PG 2 NTPC REQ

SUB-SECTION - IIIC
CONTROL & INSTRUMENTATION SYSTEM
SOLAPUR SUPER THERMAL POWER PROJECT (2x660 MW) STEAM GENERATOR PACKAGE
TECHNICAL SPECIFICATION SECTION-VI BID DOCUMENT NO. : CS-9575/9571/0370/0360/9586-102-2
CLAUSE NO.
SCOPE OF SUPPLY & SERVICES

CONTROL AND INSTRUMENTATION SYSTEM
1.00.00 1.01.00
GENERAL The Contractor shall provide Control & Instrumentation system for control, monitoring and operation of the systems, equipment etc. covered under these specifications, in all regimes of operation in safe and most efficient manner. The scope of work for the equipment, material and system to be furnished in accordance with this specification shall include design, engineering, manufacture, fabrication, assembly, pre-shipment testing at manufacturer's works, proper packing for transportation, delivery at plant site, unloading, storage, installation, interconnection with related plant and equipment, calibration, testing, commissioning and putting the Control and Instrumentation System together with all accessories, auxiliaries and associated equipment as specified hereinafter in a fully operational condition and in the manner acceptable to the Employer as covered under this specification. The Contractor shall also provide all material, equipment and services which may not be specifically stated in the specifications but are required for completeness of the equipment/systems furnished by the Contractor and for meeting the intent and requirements of these specifications. The work shall be consistent with modern power plant practices and shall be in compliance with all applicable codes, standards guidelines and safety requirements in force on the date of award of the contract. The requirements of statutory Authorities (e.g. MOEF, Inspector of Factories, IBR, TAC, CPCB/SPCB/CERC etc with regard to various plant areas like main plant, Fuel Oil Plant/System, Chlorinating Plant, Fire fighting system, Emission measurements etc.) shall be complied even if not actually spelt out. It shall be the responsibility of the Contractor to coordinate with Employer and offer Control and Instrumentation System to meet the actual requirements of the plant and furnish a complete system as per clause 1.01.00 above, and also to coordinate with other system vendors for proper interfacing of Control and Instrumentation system vendors with all other related equipment and systems. The following clauses describe the brief scope of supplies only. The detailed technical specifications are stipulated under various Control and Instrumentation Sub-sections, Part B, Section-VI of the specification as well as in various other Parts of the Technical Specifications. Contract quantities shall be as specified under Appendix-I to Subsection-IIIC of Part-A, Section-VI and as required to make the system complete. Unless explicitly stated to be common for all the unit(s), the Contractor shall provide all system/equipment described in this specification for each of the unit(s). DISTRIBUTED DIGITAL CONTROL, MONITORING & INFORMATION SYSTEM (DDCMIS) Latest state of the art microprocessor based Distributed Digital Control, Monitoring & Information System (DDCMIS) meeting the previous clause shall be provided comprising of the following as a minimum and meeting all requirements specified under Sub-section DDCMIS of Part -B, Section-VI of Technical Specification. Control system (Including its Measurement system) The control system shall broadly consist of the following system(s):The SG C&I system comprising of Burner Management system (BMS), Secondary Air Damper Control (SADC), Soot Blowers Controls, Aux. PRDS control, SCAPH drain tank level control, Separator Drain Control System, Atomising Steam/Air Pressure Control, Fuel oil
1.02.00
1.03.00
1.04.00
1.05.00
2.00.00 2.01.00
2.02.00 2.02.01 2.02.02
SOLAPUR SUPER THERMAL POWER PROJECT (2X660 MW) STEAM GENERATOR PACKAGE
TECHNICAL SPECIFICATION SECTION-VI BID DOC. NO.: CS-9575/9571/0370/0360/9586-102-2
PART-A SUB-SECTION-III:C CONTROL & INSTRUMENTATION SYSTEM
PAGE 1 OF 8
CLAUSE NO.

