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

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

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

VOLUME – V SPECIFIC TECHNICAL REQUIREMENTS - INSTRUMENTATION AND CONTROL WORKS

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

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

MB POWER (MADHYA PRADESH) LIIMIITED MB POWER (MADHYA PRADESH) L M TED
ANUPPUR TPP, PHASE – I, 1000 (+ 20%) MW,
MADHYA PRADESH, INDIA

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

VOLUME – V SPECIFIC TECHNICAL REQUIREMENTS - INSTRUMENTATION AND CONTROL WORKS

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

MB POWER (MADHYA PRADESH) LIMITED
Spec No. TCE.5657A-H-500-001
ANUPPUR PHASE-1 (1000+20%MW) THERMAL POWER PROJECT

SECTION: CONTENTS

CONTENTS

VOLUME - I
SCOPE OF ENQUIRY INSTRUCTIONS TO BIDDERS GENERAL CONDITIONS OF CONTRACT SPECIAL CONDITIONS OF CONTRACT

VOLUME - II
SCOPE OF WORKS,TERMINAL POINTS AND SCHEDULES

VOLUME - III
PART – A D1 MECHANICAL WORKS – BTG PART – B D2 MECHANICAL WORKS – BOP

VOLUME - IV
PART – A D3 ELECTRICAL WORKS – BTG Part – B D4 ELECTRICAL WORKS – BOP

VOLUME - V
PART – A D5 INSTRUMENTATION & CONTROL WORKS – BTG PART – B D6 INSTRUMENTATION & CONTROL WORKS – BOP

VOLUME - VI
D7 CIVIL & STRUCTURAL WORKS

VOLUME - VII
BID PURPOSE DRAWINGS

ISSUE R0
Consultants: TCE Consulting Engineers Ltd.

TCE FORM NO. 329 R4

OF SHEETS 8 8 17 11 4 1 3 TCE FORM NO.MB POWER (MADHYA PRADESH) LIMITED Spec No. TCE.6 TABLE. 329 R4 .5657A-H-500-001 ANUPPUR PHASE-1 (1000+20%MW) THERMAL POWER PROJECT SECTION: CONTENTS CONTENTS VOLUME – V PART .7 TITLE SYSTEM DESCRIPTION/ PLANT OPERATION PHILOSOPHY SYSTEM/EQUIPMENT/SERVICES TO BE FURNISHED DESIGN.2 TABLE.5 TABLE. NO.4 D 6.5 D 6.3 TABLE.2 D 6. MATERIAL & RATING F FOR IMPULSE PIPES / TUBES & FITTINGS GUIDELINES FOR PROVISION OF INSTRUMENTS AND SPECIFICATIONS TITLE NO.B SECTION – D6 INSTRUMENTATION AND CONTROL WORKS .1 D 6.BOP SUB SECTION D 6.6 D 6.3 D 6.7 TERMINAL POINTS CONTROL SYSTEM HARDWARE / DCS INTERFACING CODES AND STANDARDS DATA TO BE FURNISHED WITH BID LIST OF ESSENTIAL SPARES SIZE. OF SHEETS 5 1 1 1 2 5 23 ISSUE R0 Consultants: TCE Consulting Engineers Ltd.4 TABLE.1 TABLE. PERFORMANCE AND FUNCTIONAL REQUIREMENTS SPECIFICATION FOR PLC / INSTRUMENTS TO BE SUPPLIED TESTS AND INSPECTION FOR I&C SYSTEM EQUIPMENT OTHER SERVICES PERFORMANCE GUARANTEE LIST OF TABLES SUBSECTION TABLE.

14 TABLE .10 TABLE. FIELD TESTING AND COMMISSIONING REQUIREMENTS - NO.15 TABLE .11 TABLE.8 TABLE. TCE FORM NO. OF SHEETS 1 1 4 2 3 5 1 6 1 ISSUE R0 Consultants: TCE Consulting Engineers Ltd. TCE.16 TITLE GUIDE LINES FOR SELECTION OF FLOW ELEMENTS GUIDE LINES FOR SELECTION OF CONTROL VALVES MATERIAL AND ACTUATOR TYPE TESTS TO BE PERFORMED FOR DCS/PLC / PROGRAMMABLE CONTROL SYSTEM FACTORY ACCEPTANCE TESTS FOR DCS/PLCs TESTS TO BE PERFORMED FOR INSTRUMENTS FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES) TRAINING TO BE PROVIDED FOR OWNER’S PERSONNEL ERECTION. 329 R4 .13 TABLE .5657A-H-500-001 ANUPPUR PHASE-1 (1000+20%MW) THERMAL POWER PROJECT SECTION: CONTENTS CONTENTS LIST OF TABLES SUBSECTION TABLE.12 TABLE .MB POWER (MADHYA PRADESH) LIMITED Spec No.9 TABLE.

sequence of events recording and annunciation system. sensors. The I&C system shall permit operation and monitoring of the utility plant packages from the utility / local control room (LCR). 120R2 . local panels.1 The instrumentation and control (I&C) system called for in the specification shall be a comprehensive system integrating the functions of plant monitoring.5657A-C-500-002 Volume – V SECTION: D 6. The overall I & C system design shall ensure the following: (a) (b) (c) (d) (e) Maximise safety for the plant personnel and equipment Safe. unit control panel. co-ordination and autonomous operation of the plant utilities like coal handling plant. TCE.3 Logging of equipment/component failure duration and data availability for failure analysis. reliable. Ash handling plant. 1. local instruments and erection hardware. DM water plant. Alarm notification. I&C system shall consist of a functionally distributed microprocessor based system (PLC control systems). ISSUE R0 Vol V .1 INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY SHEET 1 OF 8 SYSTEM DESCRIPTION 1.TCE Consulting Engineers Limited Spec No. control and protection to facilitate the task of integration. control and monitoring. with facility for VDU (Video Display Unit) /Keyboard & Large Video Screen based operation. Raw water & pre treatment plant and other utility plants. (iv) Historical data storage and retrieval facility for long term monitoring of plant equipment performance. junction boxes.2 (f) (g) (h) 1. Reservoir intake system. The I&C system shall be interfaced with other different auxiliary plant monitoring and analysis systems to provide supervisory and reporting facilities to plant personnel and management. normal operation. cables.Part(B) Page 1 of 114 TCE FORM NO. flow elements. disturbances and shut down) automatically and/or by remote manual control from relevant control room Malfunction of any component or loss of supply leading to fail-safe condition Provide accurate and reliable information to the plant operators and management. complete with control desk. together with. system cabinets. efficient and easy operation of the plant under all operating conditions Maximise availability and efficiency of the plant through system redundancy.0 1. Provide the operators the following facilities: (i) (ii) (iii) Complete information for plant equipment status / abnormal and critical conditions. control valves. Ability to operate under all specified conditions (start-up. Consistent control & instrumentation philosophy – usage of standard functional modular hardware and software design.

The OS shall be table top mounted type. Complete monitoring of the Plant Ash handling Plant. DM Plant and their associated auxiliaries and other auxiliary systems shall be operable /monitored from VDU/Keyboard based Operator stations (OS).1.2 Two (2) nos. AHS.1 INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY SHEET 2 OF 8 1.1 2.2.1 LOCAL OPERATION OPERATION FROM LOCAL CONTROL ROOM (CCR) 2. When operated from OS.2 2. Utility plant operation / monitoring will be primarily through VDU/ KB based OS mounted on Control Desk (CD). 120R2 .0 2. Complete monitoring of plant common DM water plant & effluent treatment plant etc.. Complete monitoring of the reservoir intake water system.5657A-C-500-002 Volume – V SECTION: D 6. 2. shall be provided.2. Coal handling plant / Ash handling plant / DM Water plant & Effluent treatment plant / etc. ISSUE R0 Vol V . The OS shall be table top mounted type.1. In addition to VDU/KB based OS.1. OS shall be provided for each utility plant local control room..1 The utility and auxiliary systems viz. the operator shall be able to call for the various types of displays for all parameters as required on the screen and it shall be possible to carry out all types of operation.1 (c) (d) (e) 2. However. the operator shall be able to call for the various types of displays for all parameters as required on the screen and it shall be possible to carry out all types of operations.1 PLANT OPERATION PHILOSOPHY OPERATION FROM CENTRAL CONTROL ROOM (CCR) All equipment associated with CHS. which will be primarily operated and monitored from respective utility plant located local control room: (a) (b) Complete monitoring of plant common Coal Handling Plant.4 Details of the terminal points between BOP and others are detailed in section D6 – TABLE. When operated from OS.Part(B) Page 2 of 114 TCE FORM NO.2. will be primarily operated & monitored locally from respective utility plant located local control rooms (LCR).. facility for monitoring from CCR shall be made available through OPC over Ethernet TCP/IP. TCE. Raw water and pre-treatment system 2. one (1) no Large Display screen shall be provided for both CHP & AHP control room.TCE Consulting Engineers Limited Spec No. LCR operation/ monitoring facility through OS/LVS shall include the following as an additional facility.

TCE Consulting Engineers Limited Spec No. 2. Status of all emergency stop pushbuttons for unidirectional drives (pump/fan etc) shall be monitored into the respective control system. Plant Common DM water plant & Effluent treatment plant etc. The local pushbuttons for various drives shall be hooked up to control system as indicated below: (a) (b) All emergency stop pushbuttons shall be wired directly to MCC / Switch gears.2.5657A-C-500-002 Volume – V SECTION: D 6. 2. authorised personnel having the key may operate the motorised valve locally.1 INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY SHEET 3 OF 8 2. integral starters shall be provided and these shall have local open. close and stop push buttons in addition to local / remote selector.2 Local Operation from Field Local stop push button stations shall be provided near all the drives except for the motorised valves and solenoid valves. local start/stop operation from local pushbuttons (LPB) shall be provided for all uni-directional drives as a testing and maintenance facility. The local / remote selector switches of all integral starters shall be locked and shall have a common key. Local mode selected shall be wired to the PLC for annunciation to operator in the control room.2 Local / remote operation location selection shall be carried out from local control room through OS. Plant Common Ash Handling Plant.2.1 In addition to the Local control room operation / monitoring facility. 120R2 . For systems provided with relay based local panels. For the motorised valves.1 UTILITY PLANT CONTROL PHILOSOPHY PLC based control systems are envisaged for all other unit specific and plant common systems utility plants as detailed below: (a) (b) (c) (d) (e) (f) Plant Common Coal Handling Plant. TCE.2. Lockable type Local stop push button shall be connected to the MCC/switchgear. By unlocking the lock. Plant common raw water and pre treatment system with key pad operated. Local/remote and auto/manual selection shall be provided in the PLC HMI as soft selection for drives covered in the PLC.0 3.2. 3. Any other utility plant system/equipment not covered. the selector switches shall be provided on the local panel. ISSUE R0 Vol V .Part(B) Page 3 of 114 TCE FORM NO. Plant common reservoir intake system with key pad operated.2.

of the stacker cum reclaimer will be achieved through dedicated Programmable logic controller [PLC] based control system mounted local to the equipment. TCE. individual/sequential control. However remote I/O panels as required shall be provided and the same shall be connected to the main CHS PLC through redundant communication. dynamic status/ parameter updating on graphic pages and annunciation of the coal handling plant.5657A-C-500-002 Volume – V SECTION: D 6. ISSUE R0 Vol V . patch cable etc for the same shall be in bidders scope. control and interlocking etc. It will be complete with all safety devices. 120R2 . Control room for the CHS system shall be sized considering both phases [I & II]. The necessary media convertors. Control desk as required for the control system components like operating station / engineering station etc shall be provided for phase – I. The PLC system will be an independent system for automatic operation of the wagon tippler and single arm charger. patch cable etc for the same shall be in bidders scope. The interlocks and protections of all the drives and equipments shall be covered in the CHS PLC with operation and monitoring from the control desk mounted operator station (OS) / Operator cum engineering station (OES) The sequential operation. controls and interlocks. Wagon tippler & side arm charger shall be operated from the wagon tippler control room from a common PLC based control panel. The necessary media convertors. The PLC shall be interfaced to the CHS PLC through redundant fibre optic cable. protection. The main PLC shall be provided with remote I/Os that shall be connected to the PLC through redundant fiber optic cables.TCE Consulting Engineers Limited Spec No. The remote I/O racks for this main PLC shall be provided as required based on the detailed engineering. The PLC shall be interfaced to the CHS PLC through redundant fibre optic cable.1 INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY SHEET 4 OF 8 (a) Coal handling plant: The overall operation. indications and annunciations implemented in the PLC based system. measurement/monitoring.Part(B) Page 4 of 114 TCE FORM NO. This CHP main PLC shall perform the functions of interlock. protections.. control and monitoring of the coal handling plant shall be achieved through a PLC based system provided in the CHP control room.

