         processor, Power Supply, Communication port of OWS shall be 

 

         redundant. All OWS shall be Industrial grade,interchangeable.

 

         The configuration shall be fault tolerant. OWS shall have

 

         Following minimum specification.

 

 

(i)          Resolution (1600x 1200)

(ii)       Display Colour (128)

(iii)    RAM Capacity (1 GB)

 

      b) The printers shall be heavy-duty lasers(minimum printing

 

         speed 8 pages, minimum printing  speed  of 20 pages for 

 

         laser  printer). The laser  printer should have provision

 

         of printing computer paper apart from cut sheets.

 

c)    Five No. Large video screens (LVS), each with 67 inches

 

Diagonal graphic controller and other hardware shall be 

 

Provided. It shall have facility of integrating the CCTV

 

Signal & RGB video  signal from field.

 

2.05.04.06 Man Machine Interface (Unit wise)

 

      a) Unit Control Room PC

 

      i) Operator Work Station      8 Nos.

     ii) Large Video Screen         5 Nos.

         (67”)

      b) Computer Room PC

      i) Historian PC               2 Nos.

     ii) Programmer PC              3 Nos.

     iii)Colour Laser printer       1 No.

         (size A 3)

     iv) Laser printer(A 4 , B/W) –  1 No.

     c)  Shift Engineer PC          1 No.

         + Laser printer 

         (size A 4, B/W)

    

     d)  PC at different location –  3 Nos.

         Of unit + Laser

         printer  (Size A 4,B/W)

 

     e)  Colour Laser Printer    

         (size A 3) 

     i)  Log Printer                1 No.

    ii)  SOE Printer                1 No.

   iii)  Alarm Printer              1 No.

 

     f)  Dot Matrix Printer         2 Nos.

 

2.05.04.07  Man Machine Interface (Common for two Units)

 

         PC Station               – 10 Nos.

          

         The above PC stations are to be located at various plants

 

         location  (to be decided during  detailed  engineering).

 

         All PC Station shall be with B/W laser printer(size A4). 

 

         The function  of  above

 

         PC’s are to view the alarm, display, and generate reports of

 

         both  the units.

 

2.05.04.08 O&M Head PC Station  (Common for two units) 

 

         O&M  Head  PC shall be located at O&M  head  office  and

 

         connected  to  system bus. The function of above  PC  to

 

         view & print alarm, display and generate  reports.  This

 

         PC shall have one laser printer and one scanner. The size

 

         of printer and  scanner shall be A3. The system shall also

 

         include all  required  software  and hardware for printing

 

         of CAD  drawing  and documents.

 

2.05.04.09  Station Head PC (Common for both the units)

 

         This  PC   shall be located at Station head  office  and

 

         shall be connected to system bus.  The function of above

 

         PC is to view the alarm, displays and generate   reports

 

         of  all  units.  The  PC  shall  be  with    laser

 

         printer(size A4).

 

2.05.04.10   The   detail  documentation  of   Boiler,   Turbine,

 

         Electrical,  Instrumentation  CHP,  AHP  etc.  shall  be 

 

         available  in  shift Engineer PC, Station head  PC,  O&M

 

         head PC and other 10 Nos.PC.  The documentation shall be 

 

         in  text  &  drawing form (Minimum 2000  pages  and  100

 

         drawings/ image  size of A3.  However the above quantity

 

         may  increase  as per  actual requirement.   The  system

 

         shall include all required software & hardware.

 

2.05.04.11   Bidder  shall supply 3 PC Station + B/W Laser printer

 

         (size  A 4) per unit with network capability  and  cable

 

         etc. The location of PC shall be decided during detailed

 

         engineering   shall  be  connected   through   telephone

 

         Exchange with system bus.

 

2.05.04.12 (a) The hardware of all work station/ PC shall be same

 

         configuration make  & Model  No.as OWS.

 

     (b) All laser printers shall be  same  make and with inbuilt

 

         network capability. 