header pressure/flow control, Mill fire control, Mill lube oil system control and control of common systems like FOPH system, FO unloading control system, Mill reject system etc. The BMS shall comply with NFPA 85. The Master Fuel Trip (MFT) Sub Group of BMS shall comply with VDE0116, VDE 0160 etc.
2.02.03
The functional grouping of the above system(s) shall be as per Drawing No. 0000-101/102POI-A-009. In addition to the controls indicated in the above drawing, all controls except those indicated in exclusions at clause no 2.17.00 are to be provided in this package. The above system(s) shall include their respective measurement system for signal acquisition, conditioning and signal distribution of various types of inputs/outputs, meeting specification requirements including respective Hardware requirements as stipulated in Subsection IV;I-2(DDCMIS), Part-B, Section-VI of Technical Specification. Human - Machine Interface & Plant Information System (HMIPIS) HMIPIS configured around latest state-of-the art servers/Workstations with open architecture supporting OPC/TCP/IP protocols, etc. shall be provided. Any of the two options of HMIPIS as detailed out in Sub-section DDCMIS of part -B, Section-VI of Technical Specification shall be supplied. This will include the following as a minimum: Operator Work Station (OWS), mounted on Control Desk (UCD). (LVS Work Stations in Central Control Room shall be provided by Employer.) Processing Stations (Servers/Workstations) in redundant configuration as per DDCMIS Supplier's standard practice shall be used for historical storage and retrieval and long term storage and retrieval of data. Network ready Colour laser printers for taking printout of logs/reports colour hardcopy and for plotting curves/graphs etc. The quantity of peripherals of HMIPIS shall be as specified under Appendix-I to SubsectionIIIC of Part-A, Section-VI. Data Communication System System Bus connecting Control System and HMIPIS. Other bus systems for connecting various systems/subsystems of DDCMIS like Cubicle Bus, Local Bus, I/O Bus ( Including Remote I/O Bus) soft links (including those from Field Bus based temperature transmitter) as well as within systems/sub-systems of DDCMIS. All the bus systems shall be redundant except for back plane buses which can be non-redundant. System programming, diagnostics & documentation facility The programmer station shall be provided for configuration/tuning/structuring of control system and program development /modification of HMIPIS for each of the unit(s). A Workstation based system documentation facility for automatic generation of system documentation shall be provided for each of the unit(s) to achieve paperless documentation for the project. The diagnostic system shall have elaborate diagnostics facility giving details of fault in individual channels of I/O modules, other modules and cabinets on Monitors in form of display and text messages. Power Supplies Redundant power packs/ supplies for powering the systems described above in system cabinets with necessary auctioneering and distribution.
2.02.04
2.03.00 2.03.01
2.03.02
2.03.03
2.03.04
2.03.05
2.04.00 2.04.01
2.05.00 2.05.01
2.06.00 2.06.01
PAGE 2 OF 8
CLAUSE NO.

Cabinets (a.) System cabinets housing electronic modules and power pack supplies of system described above. Marshalling cabinets separate from system cabinets for terminating inputs from field, MCC/SWGR etc., for further wiring to control system and for terminating outputs from control system to MCC/SWGR etc. In case Bidder's system design requires the termination cabinet independent from system cabinet, the marshalling cabinets can be combined with the termination cabinet. In case, the termination arrangement is part of the system cabinet, independent marshalling cabinets shall be provided. (c.) Relay cabinets housing relays for providing contact outputs by control system to other system wherever contacts are used in circuit/scheme of Control supply/power supply of more than 24 V and in cases where the VA burden is more than the VA burden the Output module can drive. Alternatively, these relays can also be mounted in termination/marshalling cabinets also. It may be noted that relays can not be mounted in system cabinets.
2.07.00
(b.)
2.08.00
Signal Exchange Bidder shall provide all the required signal exchange between SG-C&I control system and BOP-C&I/TG-C&I DDCMIS as per Sub-Sec-IV, I-2(DDCMIS), Part-B, Section-VI of Technical Specification.
2.09.00 2.09.01
Warranty and Annual Maintenance Contract Warranty and Annual Maintenance Contract (AMC) for DDCMIS, as per Sub-section IV;I2(DDCMIS), Part -B, Section-VI of Technical Specification.
3.00.00
MAIN EQUIPMENT RELATED CONTROL & INSTRUMENTATION SYSTEM Other special C&I systems shall be provided by bidder including but not limited to the following as a minimum as per the requirement of Sub-section-IV;I-3,SG Related Control & Instrumentation System Part -B, Section-VI of Technical Specification. Flame Monitoring System and Flame Detector Testing Kit. Coal-Feeder Control & Instrumentation. Electromatic safety valves. Furnace temperature probes. Acoustic Pyrometer. Furnace and Flame Viewing System.
Acoustic Steam Leak Detection System Level switching system for Driplegs employing conductivity type probes.
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CLAUSE NO.

Mill Fire Detection System. Temperature elements for Air Heater fire detection system
4.00.00
MEASURING INSTRUMENTS (PRIMARY & SECONDARY) The following shall be provided as a minimum, meeting specification requirements of Subsection IV;I-4 MEAS INST of Part-B, Section-VI of Technical Specification.
4.01.00
Primary instruments like Microprocessor based transmitters employing HART protocol, thermocouples & RTDs along with temperature transmitters, pressure/diff. pressure/temperature/flow switches & gauges, flow sensing elements (orifice plates, flow nozzles, impact head type elements etc), Ultrasonic, Radar type level transmitters, positive displacement type flow transmitters, Oxygen analysers etc. for: (a) Main plant and auxiliary plant, as indicated in enclosed tender diagrams (P&I Ds / flow schemes) as a minimum. Integral to equipment which are not indicated in the tender drawings, but are required for control, monitoring and operation of the equipment / plant systems for which no P&IDs are enclosed, all the instruments shall be provided to meet the actual system requirements and meeting redundancy and other requirements specified under technical specifications subject to Employer's approval. For Binary and analog inputs required in major equipment (e.g. Furnace) protection triple-sensing devices shall be provided. Binary and analog inputs, which are, required for protection of more than one equipment as well as protection signals for HT Drives (fed by a supply feeder of ratings 3.3 kV onwards) etc., triple sensing devices shall be provided. For modulating control of drives supplied by the bidder and control by Employers control system, redundant field instruments are to be provided. For other critical binary and analog inputs required for protection and interlock purpose of other equipment (e.g. those interlocks which may result in loss of generation, non-availability of a major equipment etc.), triple sensors shall be provided. Temperature elements, electronic transmitters etc. are to be provided for all the cases. Use of process actuated switches is acceptable only in the cases as indicated in the tender drawings. All instruments on SG scope of piping/ducts/equipments shall be provided by the contractor (unless indicated otherwise).
(b)
(c)
(d)
(e)
(f)
(g) 4.02.00
Head mounted/ Rack mounted/ Enclosure mounted temperature transmitters (TTs) for temperature elements (TEs) in Contractors scope are to be provided by the contractor as per the following. a) In case of multiple measurement of temperature for any application resulting in trip/protection, where logic implementation tolerates failure of one TE (e.g., 2v3, 2v4, etc.), for only one of such TEs, dual TT is to be provided. In case of other applications where single TE causing trip/ protection (either part of single measurement or part of multiple measurement not tolerating failure of any TE, e.g., 1v2, 1v3, 1v4, etc.), for each of such TEs, dual-input TT shall be provided.
PAGE 4 OF 8
CLAUSE NO.