clinker grinders.5657A-C-500-002 Volume – V SECTION: D 6.1 INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY SHEET 5 OF 8 (b) Ash handling plant: A microprocessor based Programmable logic controller shall be provided for the operation and control of the Ash Handling System equipment. Loading and unloading operations and start of standby on trip of running compressor shall be performed by the ash handling system PLC. Control system – PLC shall be common for all the units. water pumps. The unloading of dry fly ash/bottom ash into the trucks shall be independently operated and monitored from their respective local relay based panel. selector switches. This LCP will be provided with conventional operational hardware’s such as push bottons. conveyors. For this purpose one number remote I/O panel is provided for the interfacing of the signals in the bottom ash area and to the LCP operational hardware. Level probes shall be provided for each fly ash hopper to enable operation of the fly ash handling system. Ash silo unloading system shall be provided with local control panel [wall/column mounted] for its local operation. The fly ash shall be removed from the ESP.Part(B) Page 5 of 114 TCE FORM NO. The HCS disposal system shall be provided with dedicated PLC based control system. 120R2 . ISSUE R0 Vol V . One number remote I/O panel shall be provided for each unit [for Pneumatic dense phase and bottom ash system] and the same shall be located in the ESP control room of each unit. air compressors.TCE Consulting Engineers Limited Spec No. APH & ECO hoppers and transported to the Intermediate fly ash storage silos either under auto mode (timer mode operation or level probe mode operation) or manual mode (one hopper at a time) selectively. The interlock requirements of bottom ash unloading shall be implemented in common AHS PLC. shall be operated from VDU/keyboard of the PLC system. The air compressors shall be provided with dedicated PLC / microprocessor based control system. TCE.. All the operation and monitoring functions are to be carried out from the VDU. The ash transmitters. indicating lamps. etc. Status signals from this system shall be hardwired to the Ash Handling System PLC for monitoring. The equipment status shall be indicated on the HMI of the AHS PLC by hardwiring the status signals to the PLC system. One local control panel (LCP) shall be provided for bottom ash unloading. In addition to this status indication shall be hardwired to the AHS PLC.

DM water transfer pumps and condensate storage tanks. This DM Plant PLC shall perform the functions of interlock. The taprogge system shall be provided with PLC based local control panel.). The same shall be in bidder’s scope. ISSUE R0 Vol V .. shall be operated from VDU/keyboard of the PLC system. Plant Potable Water System. The Reservoir intale water system PLC shall be interfaced to the DM plant PLC through redundant fibre optic cable with required media convertors. 120R2 . However. at both ends for monitoring of the same from the DM Plant control room. hooters. protection. Neutralising pumps. measurement/monitoring. DM storage tank. The local panels for the Taprogge air powered intake system. and chlorine dioxide system shall be provided with operational hardware such as push buttons. (d) Reservoir intake water system: A Programmable Logic Controller (PLC) based local panel with LCD / keypad type operator interface panel shall be provided for the operation and control of the Reservoir Intake water System equipment. clarified water storage tank. It shall be possible to perform all the operation and monitoring functions of the pumps and associated motorised discharge valves from the LCD / keypad of the PLC system. Filtered water storage tank.1 INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY SHEET 6 OF 8 (c) DM water plant & Effluent treatment plant: A microprocessor based Programmable logic controller shall be provided for the operation and control of the DM water plant and Effluent treatment plant Systems from the PC based operator stations mounted in the DM plant control room. indicating lamps. individual/sequential control. TCE. etc.5657A-C-500-002 Volume – V SECTION: D 6. All the operation and monitoring functions are to be carried out from the VDU.Part(B) Page 6 of 114 TCE FORM NO. Service Water System and Service water storage tank etc. dynamic status/ parameter updating on graphic pages and annunciation of the coal handling plant. de-mineralised (DM) plant. The WT plant supply pumps. Equipment status signals and important alarms from these local panels shall be hardwired to the reservoir intake water PLC system for monitoring from its LCD / keypad HMI.TCE Consulting Engineers Limited Spec No. the Taprogge air powered intake system and its associated air compressor and the chlorine di-oxide system shall be provided with respective skid mounted local control panels. patch cables etc. switches.

5 3. The Plant Raw water System and pre-treatment system comprising raw water supply pumps. It shall be possible to perform all the operation and monitoring functions of the pumps and associated motorised discharge valves from the LCD / keypad of the PLC system. no plant system/equipment shall have relay based control system. Ash handling plant control system. A common time synchronisation system is envisaged and the same is provided by the BTG vendor.5657A-C-500-002 Volume – V SECTION: D 6. Communication link shall be Bi-directional for Coal Handling Plant.7 3. Vibration monitoring system for each package shall be interfaced with respective PLC through redundant interfacing for necessary data exchange.10 ISSUE R0 Vol V .Part(B) Page 7 of 114 TCE FORM NO. TCE. at both ends for monitoring of the same from the DM Plant control room. Clarified Water System and Filtered Water System and CW make up pumps etc. shall be operated from LCD / keypad HMI of the PLC system.2 All PLC based utility plant control systems shall be interfaced with DCS through redundant bi-directional OPC link.5657A-IC-SK-03.9 3. patch cables etc.1 INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY SHEET 7 OF 8 (e) Raw water and pre-treatment system: Programmable Logic Controller (PLC) based local panel with LCD / keypad type operator interface panel shall be provided for the operation and control of the Raw Water and pretreatment System equipment. All different PLC based control systems for utility plant/systems and other special monitoring and analysis systems shall be suitably interfaced to Plant DCS for proper functioning.4 3.8 3.. Details of control system hardware envisaged for the total power plant with interfacing requirements with plant DCS are detailed in Section D 6. TABLE-2. The Raw water and pre-treatment system PLC shall be interfaced to the DM plant PLC through redundant fibre optic cable with required media convertors. If any considered the same shall be highlighted and it is subject to customers / consultant approval. An overview of utility plant Instrumentation and Control system is illustrated in dwg. no TCE. Hand held HART communicator shall be provided for remote calcibration of smart transmitters.TCE Consulting Engineers Limited Spec No.3 3. Provision shall be made available in the utility plant PLC’s for the acceptance of the same for synchronisation. 3.6 3. 120R2 . 3. In general. The same shall be in bidder’s scope. Reservoir intake water system & DM Plant /Effluent Treatment Plant. All PLC based utility plant control systems shall be interfaced with DCS through redundant OPC link with Ethernet based TCP-I/P protocol.

The VENDOR shall furnish English translation of all standards to which the equipment and systems offered conform to.0 4.Part(B) Page 8 of 114 TCE FORM NO. systems. TABLE-3.1 CODES AND STANDARDS All equipment. unless otherwise specified.1 INSTRUMENTATION AND CONTROL SYSTEM DESCRIPTION / PLANT OPERATION PHILOSOPHY SHEET 8 OF 8 4. International Electrochemical Commission (IEC).2 Standards not indicated in the specification are acceptable (subject to approval by the Owner / Owner’s Representative) if they are established to be equal or superior to the standards indicated in the specification. Instrumentation Systems and Automation Society (ISA). The specific codes and standards applicable are listed in Section D 6.4 ISSUE R0 Vol V . All codes and standards referred in this specification shall be understood to be the latest version on the date of offer made by the Bidder. the same shall comply with the applicable recommendations of the following professional institutes: (a) (b) (c) (d) (e) (f) (g) (h) (i) National Electricity Manufacturers Association (NEMA) The Institute of Electrical and Electronic Engineers (IEEE). American National Standards Institute (ANSI). 4. 4. TCE. 120R2 . Verin Deutschar Eisecnhuttenleutte (VDE) Indian Standard Institute (ISI). Deutsche Industries Norman (DIN).5657A-C-500-002 Volume – V SECTION: D 6. software and services covered under this specification shall comply with all currently applicable statutes.3 4. International Consultative Committee on Telephone and elegraphy (CCITT). If such standards are not existing for any equipment or system.TCE Consulting Engineers Limited Spec No. regulations and safety codes in the locality where the equipment will be installed.

xii. TCE. xix.Spec No.. Training Of Owner’s Personnel xvii. testing and commissioning of the complete Instrumentation and Control System Equipment complete with all hardware.No. reliably and safely as detailed in this section and also under System description/Operation philosophy in Section-D 6. laying & termination of complete Instrumentation. to operate the plant efficiently. vi. Supply.TCE5657A-IC-SKISSUE R0 Vol V . 2. Special cables. Consumables for Operation / Maintenance.5 with enclosed Tables and drawings. ii. i. 120R2 .3. Compensating. Engineering Documentation xvi. All the furniture in the Local control room.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL SCOPE OF WORK-SYSTEM/EQUIPMENT/SERVICES Volume – V SECTION: D 6. vii. Design philosophy in Section – D 6. erection. Trial Operation And Guarantee Test xv. together with preparation of all cabling related engineering documents like Cable Schedule. Control. viii. The offer shall comply with the latest applicable codes and standards as prevailing on the date of submission of the bids. Performance Test. Pre-fabricated cable.2 SHEET 1 OF 8 1. iii.0 SYSTEM / EQUIPMENT/SERVICES TO BE FURNISHED The Scope includes design. supply. xiii.1. manufacturing. ix. relevant technical specification in Section –D 6. iv. software and accessories and other services including the following. xviii. Auxiliary Power Supply System Maintenance and Erection Tools and Tackles Essential Spares Erection.0 PROGRAMMABLE LOGIC CONTROLLER (PLC) An overview of the required control system is illustrated in Dwg. x. xi. Field Testing And Commissioning Including Erection Hardware xiv. Inter-connecting Schedule etc. PLC based control system for auxiliary and Utility plants Control Desks and cabinets Field Instruments including pipe mounted items and accessories Final control elements Water Analysis System (SWAS) Large Video Screen Display System [LCD type] Vibration Monitoring system Hand held HART communicator. Inspection and testing of I&C system equipment. v.Part(B) Page 9 of 114 TCE FORM NO. Fibre optic cable etc.4 and Testing requirements in Section-D 6.