 

2.5.04.13   The  bidder shall  provide  consumable  i.e.  tonner,

 

         paper  for  Laser  printers for  one  year,  considering

 

         consumption  rate 30 papers per day per printer.  Bidder

 

         Shall also provide formatted, 100 CD with each PC Station/

 

 

6. System documentation

Filed under: Uncategorized — shivajichoudhury @ 5:43 am

The  system  shall  have the facility  to  generate  the 

 

         associated  documentation for both the control system  &

 

         MMIPIS.   The bidder shall furnish detailed  information

 

         about  system  documentation facilities in  his  offered

 

         system along with the bid.  The document, to be generated

 

         by the system shall include P&ID drawings, control  loop

 

         drawings,   sequence   drawings,   signal   distribution

 

         list/drawings,    system    interconnection    drawings,

 

         cabinets   general   arrangement  drawings,  measurement

 

         list,  drive schedule, alarm schedule,  system  hardware

 

         and  functional  configuration  drawings  for  displays,

 

         logs,  trends,  graphics  etc.  The  system  shall  also

 

         include  all  required software and hardware  tools  for

 

         creating, modifying and printing CAD drawings to achieve

 

         paperless documentation for DDCMIS.

 

2.06.02   To  realize  all of the functions mentioned  above  the

 

         Bidder   shall   provide    standalone   stations    for

 

         configuration  & tuning functions of control system  and

 

         MMIPIS programming, hardware of which shall be  separate

 

         from   the  hardware  of  the   respective  system   and

 

         connected  to  System Bus.  The bidder shall  provide  2

 

         Nos. of programmer station for  control system and 1 No.

 

         programmer Station for MMIPIS..  Each of the  programmers

 

         station  shall also have a colour laser  printer.   The

 

         hardware for system documentation facility(specified  at

 

         Cl.2.06.04 above)may be  a part of either  configuration

 

         and tuning unit for Control System or MMIPIS  programmer

 

         if all the functions specified above can be achieved  in

 

         these  programmer stations.  Two separate workstation,

 

         colour   laser  printer,  scanner   shall   be

 

         provided  for  documentation  facility  with   necessary

 

         software  for  other than DDCMIS. The size  of  printer,

 

         plotter,  scanner shall be A 3.  The system  shall  also

 

         includes  all required hardware & software   tools   for

 

         creating,  modifying   and  printing  CAD  drawings   to

 

         achieve  paperless documentation. The  hardware of  work

 

         station shall be same as that of OWS.

 

 

7.DATA COMMUNICATION SYSTEM (DDC)

Filed under: Uncategorized — shivajichoudhury @ 5:41 am
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2.07.00  DATA COMMUNICATION SYSTEM (DCS)

 

2.07.01  The  DCS  shall include a redundant main  system  bus  &

 

         local system buses for major subsystems with hot back-up

 

         and  other  applicable bus  systems  like  cubicle  bus,

 

         local  bus,  I/O  bus  etc.  The   DCS  shall  have  the 

 

         following minimum features.

 

2.07.01.1  Redundant communication controllers shall be  provided

 

         to  handle  the communication  between  each  functional

 

         group  of controllers of control system and the   system

 

         bus.    The  design  shall  be   such  as  to   minimize

 

         interruption of signals.  It shall ensure that a  single

 

         failure anywhere in the media shall cause  no more  than

 

         a single message to be disrupted and that message  shall

 

         automatically be retransmitted. Any failure or  physical

 

         removal  of any station/ module connected to the  system

 

         bus  shall  not  result in  loss  of  any  communication

 

         function to and from any other station/module.

 

2.07.01.2  If  the  system bus requires a master  bus  controller

 

         philosophy,   it  shall  employ  redundant  master   bus

 

         controller with automatic switchover facility.

 

2.07.01.3   Built-in diagnostics shall be provided for easy fault

 

         detection. Communication error detection and  correction

 

         facility  (ECC)  shall  be provided  at  all  levels  of

 

         communication.