For other applications where usage of dual input TTs is recommended by the equipment manufacturers the same shall also be acceptable. The exact applications for which this type of transmitters is to be provided shall be finalized during detailed engineering. Bidder shall provide enclosure/racks for mounting the dual-input TTs. However, same can also be mounted in nearby LIE/LIRs housing PT/DPT/LT/FT being supplied by the vendor. The number of Temperature Transmitters in LIEs/ LIRs and the internal arrangement of the same in enclosure/racks shall be subject to Employers approval during detailed engineering. For balance applications, following types of temperature transmitters shall be provided: Head mounted transmitters may be provided for temperature elements which are located in accessible areas as decided during detailed engineering. Remaining transmitters are to be DIN-rail mounted in JBs to be provided by the bidder. Cabling from TE to TT and TT to terminal blocks of JB is in the scope of the bidder. Temperature transmitters with Profi Bus / Foundation Field Bus/ any proven bus system / any other suitable interface with SG-C&I system hardware for Boiler SH/RH metal temperature measurement applications are also to be provided by Contractor. In case temperature transmitters are not provided with Profi Bus/Foundation Field Bus/ any proven bus system, remote I/O with required interfacing with SG C&I shall be provided.
b) c)
d)
5.00.00
ELECTRIC POWER SUPPLY SYSTEM Sets of Microprocessor based modular 24 VDC power supply system shall be used for powering the control systems including its network devices. For number of sets, refer Appendix-I to Subsection-IIIC of Part-A, Section-VI. Contractor shall provide power supply distribution panels/cabinets/boxes for sub distribution of DC/Main UPS/Utility feeders on as required basis. The power supply distribution box shall include change over circuitry, switch fuse units, MCBs , terminal blocks etc. suitable for application.
6.00.00 6.01.00
PROCESS CONNECTION & PIPING Process connection & piping including all impulse piping, sample piping, pneumatic piping/tubing, valves, valve manifolds, fittings and all other accessories required for proper installation & completeness of impulse piping system, sampling piping system and air supply system, as stipulated under Sub-section PCP, Part-B, Section-VI of Technical Specification. For all the instruments in contractors scope of supply, Local Instrument Enclosure (LIEs) shall be provided to group & mount transmitters, process actuated switches and temperature transmitters in open and dust prone environment like Boiler/Mill area. Local instrument Racks (LIRs) shall be provided to group & mount transmitters, process actuated switches and temperature transmitters in cleaner areas like TG hall. LIE/LIRs are not required for Fuel Oil applications and off site areas.
6.02.00
PAGE 5 OF 8
CLAUSE NO.