This system is detailed in write-up in Section D 6. printers and function cards is through the data bus. 2.3 and relevant specification in Section – D 6.3 and relevant specification in Section – D 6. protection and sequential control system shall be complete with processor. The bus system requirements are detailed in Section-D 6.1 MEASUREMENT SYSTEMS (MS) Measurement system shall be complete with processor. signal conditioning and monitoring cards and function cards to perform measurement system functions. Data Bus System for Control and Communication with the process.3 and relevant specification in Section – D 6. interfacing with Plant DCS and software.4. Control System. 2. The system is detailed in Section-D 6. 2.2 SHEET 2 OF 8 03.4 DATA BUS SYSTEM (DBS) The communication sub system shall be a real time reliable communication network between control processors. MMI (Operator Stations. signal conditioning and monitoring cards and function cards to perform control system functions.4.2 CLOSED LOOP CONTROL SYSTEM (CLCS) Closed loop control system shall be complete with processor. printers and associated hardware form the Operator Station (OS)/MMI. 2. 2. The system shall also be capable of transmitting the data to Operator Stations (OW)s in the Control. Printers ) and Engineering station. The system is detailed in relevant Section-D 6. 2. The system shall also be capable of executing commands from OS through key boards. The main bus shall have Dual redundancy.4. TCE.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL SCOPE OF WORK-SYSTEM/EQUIPMENT/SERVICES Volume – V SECTION: D 6.6 ENGINEERING STATION (ES) ES equipment shall have operator station & printer to perform the functions of software generation and maintenance of PLC system in addition to OS functions.7 SOFTWARE ISSUE R0 Vol V . 2.Part(B) Page 10 of 114 TCE FORM NO.Spec No. PROTECTION AND SEQUENTIAL CONTROL SYSTEM (OPEN LOOP CONTROL SYSTEM) Interlock. The requirements of the various features of the control system are detailed further below.4.4.5 OPERATOR STATION (OS)/ MMI SYSTEM VDUs/key boards of OS. The system shall also be capable of executing commands from OS through key boards.4. signal conditioning and monitoring cards and function cards to perform the sequential and combinational logic functions.This system is detailed in write-up in Section D 6. Interlock.3 INTERLOCK.This system consists of Measurement system. This system is detailed in Measurement system write-up in Section D 6. It shall also be used for monitoring the status of all equipment connected to PLC system. The data communication between VDU/key boards. Protection and Sequential Control System. 120R2 .

ash handling system & DM water / Effluent treatment system].1 TCE FORM NO. Interfacing cables required for the applications are included in BTG vendor scope of supply: Communication protocol will be decided during detail engineering stage. PLC Make/ Model Qualification: Offered PLC make / model shall have been designed.1 PLC SYSTEM INTERFACING REQUIREMENT All utility package PLC’s like Coal handling system. 2 nos Operator Stations with single VDU and single Keyboard/ mouse/ trackball for operator shall be provided for Ash handling system. 120R2 .Part(B) Page 11 of 114 2.9 2.8 2. All software used for the system shall be licensed version only.operation and maintenance functions) and communication software between various sub systems shall be supplied and implemented as detailed in relevant Section-D 6.8. TCE.0 3. Modem for Remote Diagnostic Support complete with all accessories.3 PLC Controllers: As required considering the requirements detailed in Section D 6. which are in successful commercial operation for minimum 2 years at the date of Bid opening.9. ash handling system.8.Spec No.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL SCOPE OF WORK-SYSTEM/EQUIPMENT/SERVICES Volume – V SECTION: D 6. with scope of work involving at least automatic controls and sequential controls.10 2.3 PLC SYSTEM HARDWARE I/O Modules: As required considering the requirements detailed in Section D 6. 1 nos Operator Stations with single VDU and single Keyboard/ mouse/ trackball for operator shall be provided for DM water / Effluent treatment system.8.4. manufactured and commissioned for at least 2 balance of plants for a capacity of minimum 600 MW size units or higher in last 5 years. It is the Bidder’s responsibility to offer communication link with protocol suitable for communication between plant DCS & utility package PLC’s. Bidder to furnish the necessary proof for the same in the bid offer PLC BASED CONTROL SYSTEMS FOR UTILITY PLANTS PLC based control system complete with all hardware and software shall be provided for ISSUE R0 Vol V . shall be interfaced to plant DCS.11 3.9.1 2.2 2.2 SHEET 3 OF 8 Complete software for the microprocessor based PLC system including the system software and application software (to carryout the engineering.3 Operator Stations: (a) (b) (c) 2. Engineering Station: (a) 1 nos Engineering Station (ES) with single VDU and single Keyboard/mouse/trackball for Engineer shall be provided for each utility package PLC [Coal handling system. 2. 2..8. monitoring . DM plant / effluent treatment system etc.2 2.4 1 nos Operator Stations with single VDU and single Keyboard/ mouse/ trackball for operator / Unit shall be provided for the Coal handling system.

6.0 LARGE SCREEN VIDEO DISPLAY SYSTEM 2 nos.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL SCOPE OF WORK-SYSTEM/EQUIPMENT/SERVICES Volume – V SECTION: D 6. field termination cabinets / junction boxes.4. Suitable provision shall be made in the utility package PLC’s for the synchronisation of the same. TABLE-7. The system is detailed in Section D 6.0 Coal handling plant Ash handling plant DM Water plant & Effluent treatment plant Reservoir intake water system [PLC with LCD key pad operated] Raw water & pre-treatment system [PLC with LCD key pad operated] PLC Control System Interfacing All PLC based utility plant control systems shall be interfaced with DCS through redundant OPC link with Ethernet based TCP/I-P protocol.1 4. etc. shall be supplied. The technical requirements are detailed in Section D 6.4.0 FIELD INSTRUMENTS AND ACCESSORIES All primary elements.0 VIBRATION MONITORING SYSTEM ISSUE R0 Vol V . TIME SYNCHRONISATION EQUIPMENT GPS based time synchronisation equipment for plant I&C system equipment time synchronisation shall be supplied by the BTG vendor. 5. field mounted instruments and accessories.3 / D 6.0 FINAL CONTROL ELEMENTS All final control elements as required are included in Bidder’s scope.2 3. 8.4. Screen size shall be 52 inch. interconnecting cables. The system is detailed in Sections D 6.2. Communication link shall be Bi-directional.0 WATER ANALYSIS SYSTEM Analysers as required for the DM water verification with required sampling system are included in Bidders scope. impulse pipes and fittings. 120R2 . racks. TCE. 9. The specification and the guidelines for these items are given in Section D 6.Spec No. The system shall be complete with video screen.2 SHEET 4 OF 8 following packages: The system is detailed in Section D 6. workstation for display control and all accessories. The system is detailed in Sections D 6.4 (a) (b) (c) (d) (e) 3. TABLE-7 7.Part(B) Page 12 of 114 TCE FORM NO. Large screen video display system of LCD type shall be supplied for mounting 1 no each in coal handling plant and ash handling plant local control room.

Impulse pipes. Control.4. fittings and air supply and signal piping/tubing shall be supplied for all the instruments under the scope of this specification. 14. Compensating. Pre-fabricated cable. material & rating depending upon service conditions is given in Section D 6. 11.TABLE-5. TABLE-7 of this specification. TCE.0 ENGINEERING DOCUMENTATION CONTRACTOR shall prepare engineering documents for OWNER / CONSULTANT review and approval.5 of the specification. Special cables. Table-6.2 15. test and commission all Instrumentation and Control Equipment for the complete power plant supplied under this contract to the complete satisfaction of the OWNER.0 MAINTENANCE AND ERECTION TOOLS AND TACKLES The Bidder shall include in his offer all special maintenance and erection tools and tackles as required for the system being offered.. TRIAL OPERATION AND GUARANTEE TESTS The CONTRACTOR shall conduct integrated test at manufacturer's works (FAT) and inspection. PERFORMANCE TEST.2 SHEET 5 OF 8 Vibration monitoring system shall be supplied for all HT and major drives and driven equipment bearings.Spec No. 120R2 . The performance and Guarantee test shall be conducted by the OWNER after trial operation as detailed in Section D 6. 10. 12. The system is as detailed in Section D 6. FIELD HARDWARE TESTING AND COMMISSIONING INCLUDING ERECTION The CONTRACTOR shall erect. The selection of size. CONTRACTOR’s scope of work will include any additional instruments supplied by other contractors/ OWNER which is required for proper & satisfactory performance of the power plant. etc. The details of the above power supply system are covered in Electrical section.5 of the specification. The details shall be furnished. checking and pre-commissioning tests at site as detailed in Section D 6. ERECTION.0 AUXILIARY POWER SUPPLY SYSTEM 230 V AC UPS power supply for PLC system shall be provided for Instrumentation and Control system.0 16. Format for important documents are detailed in TABLE-13.1 ESSENTIAL SPARES Scope of supply includes I&C system essential spares as detailed in Section D 6.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL SCOPE OF WORK-SYSTEM/EQUIPMENT/SERVICES Volume – V SECTION: D 6. Inter-connecting Schedule etc. laying & termination of complete Instrumentation. ISSUE R0 Vol V . are included in Bidder’s scope. The CONTRACTOR shall prove the guarantee of the system and equipment supplied. The requirements are covered in Section D 6.0 14.0 14.Part(B) Page 13 of 114 TCE FORM NO.0 INSTRUMENTATION AND SPECIAL CABLES Supply. together with preparation of all cabling related engineering documents like Cable Schedule. 13.

The following minimum equipment shall be considered for Inspection (witness) at ISSUE R0 Vol V .5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL SCOPE OF WORK-SYSTEM/EQUIPMENT/SERVICES Volume – V SECTION: D 6. Owner shall indicate his preference regarding the inspection of the equipment.Spec No. equipment and workmanship at all stages of manufacturing of all the main I&C equipment including the PLC.s charges for analysers. It is Contarctor’s responsibility to schedule the inspection & testing of different equipment / systems in a properly phased manner. 18. The requirements are detailed in Section D 6.2 SHEET 6 OF 8 17.6 of the specification. TCE. Testing requirements not explicitly specified for any equipment but required for establishing the satisfactory performance / functioning of the equipment / system are deemed to be included in the scope of work of Contractor.1 INSPECTION AND TESTING FOR I&C SYSTEM EQUIPMENT The Owner or Owner’s representative reserves the right to inspect and approve the material.3 of this specification.2 20.1 OTHER SERVICES TRAINING OF OWNER’S PERSONNEL The CONTRACTOR shall provide training to OWNER’s personnel as specified in Section D 6. each type.6 of the specification.2 PERFORMANCE GURANTEE TEST INSTRUMENTATION The CONTRACTOR shall provide PG test instrumentation as specified in Section D 6. 120R2 .0 20. Bidder shall call for inspection / witnessing the conductance of test of the equipment well in advance (minimum 21 days) to the Owner. 3 TCE FORM NO.0 18. 19. as required are included in Bidder’s scope of supply.1 CONSUMABLES The following consumable shall be supplied / Unit: (a) (b) (c) (d) (e) (f) Fuses DVD R/W CD R/W Insulation Tape Teflon tape 5 Nos. 50 nos 50 nos 50 rolls 50 rolls Reagents for 12 no.0 FURNITURE All the furniture in the Local control Room (s).0 17.5 and Section D 6. 17.Part(B) Page 14 of 114 20. 20. TABLE-10 of this specification. Inspection and testing requirements for different I&C system equipment are tabulated in Section D 6.

4 Integrated PLC testing including testing of communication links.4 TCE FORM NO.3 21.1.Part(B) Page 15 of 114 21. Programmable Logic Controllers (PLC) Video Display Unit / Keyboard All the systems in the Bidder’s scope shall work satisfactorily taking into account all the required interconnections. series and family of hardware at minimum: (a) (b) (c) (d) 21. Vibration monitoring System (b) 21. Performance Guarantee Test & Availability Guarantee Test for PLC systems as detailed in Section D 6. level & flow transmitters of differential pressure type& Temperature transmitter. Measurement and control equipment offered shall be complete in all respects and any equipment / accessories not explicitly indicated in this specification.1 To provide smooth and optimal maintenance. easy interchange ability and optimal spare parts management of I&C instruments/equipment.5 of the specification. dampers etc. the bidder shall ensure that all the similar equipments shall be of the same make. Differential pressure. Transmitters The Contractor shall conduct site tests for following equipment / systems: (a) Site Acceptance tests including Trial Operation. 120R2 . Before taking over the plant by the Owner. Any I&C equipment required during any stages for the efficient / safe / reliable operation of the plant either during detailed engineering / commissioning / after commissioning shall be installed and commissioned by the Bidder with in the quoted price. series and family of hardware 21.2 SHEET 7 OF 8 manufacturer’s works (Contractor’s and sub suppliers) by Owner as specified: (a) (b) (d) (h) 20.0 21.Spec No. TCE.2 Following equipments shall be of same make. but considered essential for proper functioning of equipment and process shall be included in the Bidder’s scope of work and supply. all the instruments.1 GENERAL Uniformity of Hardware 21. All control valves.1. Analysers. system and auto control loops shall run satisfactorily for at least one month at varying loads without disturbing any ISSUE R0 Vol V . The CONTRACTOR shall prove the guarantee of the system and equipment supplied.2 Pressure and Temperature Gauges All pressure.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL SCOPE OF WORK-SYSTEM/EQUIPMENT/SERVICES Volume – V SECTION: D 6.