         

         Failure of one bus and change over to the standby system

 

         bus shall be  automatic and completely bumpless and  the 

 

         same shall be suitably alarmed/logged.

 

2.07.01.4   The design and installation of the  system bus  shall

 

         take care of the  environmental conditions and hazardous

 

         area classification as applicable  to similar services.

 

2.07.01.5  Data  transmitting speed shall be sufficient  to  meet

 

         the  responses  of  the  system in  terms  of  displays,

 

         control etc. plus 25% spare capacity shall be  available

 

         for future expansion.

 

2.07.01.6  Passive coaxial cables or fiber optic cables shall  be 

 

         employed for system bus.

 

2.07.01.7   The redundant buses shall be  physically separate and

 

         shall be routed separately.

 

         The   bidder   shall  furnish  details   regarding   the

 

         communication   system like communication protocol,  bus

 

         utilization calculations etc.

 

2.07.01.8  In case of any distance or other limitation in the DCS

 

         bidder   will   provide  suitable   repeaters,   MODEMS,

 

         amplifiers,  special type of cables like optical  fibers

 

         as required to make the DCS fully operational.

 

2.07.01.9  The Data Hiways shall be  power  surge  protected  and

 

         conform to IEC – 801-5. 

 

2.07.02.  Station  Wide  Network

 

2.07.02.1  The   servers/Ethernet  LAN  of  the  unit  shall   be

 

         connected  to a station wide Ethernet Wide Area  Network

 

         (WAN).  Various common system & off-site plants and  PCs

 

         at  various  plant  locations  &  PLC/PC  based  systems

 

         provided both by bidder as well as by employer shall  be

 

         connected  to  this station wide  Ethernet  WAN  through

 

         TCP/IP  protocol.  The station head/ O&M  head  &  shift

 

         in charge  stations  shall  be located  in  this  WAN  to

 

         monitor data of all units as well as of the common plant

 

         location and off-site plants.

        

2.07.02.2  Further,  this  station  wide  WAN  will  have  a   PC

 

         connected  to  act as a gateway to off-line WAN  of  the

 

         entire  station  (not under  this  package)connected  to

 

         other  station off-line services  like   administration,

 

         materials  etc.  This  gateway will  also  be  able  to

 

         communicate  with employer’s corporate office through  a

 

         satellite link(provided by employer).  The exact details

 

         shall be as finalised during detailed engineering and as 

 

         approved  by  employer.   Bidder  has  to  furnish   all

 

         necessary hardware and software for this purpose.

 

2.07.02.3 There shall be continual monitoring of network performance

 

         and station.

 

 

8.Annunciation & SER

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2.08.00  SEQUENCE OF EVENTS RECORDING/ ANNUNCIATION FUNCTIONS

 

2.08.01  SER  FUNCTION

 

2.08.01.1  The  system shall monitor 250 SOE  inputs  (Tentative-

 

         considering  only  cause  of tripping of  unit)  with  a

 

         resolution  of  one milli second at all  times  for  all

 

         inputs including spare inputs.  That is, all SOE  points

 

         entering status change shall be reported and time tagged

 

         within  1(one)milli second of their occurrence.   Input

 

         card shall be equipped with digital filters with  filter

 

         delay  of  minimum 4 ms (identical for  all  points)  to

 

         eliminate  contact bounce such that field contact  which

 

         is  changing  state must  remain in the  new  state  for

 

         successive  4 ms to be reported to OWS within  1  sec.of

 

         SOE  data collection initiation.  The system shall  also

 

         have provision of rejection of chattering inputs.

 

2.08.01.2  The system shall also include provision for historical

 

         storage  and  retrieval  of SOE  reports  for 12  months

 

         period or One thousand SOE alarm pages.

 

2.08.01.3  The SOE report collection shall begin on occurrence of

 

         change  of status of any SOE point and shall be  printed

 

         after  an  operator selectable time interval of 1  to  3

 

         Min.  or 100 status changes have taken place  after  the

 

         first  event.  