INSTRUMENTATION CABLES, CONTROL & POWER SUPPLY CABLES & CABLES SUB-TRAYS All instrumentation cables twisted & shielded, FRLS PVC insulated, including thermocouple extension cables and prefabricated cables (with plug-in connectors), Power Supply cables, optical fiber cables other than shown in exclusion, as applicable for interconnection of all equipment/system/devices in Contractor's scope as well as for connection of signals from/to systems like MCC/LT SWGR/HT SWGR/Fuel Oil handling System/Temperature Transmitter (even if they are not in Contractor's Scope.) Etc. along with necessary laying & termination accessories, hardware etc. meeting requirements specified under Sub-section-IV;I-7, INST CABLE, Part -B, Section-VI of Technical Specification. All the instrument which are in the scope of Bidder and connected to Employers control system shall be wired upto the input terminals of the JB by the Bidder. The contractor shall provide Junction boxes and all sub trays along with supporting, connecting hardware etc. required for laying of instrumentation, control, power and other cables etc. up to main cable trays on as required basis. The cable interconnection philosophy to be adopted shall be such that extensive grouping of signals by large scale use of field mounted Group Junction Boxes (JBs) at strategic locations (where large concentration of signals are available, i.e. valves, limit and torque switches, switchgear) is done and consequently cable with higher number of pairs are extensively used. However, it shall be ensured that any fault in any one cable shall not result in trip of SG and important auxiliaries. Contractor shall provide redundant cable through separate and independent routes for redundant instruments, drives and field devices. CONTROL VALVES & ACTUATORS Control valves, actuators and accessories, shall be provided meeting requirements specified under Sub-section CONTROL VALVE, Part-B, Section-VI of Technical Specification. Specially designed valves/trims to prevent cavitation and limit noise and control outlet velocity, shall be provided. Microprocessor Based Electronic Positioner is to be provided with all the Control valves and all control dampers being provided by the contractor. CONTROL AND INSTRUMENTATION FOR PLANT AUXILIARY SYSTEMS Instrumentation and Control System with interlocks, protection and annunciation of the mechanical common auxiliary systems as mentioned below shall be provided. All necessary equipments / system for control, monitoring and operations of the plants as well as the incomers and bus couplers shall be provided. For certain plants, facility for control from DDCMIS shall be provided as mentioned below.. Sl No 01 Auxiliary Plant Auxiliary Boiler applicable) (if Control System Independent system in hardware control SG-C&I Connectivity/operation Dual two way Ethernet connectivity to Station LAN for information Dual to way Ethernet connectivity to station LAN for information and control. Local operation of Fuel oil Handling System
7.00.00
7.01.00
7.02.00
7.03.00
8.00.00 8.01.00
8.02.00
9.00.00 9.01.00
02
Fuel Oil Pressurization / Heating System (FOPH) & Fuel oil unloading system
Independent control system in SG-C&I based Hardware. I/O count for Fuel oil unloading system is 200 binary and
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CLAUSE NO.

Sl No Auxiliary Plant Control System 20 analogs. 03 Mill Reject System (Unitised System) SG C&I Based Control System from Control Room If the controller is integral to compressor, then Microprocessor/PLC based control system as per vendor's practice for individual Air compressors control. If the controller for individual compressors is not integral to compressor then control shall be through Station C&I (in Employers scope). For both the cases, over all Control shall be through Station C&I Package (in Employer's scope). 05 LP Dosing and Oxygenated treatment Control from Station C&I Package Connectivity/operation through GIU. Graphical interface unit (GIU) based local operation apart from CCR. Dual two way Ethernet Connectivity to Station C&I package for information and Control of Air Compressors. (Applicable only for compressors with integral controllers)
04
Air Compressor System including AirCompressors of Mill Reject System
(Instrumentation in Contractor's scope) 06 Equipment Water System Cooling Control from Station C&I System
10.00.00 10.01.00
TYPE TEST REQUIREMENT The type tests to be conducted for C&I systems & equipments shall be as detailed out in Sub-Section-IV;I-9, C&I TYPE TEST, Part-B, Section-VI of Technical Specification.
11.00.00 11.01.00
PLANT PERFORMANCE ANALYSIS, DIAGNOSIS & OPTIMIZATION SOFTWARE The Contractor shall provide a PC based On-line Plant Performance Analysis, Diagnosis & Optimization system (PADO) for the station, which will provide proper guidance to the plant operator. The PADO system shall provide the following functions in a modular and seamlessly integrated environment, using a common plant model and a dynamically shared database. (i) Performance analysis and monitoring of systems and components.
11.02.00
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CLAUSE NO.

(ii) (iii) (iv) (v) Emission Analysis and monitoring. System and performance diagnosis. System and performance optimization. Boiler performance optimization including optimized operation of soot Blowing system. Boiler stress condition analysers. Interactive water and gas chemistry management system. Regenerative cycle performance optimization system.
(vi) (vii) (viii) 11.03.00 12.00.00 12.01.00
Details regarding software, hardware, instruments etc are elaborated in PADO sub-section. TOOLS & TACKLES The Contractor shall furnish a complete new set of all special tools and tackles of reputed make and model which are required for erection, ease in maintenance to have minimum down time, testing and calibration of all the equipments and systems to be provided by the Contractor under this specification for C&I systems. MANDATORY SPARES Mandatory spares shall be provided as per the list indicated in Subsection-VII in Part A of Technical specification.
13.00.0
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CLAUSE NO.

APPENDIX-I GENERAL REQUIREMENTS OF CONTRACT QUANTITIES
The scope of C&I systems under this specification (SG-C&I system) is covered in Part-A and Part-B of this specification. The purpose of this appendix is to supplement the scope given in Part-A and Part-B of technical specification and is not intended to give total Scope. The Contract quantities of many subsystems covered under Part-A and Part-B of technical specification are generally not reproduced here to avoid duplication. However, in case of any conflict or repetition, the more stringent requirements among them are to be complied with.
PART-A SUB-SECTION-III:C CONTROL AND INSTRUMENTATION APPENDIX - I
PAGE 1 OF 11
CLAUSE NO.