Part(B) Page 16 of 114 TCE FORM NO.2 SHEET 8 OF 8 adjustment. TCE.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL SCOPE OF WORK-SYSTEM/EQUIPMENT/SERVICES Volume – V SECTION: D 6. 21. The guarantee shall be absolute and shall be a criteria for vendor selection by Contractor. ISSUE R0 Vol V . supervision and maintenance of total instrumentation equipment shall be the scope and responsibility of the Contractor’s personnel. 120R2 . During this period.5 Availability of Spares & Services Spares and services for PLC related equipment/systems shall be available for 15 years from the date of handing over of plant by EPC Contractor. The guarantee shall be re-confirmed by EPC contractor on post contract execution phase from respective equipment / system vendor.Spec No. Bidder shall furnish the guarantee for the same in the bid offer.

shutdown. PERFORMANCE & FUNCTIONAL REQUIREMENTS SHEET 1 OF 17 1. start-up.5657A-C-500-002 Volume – V SECTION: D 6. Limit Value Monitoring. All analogue parameters will be displayed. VDUs and peripherals.safe mode.e.1. The system hierarchy shall be at four levels. various function modules. sequence or on/off) functions shall form separate elements at each of the hierarchical level. hierarchical architecture.3. No single fault shall jeopardise the functioning of the entire system.2.0 INSTRUMENTATION AND CONTROL SYSTEM PHILOSOPHY MEASUREMENT SYSTEM (MS) 1.3.4.1 (f) 1. modulating) functions and open loop (i. For all drives. TCE. The closed loop (i.1.2 TCE FORM NO. Compensation for Pressure. The MS shall have the standard features not limited to the following:Linearisation. ISSUE R0 Vol V .1 The measurement system consist of primary sensors.1 CLOSED LOOP CONTROL SYSTEM (CLCS) The CLCS shall control the process variables automatically both under steady state and dynamic conditions with in the limits specified under guarantee clauses over the entire operational range of the equipment/system. 1. Square root extraction.e. No two simultaneous faults shall lead to or potentially cause damage to plant Safety related instrumentation and control shall be designed with a fail. forced outage or unit trip. The CLCS shall have the following features: (a) Provision of predictive and/or adaptive controls in addition to PID controls as required by the system. 120R2 . Remote field sensor multiplexing etc. power supplies and data networks shall be immune to the electromagnetic interference and shall conform to the internationally accepted standards. The control and automation system and the field instruments and actuators as well as it’s support systems. status indication will be displayed.3 INSTRUMENTATION AND CONTROL SYSTEM –DESIGN. The system requirements are specified in relevant Section-D 6.2 1. processors. CONTROL SYSTEM Design Features (a) (b) (c) (d) (e) No single random fault in the entire automation and control system will cause a load loss.3 1. (b) Set point adjustments and indication from operating VDU for process variables which need to be changed during load changes. the control system hardware and software shall conform to a modular. To meet the operational and safety requirements. normal or under any other emergency conditions.Part(B) Page 17 of 114 1. Flow totalising.1 1.2 1.TCE Consulting Engineers Limited Spec No. temperature & Density.

speed drive etc. The OLCS shall have the following features as a minimum: Features-General Requirements (a) The logic and sequence control shall be Digital distributed microporcessor based and programmable.2 1.3 INSTRUMENTATION AND CONTROL SYSTEM –DESIGN. PERFORMANCE & FUNCTIONAL REQUIREMENTS SHEET 2 OF 17 (c) Fixed set point at the software level/hardware level (only changeable by the maintenance engineer) and indication for those process variables which need not be changed with respect to load or otherwise. Fail safe operation of final control elements in case of failure of motive power or signal. Auto and manual control facility shall be transferable in both directions without bump of the value of the process variable to control the parameter during manual operation. 120R2 .TCE Consulting Engineers Limited Spec No. 1. Characterisation of final control element to suit the various applications with respect to load or otherwise as dictated by the process.4. Both Master Auto Manual station and Auto / Manual station for individual control element shall be provided in VDUs.Part(B) Page 18 of 114 TCE FORM NO.4. TCE.4 1. This system shall enable the operator for safe start up and shutdown and carryout normal operation both from control room and local areas. Soft Auto /Manual station interlocks to drive the final control elements to a suitable position for safe plant operation in the event of process/equipment abnormal conditions.2.4. (d) (e) (f) (g) (h) (i) (j) (k) 1. Blocking/Interlocking function as dictated by process/equipment. Monitoring of loop failures or any hardware failure in the loops.1 OPEN LOOP CONTROL SYSTEM (OLCS) Protection. Function generator to provide necessary characterisation or variation of set points with respect to load.5657A-C-500-002 Volume – V SECTION: D 6. interlock and sequence controls constitute OLCS. Manual control facility will include operation from Back Up Control Panel also in addition to operation from operator station. speed or any other requirement. Bias adjustment with indication where a single controller is controlling more than one final control element (control valve. Controls shall be provided to start/shutdown various systems and/or any equipment with associated auxiliaries and to operate the Unit on line with optimum number of operations and higher safety. control damper.1 ISSUE R0 Vol V .) to maintain the same process variable. Protection and Interlock shall be provided for all the equipment and system to safeguard the equipment against abnormal conditions which may result in the failure and less utility of the equipment and protect the operating personnel.

bearing vibrations normal. PERFORMANCE & FUNCTIONAL REQUIREMENTS SHEET 3 OF 17 (b) Enable the operator to start/stop various unidirectional motors. auto standby features shall be provided to select the standby unit and this standby unit shall start automatically on failure of running pump or on applicable process criteria (say low discharge pressure) with an alarm.2 Features-Interlock Requirements (a) Permissive conditions for a equipment start shall be provided.4.3 Features-Sequence Control Requirements ISSUE R0 Vol V .2. to open/close various valves and dampers and carry out inching operation of bypass valves or any other similar equipment both from control room and local areas. Selection of standby equipment and starting the equipment automatically on the tripping of running equipment and/or desired process parameter conditions (say loss of discharge pressure or low level in the discharge tank etc. 120R2 . (b) The permissive conditions from a process system related equipment are establishment of free path for the flowing medium under all start-up. (e) (f) All the contacts of the sensors used in protection circuit shall be monitored.5657A-C-500-002 Volume – V SECTION: D 6. (d) Where there is more than one pump or fan for the same service (say 2 pumps).4. TCE. adequate suction pressure. no protection trip command persisting (as applicable) etc. closure of discharge valve for the starting of first of the identical pumps/fans and then opening the valve after the operating condition is established etc.3 INSTRUMENTATION AND CONTROL SYSTEM –DESIGN.TCE Consulting Engineers Limited Spec No. switchgear in service. emergency and shutdown conditions.Part(B) Page 19 of 114 TCE FORM NO.) Isolation of the tripped equipment from the main process. (c) (d) (e) 1.2. (c) The system shall be designed based on the philosophy of command to energise a relay or solenoid valve. The permissive conditions within the equipment are bearing temperature normal. switchgear not in test. bearing lubrication oil pressure normal. Triple redundant sensors shall be provided when used in protection circuits for major critical equipment and 2 out of 3 logic shall be derived for further use in protection circuit 1. winding temperature normal. Any other conditions for safe starting and shutting down the equipment.

(a) Any condition which endangers the safety of the plant personnel (b) (c) Any of the permissive conditions becoming abnormal thereby producing a dangerous condition in operating the equipment.5657A-C-500-002 Volume – V SECTION: D 6. Large Screen Video Display [LCD] system. field instrumentation and associated erection hardware.4 Features-Protection Control Requirements The following minimum protection shall be provided for the various equipment/system as applicable to trip the equipment. PERFORMANCE & FUNCTIONAL REQUIREMENTS SHEET 4 OF 17 Sequence control shall be provided to start and stop the equipment and the associated auxiliaries.1 The Instrumentation and Control System called for in this specification shall consist of a functionally distributed microprocessor based system (PLC) with Vibration Monitoring system.TCE Consulting Engineers Limited Spec No. The conditions from process such as dry flow conditions. system cabinets. 2. Bypass facility for each criteria when only the feedback signal/display is incorrect but the actual condition is fulfilled. Adequate time delay between the steps as dictated by the process to establish an operating parameter or healthiness of an equipment. Diagnostics system. The sequence control shall have the following features: (a) Once the start-up or shutdown of an equipment is initiated either manually or automatically from the system.0 PLC DESIGN REQUIREMENTS GENERAL 2.4. the auxiliaries of the standby equipment should be running (as applicable) so that the standby equipment is started without loss of time. (b) (c) Criteria check up for each stage of operation with monitoring and displaying.Specific Design Requirement The microprocessor based distributed control system (PLC) offered by the Tenderer shall offer the following features: (a) Interoperability – Ability to work together with third party hardware/software without any customisation required to be carried out. 2. flashing conditions or any other conditions that may create cavitation.Part(B) Page 20 of 114 (b) TCE FORM NO. (d) (e) 1. TCE. This activity shall be logged and annunciated in control system (PLC). Normally. 120R2 . Portability – Ability to develop the application for the Plant Information and Management system in personal computer environment and download the same ISSUE R0 Vol V . interfacing with various utility plant PLC based control system and various miscellaneous monitoring and control systems– all capable of operating along with Local panels.2. the control of associated auxiliaries shall be automatic with facility for manual operation at each stage (step).2 PLC System.3 INSTRUMENTATION AND CONTROL SYSTEM –DESIGN.

at minimum cost and without interruption to the continuous operation of the system.5 (Token Ring or Token Bus) to facilitate Determinism in the Data transfer.4 (Token Passing) or high speed Ethernet or similar to facilitate determinism in the data transfer. This shall be Information Domain. (d) (e) 2.Server configuration. Each processor in the data bus system shall perform dedicated functions and the system shall be capable of determining the system performance at any stage of the system implementation.Multitasking .Part(B) Page 21 of 114 : Ability to run third party application : Pre-emptive. Quantity of the servers shall be suitably selected by considering the performance and response time of the complete system.5657A-C-500-002 Volume – V SECTION: D 6.TCE Consulting Engineers Limited Spec No. Flexibility – Ability to provide greater flexibility to the operators in terms of interactive graphics. (c) Scalability – Ability to expand the functionality of the system to any size. and NETBUI Protocols by default. servers will be residing on the main bus running on IEEE 802. In the Client .3 INSTRUMENTATION AND CONTROL SYSTEM –DESIGN.Networking .3 SALIENT FEATURES OF PLC System shall run on the latest Windows NT/2000/XP operating system.Open . The system shall support the following : .Human Interface . The operator station will reside on the data bus running on IEEE 802. Also.Integration System Architecture : -System Architecture should be secure and deterministic. : Should provide seamless integration with minimum Glues / Patchworks TCE FORM NO. 120R2 . the system shall support Windows based graphics for intuitive Graphic User Interface (GUI). with high responsiveness : Comfortable look and feel of GUI-ICON interface : Standard Interfaces like OLE. The plant bus and the lower control modules will form the control Domain. The plant bus and the lower control modules will form the control domain.3 standard.Interconnectivity . Upward compatibility – Conformance to International standards for communication network and fool proof provision for expandability with investment protection. -The Open side of the system shall run on IEEE 802. IPX/SPX. TCE.4 or 802. OPC etc.3 (TCP/IP on Ethernet) standards and will be used as the information network with connectivity to Desktop PC environment. Networking and Security features : ISSUE R0 Vol V . DDE. The operator station shall directly reside on the Main Bus running on IEEE 802. DCOM. PERFORMANCE & FUNCTIONAL REQUIREMENTS SHEET 5 OF 17 to PLC. : Should support standard TCP/IP.