 

2.08.01.4  The  SOE reports shall include a list of cause of unit

 

         trip in chronological order and include the points which

 

         initiated SOE collection and other statistical data sheet.

 

2.08.01.5 SOE System shall have  dedicated VDU (21”)with KBD and

 

         placed in computer Room.

 

2.08.02  ANNUNCIATION SYSTEM FUNCTION

 

2.08.02.1  The  annunciation system shall  be implemented  as  an

 

         inbuilt  function  of the DDCMIS.  The  field  contacts

 

         shall be acquired through DDCMIS only.  The annunciation

 

         sequence  logic shall be  implemented as a part  of  the 

 

         DDCMIS  controllers.   The  annunciation  window   lamps

 

         mounted  on unit control panel shall be  driven  through

 

         contact output modules of the control system of  DDCMIS. 

 

         In  case,  the   annunciation  sequence  logic  is   not

 

         performed within the controllers for MFT(BMS), TPS etc.,

 

         then these signals can be transmitted through some other

 

         controller through bus and  processed therein.

 

         However, the annunciation system shall have the facility

 

         of driving independent prints/ lamp box in the event  of

 

         failure of MMIPIS/ system bus in case the   annunciation

 

         system is affected due to the same.

 

2.08.02.2 The annunciation sequence shall confirm to ANSI/ISA- 

 

         18.1(1979) with first up facility.

 

2.08.02.3   The annunciation system lamp boxes shall be  suitably

 

         mounted on unit control panel as decided during detailed

 

         engineering  stage  keeping  in  view  the   operational

 

         requirements. It shall be preferable to have each window

 

         as mosaic compatible.  The lamp box shall have removable

 

         impact  polystyrene window of snap-on type. The  minimum

 

         size  of each window shall be  50 mm x 75 mm with  5  mm

 

         size inscription in black lettering on white background. 

 

         Each annunciation window shall be backlighted with  two

 

         long life  lamps/super LED. The  changing of lamps shall

 

         be conveniently  done from the front by simple  removal

 

         of windows. 

 

2.08.02.4  Audible  devices for alarm shall be cone type  speaker

 

         or metallic horn type and shall be  driven by electronic

 

         tone  generator  of  adjustable pitch and  sound  level. 

 

         Bidder  shall  provide redundant  audible  devices  with

 

         selector switches.  The trip alarms audible & ring  back

 

         audible shall be differentiated from other alarms.

 

2.08.02.5  The alarm annunciation system to be  provided in  unit

 

         control room shall have sufficient capacity to cover all

 

         pre-trip  and trip alarms related to the  unit  and  its

 

         auxiliaries.   The number of annunciation facia  windows

 

         and  the  provision  for original input will be   on  as 

 

         required  basis.  However, the minimum number  of  facia

 

         windows,  signal input to the annunciation system  shall

 

         be 450 Nos.

 

9. Master clock

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2.09.00  MASTER & SLAVE CLOCK SYSTEM

 

2.09.01 a) The Bidder shall provide a date insensitive master and 

 

         slave clock system with adequate No.of output signal  to

 

         provide  uniform  timing throughout the   various  plant

 

         facilities  supplied  by bidder as well as those  not  a

 

         bidder’s  scope.   The system shall  be   complete  with

 

         receiving  antennae (for receiving time from Satellite  &

 

         Radio  signal),  receiver  and  associated  electronics,

 

         redundant  master clocks, slave clocks,  interconnecting

 

         cables,   cubicles,   power   supplies   &   any   other

 

         accessories.  However,  a provision shall  be  kept  for

 

         synchronization of the master clock with other source as

 

         decided during detailed engineering.

 

     b)  The system shall designed in accordance to IEEE 1344.

 

2.09.02  The master clock shall drive the slave display units. It

 

         shall  be  ensured that loss of any slave  display  unit

 

         does  not  affect the display of any other  slave  unit. 