DDCMIS Contractor should note that he has to supply system complete in all respects with all software, hardware, accessories, interfacing equipment required, etc., whether specifically stated herein or not, to make the system operational and fully meeting the functional, parametric, hardware, software, interfacing, quality assurance & testing requirements within the quoted lumpsum price. The Contractor shall provide functional groups as indicated in Drg. No. 0000-101/102-POI-A009. For each of the functional groups, separate sets of redundant controllers, I/O modules, communication controllers, power packs/modules, etc. shall be provided. No. of Inputs/Outputs The quantity of I/Os, drives and other equipment related to Control system, HMIPIS shall be provided on as required basis. However, the no. of inputs and outputs to be considered for each type of drive shall be as follows:TABLE-I NO.OF INPUTS/OUTPUTS FOR DRIVES Type of drive No. of inputs (change over) No. of inputs (Nonchang eover) Total no. of binary inputs per drive No. of Binary outputs (24 VDC) No. of Binary outputs (contact type) Total no. of analog inputs per drive (4-20 mA) Total no. of Analog outputs per drive (420mA)
1.00.00
HT LT MOD/MOV MOVI/MODI DSOV SSOV Elect Breakers (Non-Synch) Elect Breakers (Synch) Modulating Drive Pneumatic operated on-off drive
1X2* 1 1 1
2 1 1 1 3 3 1 2
4+ 2 3 3 3 3 3 3 4+ 2
2 2 2 2 2 1 2 1X2
1 1X2*
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CLAUSE NO.

GENERAL REQUIREMENTS Input/output signal multiplication, and distribution of process, system and software generated points, etc. required within the DDCMIS are to be provided by the Contractor on as required basis and these are not included in the above list. For signal exchange with BOP-C&I system and TG-C&I system for information purpose, Contractor shall provide suitable data link/interface as specified in item Signal Exchange, Subsection DDCMIS, Part B, Section VI. of the specification. However, signals required to be exchanged between SG /TG/ BOP C&I system for protection of turbine, boiler and and other HT drives as well as for CMC shall be hardwired. The same shall be provided on as required basis. The quantity of drive related inputs and outputs shall be derived from Table-I by the Bidder and the quantity of input/output modules shall be decided accordingly. Bidder shall identify in his offer the different types of I/O modules offered by him which as per him are having directly or otherwise an I/O capability, (e.g., Analog input/output module, binary input/output module, etc.) meeting all specified requirements. However, the Contractor shall note that all such offered modules having I/O capability shall be acceptable only if they meet all the functional and hardware requirements of I/O modules as specified elsewhere. The I/Os for common systems shall be provided only for one unit and for balance units these I/Os need not be provided. Required Limit switch contacts of valves/dampers, breaker/contactor status contacts & other inputs etc. shall be fed as inputs to Control System at one place. The Contractor shall distribute these inputs within Control System or other places wherever required for commands, status indication, interlock and protection of drives, sequence logic, loops & other functions. Spare capacity for the system as indicated under item System Spare capacity, Subsection DDCMIS, Part B, Section VI is not included and shall be additionally provided by the Contractor. Suitable devices (like diodes, etc) are to be provided, if required, for signals which are to be shared between more than one I/O modules. The non-changeover DI signals (NO/NC) in Table I indicates that either NO or NC can be connected to control system, as per process requirement. (i) In the Table Drive I/Os, wherever contact type binary outputs are specified (which are applicable for drives specified in Table-I), relays are to be provided. These relays shall be driven by 24 V DC command outputs through DO modules. In case redundancy in outputs of these types is required, redundancy shall be provided only in DO modules, but not for the relays. The power supply for energizing such drives in the field shall be routed through contacts of the above mentioned relays. The monitoring of power supply extended through contacts of the relays shall be done for a group of drives. The no. of drives per group, can be maximum 4. One contact of power supply monitoring device (relay/ MCB with contact or equivalent scheme, as approved by Employer during detailed engg. stage) shall be wired to DDCMIS, and the same shall be used for drive disturbance for all the drives in the group.
1.01.00 1.
2.
3. 4.
5. 6.
7.
8. 9.
(ii)
10.
Redundancy in binary and analog outputs for drives shall be as per Table-II
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Table-II Redundancy of Command Output Signals (Both Modulating and Binary) S No 1 2 3 System/Equipment ERV FTP Mill Reject Handling system: a. Compressors b. Equipment other than compressors SCAPH FOPH, CBD: a. Control valves b. Equipment other than control valves (e.g. isolation valves etc.) Sootblower control system SADC system Outputs for indications in all systems Coal/Mill system Oil system Scanner air and seal air systems Requirement outputs Required Not required Required Not required Not required Required Not required Not required Required Not required Required Required Required of Redundant
4 5
6 8 9 10 11 12
Also, please note that: 1. Output signals to other systems shall remain as per interlock and protection philosophy. 2. Output signals for indications on mosaic items/local panels (as applicable) shall not be redundant. 11. The contact rating of DO (contact) type outputs shall be as follows. The contact rating for such outputs for SG DDCMIS shall be minimum 60VA, and shall be suitable for contact interrogation at 24 V DC. For such outputs for other DDCMIS systems, relays shall be provided for each of such outputs, and the rating of contacts of the relays shall be as specified in Part-B of specification. Additional note for TableDrive I/Os (*) The on/off status of HT drives of Unit DDCMIS will be wired to DI modules in parallel. The open/ close status of sync type electrical breakers of Unit DDCMIS will be connected in parallel to DI and DISOE modules. For these types of drives in other DDCMIS systems the status will be connected to only one DI module. 2.00.00 The following back-up instrumentation and Secondary instruments shall be provided by the Employer under Station C&I package as a minimum for SG package applications. The exact quantity of the back-up instrumentation shall be as finalised during detailed engineering in consultation with the Contractor. Contractor has to supply all the required input output modules in SG C&I part of DDCMIS for interface of these modules without any cost implication to the employer. The quantity indicated here is for each unit. (i) (ii) 2 PB + 3 LED EMERGENCY TRIP PB 10 nos. 5 nos.
12.
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CLAUSE NO.