OLE and OPC. Data Exchange between Information and control domain shall have access security levels defined in the security features.1): ISSUE R0 Vol V . It should be possible to launch the above information through an operating graphic. Engineering station shall be provided with redundant hard disk. Graphics editing. database generation. eg. Engineering Tools : The tools should facilitate both Online and Offline Engineering of the system Engineering tools to build Graphics and database should be available on a standard desktop Environment viz.5657A-C-500-002 Volume – V SECTION: D 6. Any third party system supporting the above Industry standards should be able to interact with the system with minimum Glues or Gateways. calling up a procedure during operation. the global database.Part(B) Page 22 of 114 TCE FORM NO. Windows NT. TCE. Self documenting. DDE.0 PLC SYSTEM PERFORMANCE REQUIREMENTS (Under worst loading conditions as defined in Clause 3. Operator Logs (Should have write access to operator). Graphics capabilities. Engineering Station should be able to carry out all the above functions in addition to System configuration. Station function building. Operator. with appropriate authority. 3.3 INSTRUMENTATION AND CONTROL SYSTEM –DESIGN. 120R2 .TCE Consulting Engineers Limited Spec No. System maintenance and Remote diagnostics. PERFORMANCE & FUNCTIONAL REQUIREMENTS SHEET 6 OF 17 The Node connectivity on the open side shall support Network infrastructure based on TCP/IP protocols. System MMI should have the capability of the following information. MMI Requirements : Area/Group/loop wise plant control functions. Multi-window capability with Display management tools shall be available as options Flexibility to the operators in terms of interactive graphics Dedicated Alarm view availability while operating through the Process graphic. Engineer or Manager should be able to view and edit. Data Exchange Procedure The Data Exchange between Control Domain and Information Domain shall comply with de-facto standards like DCOM.

100 ms Maximum 250 ms (For all Loops) Maximum 100 ms (For all Loops) Every 250 ms (For all CLCS Loops) Every 100 ms (For all OLCS Loops) Max. Control/information request is initiated on control VDU. 60 % Max.Part(B) Page 23 of 114 TCE FORM NO. PERFORMANCE & FUNCTIONAL REQUIREMENTS SHEET 7 OF 17 (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) 3. 50 % 99. (b) (c) (d) (e) (f) 3.TCE Consulting Engineers Limited Spec No. 2 seconds (for measurement) Max. 4 seconds (for measurement) Max. 100 ms Max. 1 sec Max. 1 second for OLCS/CLCS Max. 100 digital alarms are generated per second for a period of 10 seconds. TCE.1 Scanning rate of analog signals Scanning rate of digital signals Scanning rate of pulse signals Loop execution time for CLCS Loop execution time for OLCS Controller output update for CLCS Controller output update for OLCS Updating rate of Analog display Updating rate of Analog display Updating rate of Digital value display Updating rate of Digital value display Maximum 1 sec for measurement Maximum.2 All closed loop controls in operation All open loop controls in operation All output devices are in operation with rated performance/speed. PLC System Reliability / Availability Requirement ISSUE R0 Vol V .5657A-C-500-002 Volume – V SECTION: D 6.3 INSTRUMENTATION AND CONTROL SYSTEM –DESIGN. 120R2 . 1 second for OLCS/CLCS Max 1-2 seconds on demand Max. In burst mode operation.7 % Time for display in CRT screen Keyboard command execution time Controller Loading Data Bus Loading Overall system availability Worst Loading Conditions: For distributed control system the worst loading condition shall include the following tasks: (a) All process inputs scanning and processing is in progress and all the data is transmitted over the main data bus every one second.

2.3 INSTRUMENTATION AND CONTROL SYSTEM –DESIGN.TCE Consulting Engineers Limited Spec No. The basic system design objective for availability is an annual availability that exceeds 99. Quantitative: Comparative analysis. 3. sensitivity analysis.2. if any. single failure analysis and fault failure analysis. common mode failure analysis.5657A-C-500-002 Volume – V SECTION: D 6. TCE.Part(B) Page 24 of 114 TCE FORM NO.Total Accumulated System Outage Duration )] / Test Duration (b) Total Accumulated System Outage Time is a total duration for which Contractor supplied system / functions are not available. of the following conditions occur: (a) (b) (c) (d) (e) Failure of the communication system Failure of all Operator Station Loss of MMI capability through failure of control room operator keyboard Malfunction of analog /digital input system in the loss of more than 5% of the total number of inputs Failure of > one controller ISSUE R0 Vol V .2 3.2. 120R2 .2. studies and associated mathematical modules. 3. These analysis be of two types: (a) (b) Qualitative: Failure modes and effect analysis. PERFORMANCE & FUNCTIONAL REQUIREMENTS SHEET 8 OF 17 3.3 PLC system availability shall be computed as following: (a) System Availability During Test Period In % = [100 x (Test Duration .4 3. System Outage Duration = (Outage Duration of individual equipment /system / function) x (Weightage Factor) (c) Weightage factor is the relative importance / criticality of the individual equipment / system / function to the total requirement for the PLC system and to be used to determine the amount of total outage time due to partial failures. Total system failure (weightage=1.1 The reliability of the system shall be demonstrated by an analysis of system. Details of the reliability analysis employed by the Bidder during system design and development and used to obtain the required system availability shall be available for Owner/consultant review.0). Availability during system design and by test upon installation in the plant. The system shall be considered unavailable (weightage factor=1.0) and weightage factors for partial failures shall be as detailed subsequently.5 PLC system availability test duration shall be minimum 6 months on a continuous basis.7% for certain number of years.2.

3 INSTRUMENTATION AND CONTROL SYSTEM –DESIGN.0 4. Redundant sensors shall be provided for all control applications.7 PLC system availability shall be guaranteed by the Contractor.7%.2. Contractor to prove the guaranteed system availability of 99. Availability guarantee test shall be conducted as specified in this specification.5657A-C-500-002 Volume – V SECTION: D 6. For all important and critical controls (CLCS) triple redundant sensors shall be provided. PERFORMANCE & FUNCTIONAL REQUIREMENTS SHEET 9 OF 17 (f) 3. 10% spare rack space shall be provided and distributed among the control processors.0 (a) (b) (c) (d) 6. Closed Loop Control System (CLCS) and Open Loop Control System (OLCS) shall all be configured with redundancy at processor modules. REDUNDANCY AND AVAILABILITY REQUIREMENTS 4.0 Spare I/O Channels: All types of I/O modules shall be provided with 10 % spare channels. Critical closed loop controls are detailed in Clause 18.0 of this specification. 10% hot spare I/O modules (installed) shall be provided. data bus and power supply modules. SPARE PHILOSOPHY FOR PLC I/O CHANNELS: 4. For all other control application dual redundant sensors shall be provided.6 Total failure of historisation facility/capability Weightage factor for various partial failures to be considered shall be as follows: (a) (b) (c) (d) (e) (f) (g) Loss of one critical CLCS / OLCS loop Loss of one non-critical CLCS / OLCS loop Loss of one complete DPU (both main and standby controller) Loss of one DPU (redundant in operation) Loss of I/O (For Non-Redundant Modules) > 5% Loss of one OS Loss of data bus (redundant in operation) 0. communication modules.3 5.TCE Consulting Engineers Limited Spec No.Part(B) Page 25 of 114 TCE FORM NO.2.20 0. This will include sensors provided for compensation also.30 0. Similarly for critical protection logic requirements triple redundant sensors for 2 out of 3 logic shall be provided to avoid spurious tripping. Spare channels shall be wired and shall be distributed among the control processors. 10% spare slots for I/O modules distributed among the control processors.50 0.2 4.20 0. 120R2 .20 0.10 0. GROUPING OF CONTROLLERS ISSUE R0 Vol V . TCE.1 Measurement system (MS).3 3.

For pressure switches and temperature switches. including the spare slots mounted with modules. alarm and trip levels.7 %.5 8. Contractor to submit the procedure for the availability test to be approved by Purchaser/Consultant and this shall be demonstrated during warranty period. All pump suction measurement and steam pressure measurements in extraction steam and in heaters will cover the negative pressure range also and all draft gauges will cover the negative pressure as well as the positive pressure as the case may be.2 6.0 of this specification. For level measurement. PERFORMANCE & FUNCTIONAL REQUIREMENTS SHEET 10 OF 17 6. the set points shall fall within 40% to 70% of the scale range selected. the maximum range shall be fixed at about 10 to 15% above the ISSUE R0 Vol V .4 7.1 The grouping of control loops in controllers shall be done based on the input / output (I/O) handling capacity of the individual controllers such that the system availability in the event of loss of one controller is not less than 50% (ie. The controller spare processing capacity shall be demonstrated during Factory Acceptance Test by loading all the spares as specified. Whenever there is more than one similar equipment.1 8. Also.3 8. TCE.3 Control loop grouping philosophy to be followed in minimum are detailed in Clause 19. the gauge glasses will be stacked with overlap to cover permissive. 120R2 . For flow measurement.4 8.0 The various field instruments shall confirm to the specifications as per Table-7. the maximum operating temperature will be within 80 to 90% of the maximum scale range. The selection of a particular type of instrument for a specific application shall confirm to established engineering practices in a Power Plant and is subject to approval by Owner / Consultant during detailed Engineering. the maximum operating pressure will be within 70 to 80% of the maximum scale range.3 INSTRUMENTATION AND CONTROL SYSTEM –DESIGN. the maximum of the range will cover the overflow point or six inches from the top of the vessel and the minimum of the range will be six inches above the bottom of the vessel.TCE Consulting Engineers Limited Spec No. necessarily the two shall be implemented in different controllers) and fulfilling the following specific requirements: (a) I/O channel & module requirements considering spare channel requirement (b) Controller Loading considering the specified loop execution time (spare processing capacity shall be minimum 40%) 6.2 8.6 TCE FORM NO.0 8.Part(B) Page 26 of 114 8. The system availability for PLC shall be 99. GENERAL GUIDELINES FOR FIELD INSTRUMENTATION 6. For temperature measurement.5657A-C-500-002 Volume – V SECTION: D 6. SELECTION OF RANGES FOR INSTRUMENTS The ranges of the instruments shall be selected based on the following philosophy indicated below: For pressure and draft measurements.

Part(B) Page 27 of 114 TCE FORM NO. TCE. Pressure and differential pressure measurement (i) (ii) 2 1 25 NB 15 NB >=62 bar OR 425 degree C < 62 bar AND425 degree C. NO. Temperature test points shall be provided with thermowell. the maximum range will be around 10 to 15% higher than the recommended alarm settings. Level measurement a) (i) (ii) Level Gauge & Switch 2 1 25 NB 25 NB >=62 bar OR425 degree C < 62 bar AND425 degree C.0 For electro-chemical measurements (conductivity. SIZE OF TAPPING POINT STUB. B. AND SIZE OF ROOT VALVES FOR DIFFERENT TYPE OF MEASUREMENTS These shall be as follows Sl Quantity of No. pH. 120R2 .1 9.5657A-C-500-002 Volume – V SECTION: D 6. In addition.TCE Consulting Engineers Limited Spec No.2 Pressure.4 10.3 9. Silica etc. 8. ISSUE R0 Vol V . pressure and temperature test points shall be provided for the following services: (a) At the discharge of all pumps and fans (b) (c) (d) At the inlet and outlet of the heat exchangers for the fluid media involved Adequate number at the Combustor at different zones At the inlet and outlet of each control valve 9.7 9. dissolved O2. root valves -------------Size of stub and root valve -------------Service Condition ----------- A. temperature and flow test points shall be provided in line with latest performance test code requirements.3 INSTRUMENTATION AND CONTROL SYSTEM –DESIGN..). PERFORMANCE & FUNCTIONAL REQUIREMENTS SHEET 11 OF 17 maximum operating flow. PG TEST POINTS 9.0 Pressure test points shall be complete with root valves and shall terminate with a nipple.

raw water and pre-treatment plant and DM water / Effluent treatment plant independent. C.2 deg. Sampling system measurement (steam & water service) i) ii) 11.1 Local control room shall be made independently for Coal handling system.5657A-C-500-002 Volume – V SECTION: D 6.5 The control room shall be designed with diffused illumination uniformly over the entire ISSUE R0 Vol V . Each package shall have its own separate area/ desk for control & monitoring. Stand pipe for level measuring instrument 2 1 80 NB 80 NB >=62 bar OR425 degree C < 62 bar AND425 degree C. Flow measurement i) ii) 2 1 25 NB 25 NB >=62 bar OR425 degree C < 62 bar AND425 degree C.0 2 1 25 NB 25 NB >=62 bar OR425 degree C < 62 bar AND425 degree C.3 11. Ambient condition in the control room shall be as follows: (i) (ii) Temperature: 23. 120R2 . C Relative humidity: 55%+/. Reservoir intake water system. TCE.Part(B) Page 28 of 114 TCE FORM NO. PERFORMANCE & FUNCTIONAL REQUIREMENTS SHEET 12 OF 17 b) (i) (ii) c) (i) (ii) Level transmitter (displacement type) 2 1 40 NB 40 NB >=62 bar OR425 degree C < 62 bar AND425 degree C. CONTROL ROOM LAYOUT 11. The Local control room to house the following equipment: (a) (b) (c) (d) Control Desk Large Screen Video Display Unit [LCD] The system cabinets. 11. 11.TCE Consulting Engineers Limited Spec No.5%.2 11. D.4 Control room floor shall be provided with anti static matting. marshalling cabinets Uninterrupted power supply system (UPS) in UPS room. ash handling system.0 +/.3 INSTRUMENTATION AND CONTROL SYSTEM –DESIGN.