 

         The   MMIPIS,  shall be  synchronized  with  the  master

 

         clock  once  in  every  hour  The   switchyard   event

 

         recorder  and  other plant  PLCs shall  be  synchronized

 

         with the  master clock once every minute.

 

2.09.03  The  master  clock shall be located in the control  room

 

         and shall have facility for automatic synchronizing with

 

         GPS for IST.

 

2.09.04  The  bidder shall provide a  minimum 25 Nos.per unit  of

 

         slave   clocks which shall be  located at   the  various

 

         plant   facilities   as   finalised   during    detailed

 

         engineering stage. System shall have expandable up to  30

        

         Nos. slave digital clock.

 

2.09.05       The system include two Master Clock in 100% redundancy configuration (one working other standby). Power supply module for each Master Clock shall be redundant. 

2.09.06 The cable from Master Clock to all Aux.plant PLC and slave clock shall be  in bidder’s scope.

 

10.Gounding

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2.10.00  GROUNDING

 

2.10.01  All  panels,  desks cabinets shall be  provided  with  a 

 

         continuous bare copper ground bus.  The ground bus shall

 

         be bolted/ welded to the panel structure and efficiently

 

         ground  the  entire structure.  All  individual  cabinet

 

         grounds shall be  connected to separate earthling  riser

 

         to be provided for C&I system signal grounding, as  per   

 

         IEEE   standard   No.1050.   “IEEE    guide    for 

 

         Instrumentation   and   control  system   grounding   in

 

         generating  station.”   The  grounding  requirements  of

 

         various parts of the  C&I system shall be separate  from

 

         plant earthing. The exact grounding scheme shall be   as

 

         finalised during detailed engineering.

 

 

11. System software requirments

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2.11.00   SYSTEM SOFTWARE REQUIRMENTS

 

2.11.01  The  bidder shall provide all software  required by  the

 

         system for meeting the intent and functional/ parametric

 

         requirements of the specification.

 

2.11.02  Industry  standard  operating system  like  UNIX/WINDOWS

 

         NT/OPEN-VMS etc. to ensure openness and connectivity with

 

         other  system  in  industry   standard  protocols(TCP-IP

 

         etc.)shall  be  provided.  The system  shall  have  user

 

         oriented programming language & graphic user interface.

 

2.11.03  All   system  related  software  including   Real   Time

 

         Operating  System,  File  management  software,   screen

 

         editor,   database   management   software.    On   line

 

         diagnostics/debug software, peripheral drivers  software

 

         and High-level language compilers for FORTRAN, C, PASCAL

 

         etc.latest  versions of standard PC-based software  like

 

         latest   WINDOWS  based  packages/  Unix,  SQL,   RDBMS,

 

         Antivirous etc. and any other standard language  offered

 

         shall be furnished as a minimum.

 

2.11.04  All application software  for control system functioning

 

         like    input   scanning,   acquisition,    conditioning

 

         processing  &  control  along with  communication   among

 

         various  control  system functional blocks,  MMIPIS  and

 

         system  bus, MMIPIS software for operator  interface  of

 

         monitors,  displays  trends,  curves,  bar  charts  etc.

 

         performance calculations (with steam properties routines

 

         utilities)  Historical  storage and  retrieval  utility,

 

         sequence  of events recording system functions shall  be 

 

         provided.

 

2.11.05  The  bidder shall provide software/ hardware  locks  and

 

         passwords  to Employer/ Project Manager at site for  all

 

         operating  &  application software in order  to  prevent

 

         unauthorized  access  and  only  Employer’s   authorized

 

         representatives are able to do modifications at site.

 

2.11.06  Multiple  sets of back-up software on media, on  CD  ROM

 

         shall be provided by bidder.

 

2.11.07  The  bidder  shall  provide  software  license  for  all

 

         software  being used in DDCMIS/ Computer.  All  licenses

 

         shall valid for continuous service life of plant.