INDEPENDENT CONTROL SYSTEMS Sl No DDCMIS SYSTEM 1. 2. Auxiliary Boiler (if applicable) Fuel oil Pressurization system LOCATION Auxiliary Boiler building Fuel Oil pump house
3.00.00
4.00.00
LIST OF AREAS FOR WHICH SOFT SIGNALS ARE TO BE CONNECTED TO SG C&I OR BOP C&I Sl No Area System to which Connected SG C&I System of each unit Minimum Qty of links/ Location Two nos. per unit Type Qty of signals
1.
Steam Generator floor per Unit
Field bus / Profibus/other industry standard bus for temperature transmitter RS 485/ RS232 20 per charger
2.
SG Charger in each unit
SG C&I of respective unit
5.00.00
Control Systems of the auxiliary systems shall be provided with connectivity to DDCMIS systems as follows: Sl No. Description of the system System to which to be connected Station wide LAN under BOP C&I BOP C&I for supervisory control of all compressors. If any signals are required for control or monitoring and the same are not available through link, the same shall be hardwired to BOP C&I . Remarks
1.
Control system of Fuel Oil Pressurizing/Heating System Air compressor system
2.
3.
Air compressors of Mill reject system Auxiliary system Boiler Control
BOP C&I
4.
SG C&I
(if applicable)
6.00.00 7.00.00
The quantities of other equipments related to Control System, HMIPIS etc is enclosed at Annexure-1 to this APPENDIX. 24 V DC POWER SUPPLY SYSTEM 24 V DC Power Supply system shall be of continuous duty for the following estimated loads:
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Description of Loads Contr- Emplactors oyers load load Total Rating (Amp) Quantity per unit I. a. UNIT SG C&I :- 24 V DC for all Contractors load including SG-C&I system (see note-1 below); * * 2 sets
Common
b. Any other load of Contractor supplied system/equipment requiring 24 V DC supply II. Auxiliary Boiler (if applicable):- 24 V DC for all Contractors load including
* * * 2 sets
a. Control system equipment located in Auxiliary Boiler building. III. Fuel Oil Pressurizing system :- 24 V DC for all Contractors load including a. Control system equipment located in Fuel Oil pump house * 10 A -2 sets
The rating marked * are for instrument/equipment/system being supplied by Contractor. The Bidder shall estimate the requirement of these and provide additional capacity margin of 5% of the estimated Contractors load for all the items and thereafter add the Employers loads to get the load for the entire system. Note: 1. Control system would cover as a minimum, controllers, I/Os, associated modules etc. as well as, data communication system & Network devices (like LAN Switches), related to control system associated relays and solenoid valves driven by 24 V DC system, etc;. Any other loads of Contractor requiring 24 V DC supply shall also be included in this calculation. The configuration of Sl. no. I (i.e. UNIT SG C&I) shall be as per cl 1.03.00 (A), Subsection-IV I-5 of Part-B (Electrical Power Supply) and configuration of Sl. no. II & III (i.e. Auxiliary Boiler & Fuel Oil Pressurizing system) shall be as per cl 1.03.00 (B), Subsection-IV I-5 of Part-B (Electrical Power Supply). Power supply of integral microprocessor based control system like compressors shall be redundant with battery back-up and shall be as per with manufacturers standard practice subjected to the approval of Employer during detailed engineering. One set of manual discharge resistance bank of adequate capacity shall be provided per unit for the main plant 24V DC system of SG C&I control system.
2.
3.
4.
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UPS Uninterrupted Power Supply of required capacity shall be provided by the Contractor as per following:Description of Loads I. HMI and other relevant equipment at Fuel Oil Pump House II. HMI and other relevant equipment at Auxiliary Boiler (if applicable) Qty 1 no. 1 no.
7.01.00 7.02.00
8.00.00 8.01.00
PROCESS CONNECTION AND PIPING The Contractor shall provide, install and test all required material which is necessary for proper installation and interconnection of the equipment/systems furnished by the Contractor as per this specification and their integration with Employer's main equipment/systems as per Technical Specification requirements and its sub-clauses, enclosed installation drawings and other applicable clauses on as required basis. The Contractor shall furnish, within his quoted lump sum price, all hardware and accessories to ensure that the equipment/systems furnished against this specification form a complete and operational system meeting the intent and requirement of this specification. The Bidder shall note that no price adjustments shall be applicable for the equipment and services furnished as per this sub-section since the Contractor has to furnish these equipment/services on as required basis. Local Instrument Enclosures (LIEs) and Local Instrument Racks (LIRs) a) Local Instrument Enclosures (LIEs) complete with all fittings, mountings & accessories etc for each unit on as required basis. Local Instrument Racks (LIRs) complete with all fittings, mountings & accessories etc. for each unit on as required basis.
8.02.00
8.03.00
b)
9.00.00
The following contract quantities of equipments for local operation shall be furnished for the following systems.
Sl No 1
Item Description Graphical Interface unit. Graphical unit. Interface
Qty per unit 1 no per compressor
Application and location Operation of Compressors of Mill reject system Operation of Compressors of Instrument air system
1 no per compressor
Minimum specifications of Graphical Interface unit shall be as follows: Sl No. 1. Description Power supply 24 V DC/as per manufacturers standard practice for Air compressors
PAGE 7 OF 11
CLAUSE NO.