SUPP. SPECIFIC DESIGN REQUIREMENTS VALVE ACTUATOR / PLC / MCC INTERFACE 12. TCE. DI AI Signal Type Remarks 1 2 3 4 5 DI DI DI It includes THERMAL O/L OPTD / CONT. no.6 11. (b) (c) (d) 12. In addition to the above furniture as required shall be provided for the Instrument lab.3 INSTRUMENTATION AND CONTROL SYSTEM –DESIGN. At this area variable lighting shall be envisaged such that displays shall be visible brightly against the area lighting.6. 120R2 .5657A-C-500-002 Volume – V SECTION: D 6. FAIL / MCC ISOLATED Applicable for rating 50 kW and above. B LT drives – bidirectional (integral starters) ISSUE R0 Vol V .0 Any other equipment to be located in control room shall be provided with metallic tables. independently adjustable seat and back chairs to be located at each Local control room for all OS and ES/OS. 11. Lockable type emergency stop push buttons to be provided.1 Following furniture shall be provided for the central control room and utility plant local control rooms: For Central control room (a) Cushioned revolving. DO DO Output interposing relays to be mounted in independent relay cabinets of the PLC. Drives less than 200 kW .1 A Sl.Part(B) Page 29 of 114 TCE FORM NO.Unidirectional Service Feedbacks from switchgear to PLC Motor running Motor stopped MCC disturbed Local emergency stop operated Motor current Commands from PLC to switchgear 6 7 Command to start motor Command to stop motor Local push button station to switchgear 8 Local emergency stop Direct to switchgear. PERFORMANCE & FUNCTIONAL REQUIREMENTS SHEET 13 OF 17 area except where the large screen video displays are placed. Metallic half consoles for mounting operator station video monitors.TCE Consulting Engineers Limited Spec No.

DI 6 7 Integral starter panel disturbed Local mode selected Commands from PLC to integral starter 8 9 C Sl. Remarks Output interposing relays will be mounted in independent relay ISSUE R0 Vol V .TCE Consulting Engineers Limited Spec No.5657A-C-500-002 Volume – V SECTION: D 6. PERFORMANCE & FUNCTIONAL REQUIREMENTS SHEET 14 OF 17 Sl. Service Feedbacks from valve actuator to PLC Signal Type Remarks 1 2 3 4 5 Limit switch opened Limit switch closed Opened torque switch not operated Closed torque switch not operated Position feedback Signals from Integral starter panel to PLC DI DI DI DI AI Applicable for inching valves. SUPP.Part(B) Page 30 of 114 TCE FORM NO. FAIL / MCC ISOLATED Output interposing relays shall be mounted in independent relay cabinets of the PLC. no.3 INSTRUMENTATION AND CONTROL SYSTEM –DESIGN. no. TCE. 120R2 . Command to open Command to close Solenoids Service Feedbacks from valve limit switches to PLC 1 2 Limit switch opened Limit switch closed Commands from PLC to switchgear 3 Command to open / close DO DI DI Signal Type DO DO DI It includes THERMAL O/L OPTD / CONT.

12 Local emergency stop Direct to switchgear . two independent outputs shall be provided for open and close. S/C PROTN OPTD. MASTER TRIP RELAY RESET and SPRING CHARGED.TCE Consulting Engineers Limited Spec No. TCE. ISSUE R0 Vol V .3 kV and 11kV) – UNIDIRECTIONAL Service Feedbacks from switchgear to PLC 1 2 3 Motor running Motor stopped Motor tripped on fault DI 4 Breaker ready to close DI DI DI It includes DIFFERENTIAL PROTN OPTD. Lockable type emergency stop push buttons to be provided. DRIVES ABOVE 200 kW (3.Part(B) Page 31 of 114 TCE FORM NO. TRIP CIRCUIT HEALTHY. Signal Type Remarks 5 6 7 8 9 Breaker in remote Control circuit fault Local emergency stop operated Motor current Motor kW Commands from PLC to switchgear DI DI DI AI AI 10 11 Command to start motor Command to stop motor Local push button station to switchgear DO DO Output interposing relays will be mounted in independent relay cabinets of the PLC. D Sl. 120R2 . Command shall be to energize or deenegize decided based on fail safe condition.5657A-C-500-002 Volume – V SECTION: D 6. It includes BREAKER IN SERVICE.3 INSTRUMENTATION AND CONTROL SYSTEM –DESIGN. COMPOSITE MOTOR PROTN OPTD. no. For solenoids with dual coils. PERFORMANCE & FUNCTIONAL REQUIREMENTS SHEET 15 OF 17 cabinets of the PLC.

Canopy for the same shall be provided. All motorised isolation and inching service valves and dampers shall be provided with integral starters. All Temperature sensors shall be Duplex type and field mounted temperature transmitter shall be provided for all temperature measurement applications.TCE Consulting Engineers Limited Spec No. 12.3 Both open / close torque switches and Limit switches shall be individually wired to PLC. No temperature transmitters are required for these signals. All local cabinets / utility plant control panels with bottom cable entry shall be provided with suitable pedestals for easy cabling. All panel / cabinet / desk shall have following colour scheme: (a) Exterior: RAL 7035 with texture finish.) shall be provided only for critical equipment trip. TCE.11 12.14 12.6 12.8 12.13 12. Combination of I/P + Pneumatic positioner is not acceptable. 120R2 . For all HT drives alarm and trip signals for bearing and winding temperatures shall be considered through soft LVM from temperature element signal only. Switches (pressure. All outdoor field instrument / panel /cabinet shall have IP-65 protection. (b) Interior: Brilliant white with glossy finish. temperature.3 INSTRUMENTATION AND CONTROL SYSTEM –DESIGN.15 12.2 12. Similar make and model shall be provided for same type of I&C system equipment. are sought to be performed based on a parameter value.5657A-C-500-002 Volume – V SECTION: D 6. Interrogation voltage for the Digital inputs shall be of 24VDC. All Critical control valves shall be provided with anti-cavitation trim.12 12.16 Uniform KKS tag numbering philosophy through out the plant shall be used.10 12.7 12. Wherever possible.5 12. Direct wiring of RTD or T/C to PLC is not preferred. in minimum dual sensor shall type be provided.Part(B) Page 32 of 114 TCE FORM NO. level & flow etc. All outdoor field equipment shall be provided with epoxy painting.4 12. Where multiple functions like monitoring /control/alarm etc. All inching valves shall be supplied with position transmitters integral with the valve positioner. Control valves / dampers shall be supplied with all accessories including non-contact type position transmitters and E/P Positioners. The panels shall be designed for ease of operation of operating hardware and monitoring the indicators.9 12. PLC. PERFORMANCE & FUNCTIONAL REQUIREMENTS SHEET 16 OF 17 12. This shall specifically apply for field transmitters. transmitters shall be provided with required redundancies for all other purposes. All transmitters shall be SMART type with integral local LCD indication and HART protocol. control valves etc. ISSUE R0 Vol V .

TCE Consulting Engineers Limited
Spec No.
TCE.5657A-C-500-002

Volume – V SECTION: D 6.3

INSTRUMENTATION AND CONTROL SYSTEM –DESIGN, PERFORMANCE & FUNCTIONAL REQUIREMENTS

SHEET 17 OF 17

12.17

All local panel indicating lamp/indicating type Push button should be of cluster LED type only. All local panels shall be of double door type instead of double leaf type to avoid ingress of dust in dust prone areas. All motorised bypass valves shall be inching type and shall be provided with position transmitters of non-contact type. Spring-loaded terminals shall be used for termination of instrumentation cables at field JBs, FTCs and local panels. Fused terminals shall be used in marshalling cabinets at Control room for all analog signals. Instrumentation cables shall be laid in separate cable trays. Cable number tags and markings will be provided at every 30 meters along the entire length of cable. Instrumentation cable trays will be run on the top in the cable gallery. Cable routing to the control system from field instruments and devices shall be through junction boxes. Cable glanding to be made at all ends like field instruments, junction boxes inlet and outlet, control panels or instrument panels. Cladding of cabling is not acceptable. All instrument marshalling / system / local control panels shall be provided with gland plates [preferably of 4 quadrant] at the bottom for glanding the cables.

12.18 12.19 12.20 12.21 12.22 12.23 12.24

12.25

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TCE FORM NO. 120R2

Spec No.
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TCE Consulting Engineers Limited
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM - TECHNICAL SPECIFICATION

Volume – V SECTION: D 6.4 SHEET 1 OF 11

1.0

PROGRAMMABLE LOGIC CONTROLLER (PLC) MEASUREMENT AND CONTROL SYSTEM

1.1 1.1.1

CONTROL PROCESSOR Processor will be minimum 32 bit with floating point arithmetic capability. It will have adequate capacity of volatile memory to store dynamic plant data, control programmes and self- diagnostic routines. Also it will have adequate capacity of nonvolatile memory to store programmes, standard software to perform control data acquisition and diagnostic functions. Battery back up (if applicable) for duration not less than 50 hours shall be provided. Memory expandability of 150% of offered capacity shall be provided.

1.1.2

Processor shall have the following functional capabilities as a minimum: a) Mathematical Functions : To meet the functional requirement of the control system and provision to add more algorithms by the purchaser. b) Logic Functions : For performing Boolean operations and time delay requirements c) Control Techniques: Shall include Multivariable, feed forward, feedback, cascade, auto tracking, ratio and bias, dynamic dead band, proportional, integral, derivative and their combinations, auto inching, auto limits, blocks, run- ups, run downs, over rides, analogue hold and any other techniques as may be necessary. d) Point Status and Quality feed back

1.2 1.2.1

1.2.2

INPUT/OUTPUT MODULES Digital Input Modules shall have the following features: (a) Signal isolation (optical) (b) Fuse protection (c) Contact bounce protection (d) Field cable monitoring (e) Short circuit protection (f) Configurable as status input, latched input (g) Alarming of abnormal state (h) The interrogation voltage for digital inputs shall be 24 V DC Digital output Modules shall have the following features: (a) Individually fused (b) Individual contact suppression (c) Configurable as momentary, latched or pulse-width modulated outputs (d) Individually definable default state (e) Output read back verification (f) Short circuit protection (g) Interposing relays shall be provided for all DO’s. Relya boards are not acceptable.
Analog Input Modules shall have the following features:

1.2.3

Analog inputs can be 4-20 mA DC, (a) Signal isolation (Galvanic/ Opto-coupler) (b) Fuse protection and fuse failure detection (c) Transmitter power supply at 24 V DC (d) Input filtering for noise level
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Spec No.
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TCE Consulting Engineers Limited
INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM - TECHNICAL SPECIFICATION

Volume – V SECTION: D 6.4 SHEET 2 OF 11

(e) (f) (g) (h) (i) (j) (k) (l) 1.2.4

Cold junction compensation for thermocouples Transmitter monitoring for parity, wire break and limit values Monitoring of A/D conversion Conversion to engineering units Test for normal or extended range Detection of open circuit for thermocouples Detection of open circuit for thermocouples Alarm limit testing for high, high-high , low, and low-low substituted values