2. 3. Display Type Humidity & Temperature Protection class Operating Colour, TFT screens 5-95%, 0-50 deg C
4.
IP-65 for extremely dust prone area, otherwise IP55. Enclosure shall be provided to prevent ingress of dust. Function keys and numeric keys Interface with SG C&I systems Ability to operate drives locally using function keys Ability to do programming Graphics display including alarms and operator guidance messages
5. 6. 7.
Keys Interfacing requirements Functional requirements
10.00.0
Furniture for control areas as defined below shall be provided: Sl no Area Item Description 1. Auxiliary Boiler building (if applicable) a.Chair b.Keypad, Locker set 2. Mill reject Control Room a.Chair b.Keypad, Locker set 3. Fuel Oil pump control room house a.Chair b.Keypad, Locker set c.Computer table
Qty 3 1 each 3 1 each 3 1 each 1 no. to accommodate 2 OWS
11.00.0
For other equipment/system/items like Measuring Instruments, Control Valves and Actuators, Other SG C&I systems, PADO system and Instrumentation and Power supply cables, contract quantities shall be governed by corresponding Sub-sections in Part-B.
PAGE 8 OF 11
CLAUSE NO.

Annexure-1 to Appendix-1 HMI Quantities
Sl no
Item name
Unit Unit DDCMIS
DDCMIS BASED FOPH Auxiliary boiler (if applicable) Common qty On as required basis s per drg no. 0000101/102-POI-A009 on as required basis
Remarks
1 1.1
Control System Functional groups Nos.
Qty/unit On as required basis, minimum number as per drg no. 0000101/102-POI-A009 on as required basis
Common qty On required basis as
1.2
1.3
1.4
1.5
Control Cabinets for housing Control system hardware Control Cabinets for housing Remote I/O hardware (wherever specified / applicable) Marshalling Cabinets, , Termination cabinets, Relay Cabinets Relays
Nos.
on required basis
as
Nos.
on as required basis
on required basis
as
Nos.
on required basis
as
Nos.
on as required basis on as required basis
1.6
Cubicles for mounting network components & power supply distribution equipment. Human Machine Interface Redundant Servers (Only for Alternative 1)
Nos.
on required basis on required basis
as
on as required basis on as required basis
as
2.1
Sets
1 set is two nos. servers minimum.
PAGE 9 OF 11
CLAUSE NO.

Item name Operator Work Stations Unit Nos. 1 in CCR, 1 in CER DDCMIS BASED 2* 2* Remarks * The function of OWS can be implement ed in the server itself for Alternate 1 If system documenta tion facitliy is not part of this station, separate workstation s shall be provided for the same. * The function of Information Wokstation s can be merged with each of the OWS .
Sl no 2.2
2.3
Programming station
Nos.
1 in CER, One in Programmer Room
2.4
Information Work Stations (only for Alternative 2)
Nos.
1*
1*
2.5 2.6
Large Video Screens(LVS) Work Station for LVS
Nos. Nos.
NIL 3
NIL NIL
NIL NIL Including that for flame camera. Each set will include component s for respective remote I/O & FGs.
2.7
Suitable redundant interfaces and redundant links for connectivity between Unit LAN, stationwide LAN, and DDCMIS sub systems, unit / station PLCs, PC stations, PADO, Remote Service Centre as applicable .
sets
PAGE 10 OF 11
CLAUSE NO.

Item name Control System Programming device including EPROM Writer/eraser etc. (if applicable.) Data Communication System Remote Service centre hardware Graphical Interface Unit(10") Unit Nos. 2 DDCMIS BASED 1 1 Remarks This item is not required in case not applicable.
Sl no 2.8
2.9
As basis As basis Nos
required
As required basis
As basis
required
2.1
required
2.11
2 nos per unit for local operation of Mill Reject system(unitised part)
1 no in Fuel Oil Unloading station for local operation
Technical specificatio n of GIU shall be as detailed in main portion of Appendix-I.
3 3.1
Printers Color Laser Printer (A3 size)
nos
3.2
Laser jet colour printer (A4 size) Software Software for DDCMIS meeting requirements specified under item SYSTEM SOFTWARE REQUIREMEN TS, subsection DDCMIS, Part B, Section VI of technical specifications
1 for each programmer/ programmer cum documentation stn 1
As basis
required
As required basis
As basis
required
PAGE 11 OF 11

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SUB-SECTION - IIIC

CONTROL & INSTRUMENTATION SYSTEM

TECHNICAL SPECIFICATION SECTION-VI BID DOCUMENT NO. : CS-9575/9571/0370/0360/9586-102-2

SCOPE OF SUPPLY & SERVICES

2.02.00 2.02.01 2.02.02

TECHNICAL SPECIFICATION SECTION-VI BID DOC. NO.: CS-9575/9571/0370/0360/9586-102-2

PART-A SUB-SECTION-III:C CONTROL & INSTRUMENTATION SYSTEM

SCOPE OF SUPPLY & SERVICES

TECHNICAL SPECIFICATION SECTION-VI BID DOC. NO.: CS-9575/9571/0370/0360/9586-102-2

PART-A SUB-SECTION-III:C CONTROL & INSTRUMENTATION SYSTEM

SCOPE OF SUPPLY & SERVICES

TECHNICAL SPECIFICATION SECTION-VI BID DOC. NO.: CS-9575/9571/0370/0360/9586-102-2

PART-A SUB-SECTION-III:C CONTROL & INSTRUMENTATION SYSTEM

SCOPE OF SUPPLY & SERVICES

TECHNICAL SPECIFICATION SECTION-VI BID DOC. NO.: CS-9575/9571/0370/0360/9586-102-2

PART-A SUB-SECTION-III:C CONTROL & INSTRUMENTATION SYSTEM

SCOPE OF SUPPLY & SERVICES

TECHNICAL SPECIFICATION SECTION-VI BID DOC. NO.: CS-9575/9571/0370/0360/9586-102-2

PART-A SUB-SECTION-III:C CONTROL & INSTRUMENTATION SYSTEM

SCOPE OF SUPPLY & SERVICES

TECHNICAL SPECIFICATION SECTION-VI BID DOC. NO.: CS-9575/9571/0370/0360/9586-102-2

PART-A SUB-SECTION-III:C CONTROL & INSTRUMENTATION SYSTEM

SCOPE OF SUPPLY & SERVICES

Air Compressor System including AirCompressors of Mill Reject System

TECHNICAL SPECIFICATION SECTION-VI BID DOC. NO.: CS-9575/9571/0370/0360/9586-102-2

PART-A SUB-SECTION-III:C CONTROL & INSTRUMENTATION SYSTEM

SCOPE OF SUPPLY & SERVICES

(vi) (vii) (viii) 11.03.00 12.00.00 12.01.00

TECHNICAL SPECIFICATION SECTION-VI BID DOC. NO.: CS-9575/9571/0370/0360/9586-102-2

PART-A SUB-SECTION-III:C CONTROL & INSTRUMENTATION SYSTEM

SCOPE OF SUPPLY & SERVICES

TECHNICAL SPECIFICATION SECTION-VI BID DOC. NO.: CS-9575/9571/0370/0360/9586-102-2

PART-A SUB-SECTION-III:C CONTROL AND INSTRUMENTATION APPENDIX - I

SCOPE OF SUPPLY & SERVICES

TECHNICAL SPECIFICATION SECTION-VI BID DOC. NO.: CS-9575/9571/0370/0360/9586-102-2

PART-A SUB-SECTION-III:C CONTROL AND INSTRUMENTATION APPENDIX - I

SCOPE OF SUPPLY & SERVICES

TECHNICAL SPECIFICATION SECTION-VI BID DOC. NO.: CS-9575/9571/0370/0360/9586-102-2

PART-A SUB-SECTION-III:C CONTROL AND INSTRUMENTATION APPENDIX - I

SCOPE OF SUPPLY & SERVICES

TECHNICAL SPECIFICATION SECTION-VI BID DOC. NO.: CS-9575/9571/0370/0360/9586-102-2

PART-A SUB-SECTION-III:C CONTROL AND INSTRUMENTATION APPENDIX - I

SCOPE OF SUPPLY & SERVICES

Steam Generator floor per Unit

SG Charger in each unit

SG C&I of respective unit

Control system of Fuel Oil Pressurizing/Heating System Air compressor system

Air compressors of Mill reject system Auxiliary system Boiler Control

TECHNICAL SPECIFICATION SECTION-VI BID DOC. NO.: CS-9575/9571/0370/0360/9586-102-2

PART-A SUB-SECTION-III:C CONTROL AND INSTRUMENTATION APPENDIX - I

SCOPE OF SUPPLY & SERVICES

TECHNICAL SPECIFICATION SECTION-VI BID DOC. NO.: CS-9575/9571/0370/0360/9586-102-2

PART-A SUB-SECTION-III:C CONTROL AND INSTRUMENTATION APPENDIX - I

SCOPE OF SUPPLY & SERVICES

Item Description Graphical Interface unit. Graphical unit. Interface

Qty per unit 1 no per compressor

TECHNICAL SPECIFICATION SECTION-VI BID DOC. NO.: CS-9575/9571/0370/0360/9586-102-2

PART-A SUB-SECTION-III:C CONTROL AND INSTRUMENTATION APPENDIX - I