Analog Output Modules shall have the following features: (a) Analog outputs shall be 4-20 mA DC (b) Direct or reverse operation (c) Loop check back of output (d) Default options upon failure Design Features/Requirements of Process Controllers

1.2.5 1.2.5.1

Microprocessor based multiloop controllers with input/output ports/cards shall be used with configuration and control software. All open/close control loops shall be easily configurable using user-friendly software. Controllers shall be able to operate in either manual, auto, cascade mode. Mode changeover in either direction shall be bumpless. The controller shall also have facility for slow and fast ramping of set point and output. The controller should be capable of implementing complex and advanced control strategies through the use of exhaustive set of control algorithm/software blocks. These shall include PID, adaptive, feed forward, dead time, lead-lag compensation, high-low signal selection, curve fitting, real time computational capability etc. In addition the controller shall be able to perform batching, sequencing, interlocks and logic functions. Failure of one loop shall not result in failure of other loops. The distributed processing unit shall be provided with redundant floating power supply. The power supply modules, which are vital to the system’s continuous operation, shall have the means to receive power from two (2) independent power sources. Suitable battery back up shall be provided for protection of volatile memory (for 72 hours). The system shall have 1:1 redundancy with respect to the processor modules, power supply modules, communication modules and network interface. The system shall be designed in such a manner that in the event of failure of the primary controller, the entire configuration of the failed controller shall be instantaneously and automatically transferred to the back-up controller without operator’s intervention. Mode changeover in either direction shall be bumpless. Simultaneously, a message should appear on the video-monitors of the Operator's/Engineer's work station indicating the failure.
OPERATOR STATIONS (OS)

1.2.5.2

1.2.5.3

1.2.5.4

1.3 1.3.1

OS shall provide man machine interface for monitoring and operating the plant equipment with the help of various graphics and displays and also generate various
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Low and Low-Low limits • Automatic inhibition for "Bad" and "Out of service" points from limit checking • The alarm display shall contain the latest 20 alarms.4 SHEET 3 OF 11 1. manual sequence control. group displays.3.2 1. controller tuning parameters. of lines per display page shall be 48. Auto/manual mode change. C&I faults. Display call up time and updating of dynamic information will be as per clause 1.2.3.1.3. deviation limits.1. Alarm summary in the order of priority and chronological order within priority shall be possible. performing control actions through touch panels in mimic diagram (graphics) shall be provided. Storage for minimum 10 pages shall be provided. The parameters like set point.1 logs/reports for effective plant operation.3 1.4 3 levels of process alarm prioritising facility shall be provided. above ISA standard graphic symbols library for generating mimics shall be provided. The alarm messages shall be printed on dedicated printer on occurrence of fault or on demand strictly in chronological order.1. sequencing and intermediate step operation shall be provided. 120R2 Vol V . Display of alarm messages on VDU shall be in the order of occurrence. Lock-out alarms.TECHNICAL SPECIFICATION Volume – V SECTION: D 6. sequence status and criteria. control deviation. Minimum 300 mimic diagrams shall be provided. 1. Alarm Notification/Actions : 1. No. individual input/output point displays and logical function displays. criteria bypass. Alarm Summaries shall be provided for existing alarms. A display page shall have maximum 8 loops. Plant Schematics : Facility for overlaying displays with other displays on mimics. set point/ bias/output change.5 ISSUE R0 TCE FORM NO. bad-inputs.Spec No. TCE. measured value.1.3. points out of scan. Alarm display shall be provided for the following functions : • Equipment malfunctions • Control deviations of process variables indicating High. Minimum 24 dedicated display push buttons shall be provided. waiting and monitoring time. It shall be possible to perform both open loop and closed loop control from these displays. controller output.Part(B) Page 36 of 114 . These displays shall be organised in the form of plant overview display.1. OS shall be Freely assignable and have the following features as a minimum: Plant Control Displays: Control displays shall facilitate normal plant operation. position of final control element shall be monitored. automatic/step-by-step.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM . with the previous alarms (back log) stored in memory as an additional page.3. High-High.

Part(B) Page 37 of 114 . shall be provided.5 Logs/Reports: Event activated logs/reports consisting of pre and post trip log with 100 points sampled at 10 secs intervals with 5 minutes history of all relevant analog points. of major equipment shall be provided. fuel storage availability status. daily power generation. Time activated report consisting of daily report of fuel consumption.3. Contractor to state the no.Spec No. On demand logs consisting of analysis logs with 120 points in 10 groups. Periodic log of 300 parameters.4 SHEET 4 OF 11 1. which are grouped in 25 groups of 12 points each collected at the end of each hour. etc.4 X-Y Plots: Facility to plot up to four variables on vertical axis against one variable on horizontal axis shall be provided. of historical points supported by the system.3. Real time trending and historical trending of 1 sec. Unit 'Snap-shot' report of 100 analog and 25 digital points shall be provided.3. ENGINEERING STATIONS (ES) ISSUE R0 TCE FORM NO.3.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM .6 Equipment Operating History 1. Bidder to state the maximum number of configurable trend groups and max.2 Individual Point Data: The display of analog/digital inputs shall contain the following data (i) PID number (ii) Point description (iii) Current value/status (iv) Sensor/transmitter/ instrument tag number (v) Scan status (under scan/out of scan) (vi) Data quality (type status) (vii) Scan frequency (viii) Current alarm status (ix) Alarm limits. of X-Y plot variables configurable/group display page. auxiliary power consumption.3 Trend Plot features: Configuration of up to 8 pens per trend plot for real time and historical trending should be provided.4 Facility to accumulate run time from initial commissioning and last overhauls of the equipment. Minimum configurable scan rate is 1 sec. no. TCE. 120R2 Vol V . 1. over the shift and status of maximum 25 nos.3. daily power consumption shall be provided. fuel consumption.TECHNICAL SPECIFICATION Volume – V SECTION: D 6. 50 predefined key parameters at the end of the shift and accumulated values of certain parameters like power generation. 1. 1. shall be printed at the end of each shift. 1. Shift report consisting of approx. The display of analog/digital outputs shall contain the following data : PID number (ii) Point description (iii) Current value/status (iv) Drive/device tag number (v) Update status (active/blocked) (vi) Up date frequency.

The communication controller. 1. To accumulate I&C faults to analyse downtimes and time to repair. Resolution shall be 1280 x 1024 pixels minimum. key boards. To generate graphic display and control displays. facility to change/enter all the attributes of analog and digital I/O points. printers.2 Data Bus System shall have the following features: • Coaxial or fibre optic data bus in redundant hot stand by mode • Minimum transmission rate of 10 Mbps. TCE. To run offline system diagnostic programmes.4. 1.5.6 The CPU shall be 32 bit RISC based processor. • Provision for 25% expandability • On-line addition/removal of distributed processing units • 50% spare bus loading capacity considering the 25% expandability requirements • Direct connectivity with Ethernet operating at 100 Mbps CENTRAL PROCESSING UNIT FOR MAN MACHINE INTERFACE (CPU) 1.line fault detection through diagnostics Other maintenance Engineer's functions. Total number of characters shall be minimum 256 graphic characters + ASCII.7 COLOUR GRAPHICS VIDEO DISPLAY UNIT 21" colour TFT monitor with mouse / track ball facility shall be provided. Minimum ISSUE R0 TCE FORM NO. • • • • • • 1. suitable for real time Process applications and supports man machine interface equipment like VDU's. bulk data storage unit and communication control and monitoring system. To test. configure/reconfigure process interface modules/cards.Part(B) Page 38 of 114 . calculated and Boolean variables and constants like scan rate. main data bus and the cubicle bus shall be configured in redundant mode with bump less auto switching feature. CLCS tuning. process range.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM . OS and ES.1 DATA BUS SYSTEM The data bus system comprises the following: (i) Main data bus for communication between various distributed processing units (DPU). (ii) Communication controller (iii) Cubicle bus local to the DPU's. • Communication protocol shall be token passing/master less as per IEEE 802.3 / 802. Number of characters per line shall be minimum 80 and number of lines per display page shall be minimum 48.5 1.5. 120R2 Vol V .4 SHEET 5 OF 11 ES shall have all the features of OS and in addition shall have the following capabilities as a minimum: • • To generate control software through logic diagrams with out any programming knowledge. On.TECHNICAL SPECIFICATION Volume – V SECTION: D 6.Spec No.

1. Writable CD with formatted capacity of 640MB Data transfer rate shall be minimum 5 MB per minute and seek time shall be 22 milli seconds or better. • Data transfer rate shall be 1. able to support all the equipment/peripherals and execute all the tasks as stipulated in this specification. program etc.TECHNICAL SPECIFICATION Volume – V SECTION: D 6.12 Capacity shall be minimum of 2 GB CD ROM drive shall be provided for loading the system software. Anti-reflection feature shall be provided.Spec No. • The Real Time operating System (RTOS) supplied shall be proven. Main memory capacity shall be 8 MB with minimum 160GB Hard disc capacity and shall have a DVD / CD RW drive. The VDUs shall be table top mounted type. BULK MEMORY UNIT (BMU) The BMU shall have the following features: • Two discs in hard stand by mode • Fixed disk drives with one controller per drive • Disk capacity to meet functional requirements of the control system with a minimum formatted disk capacity of 250 GB. 1. The keyboard shall have a minimum of 80 configurable keys for assigning most frequently used displays. It shall be possible to perform OS functions from VDU of ES. 120R2 Vol V .2 Keyboard for ES : Qwerty type Keyboard shall be provided to enable the maintenance engineer to develop graphic displays. TCE.1 1. Assignable function keys shall be provided for execution of command. The VDU's shall be fully assignable and functionally interchangeable. The system shall support Seven (7) types of audible alarms (3 Process related.5 MB/second • Average access time shall be less than 40 milliseconds.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM .9.1 KEYBOARD Keyboard for OS Flat Membrane type Keyboard shall be provided for operator interface with process for plant control and display functions to access plant data in conjunction with Operator station VDUs. A minimum of Sixty-four (64) of those keys shall have two independently lit LED's used for event-specific alarm annunciation.8. • Facility shall be provided for direct transfer of bulk data from BMU to CD drive unit SOFTWARE: The software supplied shall meet the following requirements.Part(B) Page 39 of 114 .10 1.word protection facility shall be provided to set ES in engineer or operator mode. control system software and system configuration for the PLC.8 1. Pass. • Error checking and Error recovery feature CD ROM DRIVE & CD WRITER The features shall include: 1.8. 2 no system related and 2 keyboard related).9 1.4 SHEET 6 OF 11 Sixteen (16) colours shall be provided. The background executive shall enable software development • • • • ISSUE R0 TCE FORM NO. All VDU's shall have dedicated keyboard.

man machine interface software. test and maintenance program. The redundant UPS power supply shall be provided for the PLC system. 120R2 Vol V .0 2. power supply and communication interfaces. memory modules. The system shall have facility for connecting to DCS using hot redundant bi-directional OPC communication link. file handling unit. CONTROL SYSTEM The microprocessor based Hot-redundant PLC system shall perform protection logic. The system shall be loaded to maximum 60% under worst loading conditions. • The control software resident in each DPU’s shall enable the execution of both modulating and sequential control without interrupts to ensure security of controls software for performing mathematical function routines/algorithms and logic functions for control loops as specified.Part(B) Page 40 of 114 . PLC shall complete with processor. mounting accessories. • All software used for PLC shall be licensed version only. This shall mean the fulfilment of both the following requirements: (i) (ii) (c) Automatic synchronisation of primary processor/controller of PLC with secondary processor/controller Bumpless switchover to secondary processor/controller of PLC when the primary fails. data base management. The scan time for digital inputs shall not be more than 60msec and execution 120msec.4 SHEET 7 OF 11 2. • Utilities like report and display generation. racks.Spec No.1 2. processing and alarm monitoring/ reporting software resident in each DPU shall enable processing of raw process data including Engineering unit conversion and process alarm time checking.3 in time sharing mode by two or more programmes simultaneously and shall run/Test any program without making it into an online program. soft ware development. math functions. screen editor. communication.2 2. interlock and sequential control functions such as binary logic operation. online system back up. The system shall have self diagnosis features. timers. counters. full scale water property routines conforming to ASME 1967 steam table and any other utility soft ware to meet the functional requirements of the intended control system shall be supplied. Self diagnostics shall include both module level diagnostics as well as channel level diagnostics PLC shall have redundant processors/controllers. anti virus vaccine/detection utility. Automatic program and data equalisation in the event of any on-line program ISSUE R0 TCE FORM NO. logic blocks. on line diagnostics. The system shall be redundant in processor. log generator. I/O cards. set/rest operation. The generation of control software shall be based on logic blocks and ladder diagrams and no programming knowledge shall be necessary.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM . data transfer from magnetic tape to disk and vice versa. monitoring and programming shall be performed from the CRT station. on line debugger and down loader. Boolean functions & timer functions.TECHNICAL SPECIFICATION Volume – V SECTION: D 6. TCE. PLC shall specifically meet the following requirements: (a) (b) PLC shall have extensive self-diagnostic capability. • The data acquisition. The operation.

type of chemical analysis to be carried out for each sample. The tenderer shall provide a composite system including sample probes. safety valves. on line analysers etc.2. sample piping. screened junction box for electrode. Analyser panel shall be located in a separate air-conditioned room. All panels shall be designed for ready access of components for easy maintenance. pressure. shall be subject to the approval of the Owner.2 3.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM .0 3. No TCE.5103A-IC-SK-03. grab sample collection facility. Housing for electrode and analyser shall be IP65.1 3.D. The system shall include the following: Sample conditioning panel with all accessories-Typical scheme for sampling is illustrated in dwg. manual zero and span calibration.4 SHEET 8 OF 11 / edit executed in the primary processor/controller of PLC. TCE.Spec No. Analyser panel housing cells.4 Vol V .2 3. analysers. The sample conditioning and analyser panels shall be physically separated from each other.TECHNICAL SPECIFICATION Volume – V SECTION: D 6. relief valves. Communication speed shall be minimum 2 MBPS. ball valves. monitors etc. All sample lines shall be sloped towards the sampling panel. WATER ANALYSIS SYSTEM The water chemical sampling system shall be designed to monitor the chemistry of the water cycle to ensure the desired quality. All sample lines shall be annealed seamless 304 stainless steel of 12 mm O.3 3. The sample points. auto zero check.02 pH. isopotential adjustment having flow type cells.. automatic ultrasonic cleaner.2. temperature. pH Measurement Solid state/micro processor based system with system accuracy of 0. to provide an indication of the general condition of the mechanical plant.Part(B) Page 41 of 114 . Online reading shall be provided at Main Plant Control room ISSUE R0 TCE FORM NO.2. their location. measurement ranges etc. coolers. Sample conditioning panel shall be walk in corridor type/open rack type. (d) (e) 3. Information from the analyser shall be used to control the high pressure and low pressure dosing system. Output shall be isolated 4-20 mA DC linear signal. integral indicator. Long term monitoring and trending of essential elements shall be carried out. auto temperature compensation. Accessories shall include preamplifier. The layout and general arrangement of these panels shall be subject to Owner’s approval. flow indications. 120R2 3. level.3 3.1 Automatic “Forcing Bit” update in the secondary processor/controller of PLC when any “Forcing is applied in the primary processor/controller of PLC.

5 Conductivity Measurement Solid state/micro-processor based system with an accuracy of +1 FSD.6 Dissolved Oxygen Measurement Solid state/micro-processor based system with an accuracy of +1 ppb.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM . Fault diagnosis data shall include faults in analog/digital circuits. TCE. response time better than 12 min for 90% change. 3. 120R2 Vol V . calibration fault and silica concentration low/high. power supply failure and sample failure. The analyser shall have features like auto zero & ISSUE R0 TCE FORM NO. ambient temperature compensation.7 Silica Analyser Solid State/micro-processor based system with an accuracy of +2 ppb. Online reading shall be provided at Main Plant Control room.Spec No. and integral indicator etc. Self diagnostic features shall include alarm for no reagent. having features like auto temperature compensation. Output shall be isolated 4-20 mA DC linear signal. 3. Housing for cell and analyser shall be weather and water proof. Housing for cell and analyser shall be IP54 or equal. auto temperature compensation. repeatability of +2% FSD.8 Online reading shall be provided at Main Plant Control room Hydrazine Analyser Polaro graphic type. six number of sample streams having features like auto zero & span calibration. zero check and integral indicator having gate valve insertion type (withdrawable) cell for hotwell conductivity measurements and flow line (screwed) type cell for other services. auto zero & span calibration and integral indicator. power supply failure and sample failure.9 Online reading shall be provided at Main Plant Control room Sodium Analyser : The Analyser shall be continuous flow through sample .Part(B) Page 42 of 114 . The range shall be 0-20 /0-200 ppb. Output shall be isolated 4-20 mA DC linear signal. auto calibration. ambient temperature compensation and integral indicator. Analyser housing shall be weather and water proof. Online reading shall be provided at Main Plant Control room 3. single stream with accuracy + / . Fault diagnosis data shall include faults in analogue/digital circuits. Solid state/micro-processor based system with an accuracy of +5% FSD. Analyser housing shall be weather and water proof.TECHNICAL SPECIFICATION Volume – V SECTION: D 6. faults in calibrated values.10 and response time less than 2 minutes for 90% of full scale readings. Output shall be isolated 4-20 mA DC linear signal. response time of 90% of any change indicated in 6 min having features like auto zero & span calibration. faults in calibrated valves. Output shall be isolated 4-20 mA DC linear signal.4 SHEET 9 OF 11 3. 3.

Fault diagnosis data shall include faults in analog/digital circuits.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM .1.0 5. together with all necessary equipment and accessories. software.6 Vibration monitoring system shall provide the vibration measurement in the form of 420 mA DC signal to be directly connected by hardwired cable to applicable control system [PLC] for monitoring. CONTRACTOR shall supply as per these specifications and ISSUE R0 TCE FORM NO.3 4. and integral indicator etc.Spec No. 4. Vibration monitoring system shall be independent for each package.1. amplifiers.2. Analyser housing shall be weather and water proof.0 4.2.2 The vibration monitoring system shall be complete with eddy current type proximity vibration sensors.2 The vibration monitoring system shall provide monitoring on continuous on-line basis.1.1 Specification of instrumentation and special cables application guide. Bidder’s offered system shall include but not limited to the details specified in subsequent paragraphs. For bearings of high speed machines (= / >1500 rpm) accelerometer type sensor and for low speed machines (<1500 rpm) velocity type sensor shall be provided.2. Limit value generation (soft) for alarm and protection applications for the auxiliaries and their drive equipment shall be carried out in applicable control system (PLC).lines are listed in Section D 6. TCE.4 4.2. 4. firmware and interfaces. Vibration sensors shall be provided for measurement in both X (horizontal) and Y (vertical) axis at 900 angle to each other for each bearing.4 SHEET 10 OF 11 span calibration. Table-8.TECHNICAL SPECIFICATION Volume – V SECTION: D 6. Output shall be isolated 4-20 mA DC linear signal. 120R2 Vol V .3 4.1 4. Necessary. 4. all special and field signal cabling required for implementing a fully functional system. The system to be provided shall include all necessary hardware. Vibration pickup shall meet the following requirements: (a) (b) (c) Pick-up sensitivity-Minimum 25 mv / mm / second Enclosure protection. ambient temperature compensation. signal conditioning cards. one or two stage integrators for obtaining vibration measurement in terms of displacement shall be provided in the system. vibration monitor (if required) etc.2. INSTRUMENTATION AND SPECIAL CABLES 5.1 VIBRATION MONITORING SYSTEM GENERAL 4. power supply failure and sample failure. Online reading shall be provided at Main Plant Control room. special cables.IP 65 Pick ups suitable to function in temperature range of (-)10 0 To (+) 200 0 C. faults in calibrated valves.Part(B) Page 43 of 114 .5 4.

TCE.TECHNICAL SPECIFICATION Volume – V SECTION: D 6.Part(B) Page 44 of 114 . ISSUE R0 TCE FORM NO.0 QUALITY ASSURANCE 6. 120R2 Vol V .4 SHEET 11 OF 11 deviations if any are subject to approval by OWNER / CONSULTANT.Spec No.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM .1 Bidder shall furnish a detailed Quality Assurance / Quality Control Plan (QA/QC) for each Instrument/System covered under this specification for OWNER/ Consultant review and approval. 6.

Part(B) Page 45 of 114 TCE FORM NO.FAT Inspection/ Test’ to be carried out by Contractor/ Vendor. Pre-FAT inspection / test shall be carried out as per approved FAT procedure detailed above and shall submit ‘Pre.0 2.3 2. Site Test (SAT) Tests to be conducted at site will involve the following: (a) Site Pre-commissioning Tests comprising the following to be conducted by Contractor at site: 2.0 TESTS AND INSPECTION FOR INSTRUMENTS 1. all instruments shall be tested and calibrated at Factory. TABLE-10 and any other tests as required by the Standards and Codes. CONTRACTOR shall be responsible in obtaining test certificates related to calibration of all the Instruments and submit for Owner/Engineer’s approval.1 Factory Acceptance Test (FAT) FAT shall be a complete integrated test of the PLC system and carried out at CONTRACTOR’s / Sub-Vendor’s works on completion of manufacturing of the system.5 INSTRUMENTATION AND CONTROL TEST AND INSPECTION FOR DCS/ PROGRAMMABLE SYSTEM SHEET 1 OF 4 1. successful completion of which will be the basis for ‘Authorisation for Shipment to Site’. TCE.1 After Manufacturing. Site Test (SAT): Involves tests for site commissioning.3.1 Tests for PLC system will include the following: (a) Factory Acceptance Test (FAT): To be carried out at PLC system CONTRACTOR’s / Sub-Vendor’s works and witnessed by Owner/Engineer. The CONTRACTOR shall submit a detailed "Factory Acceptance Test Procedure" in line with the above specified guidelines for Owner / Consultant approval.FAT Inspection/ Test’.2.5657A-C-500-002 Volume – V SECTION: D 6. The details of the tests to be carried out for the different instruments / field equipments/ Systems shall be as indicated in the Section D.2 2. TESTS AND INSPECTION FOR PLC 2.TCE Consulting Engineers Limited Spec No. Owner/ Consultant shall witness the actual FAT on the basis of successful completion of ‘Pre.1 ISSUE R0 Vol V . CONTRACTOR shall allow despatch of these instruments only after passing applicable Factory Acceptance test and approved by Owner/Engineer. 120R2 . The various tests to be performed for PLC system equipment / total system together with the guideline for Factory acceptance test (FAT) procedure are detailed in Section D 6.2. it is expected to perform while in actual service.2 2. FAT shall be preceded by a pre-FAT inspection/test by Vendor. guarantee tests for system performance & availability to be conducted in the presence of Owner. The test shall be performed with the completely assembled system and performing all the functions.FAT Inspection/ Test’ report for Owner/Consultants review and approval. FAT shall be preceded by a ‘Pre. (b) 2. TABLE-11.

If the total interruption period (outage time) is more than 4 hours. Simulation input from site Trial Operation of the PLC system functioning. checking and satisfactory pre-commissioning tests detailed at 2. the plant operation shall not be disturbed and the control loops shall continue in auto mode. The trial operation shall be considered successful provided that each item of equipment can operate continuously at the specified characteristics for the period of trial operations.1 Trial operation test of PLC system shall be conducted on completion of installation as per specification requirements.TCE Consulting Engineers Limited Spec No. During each redundancy check.0 Calibration of monitoring and control equipment Integrated loop test wiring. Test duration shall be of 14 days out of which 72 hours shall be continuous operation performing all the specified functions. Performance Guarantee Test for I&C systems Availability Guarantee Test for PLC system TRIAL OPERATION OF THE PLC SYSTEM FOR EACH PACKAGE 3.1 (a) above.5657A-C-500-002 Volume – V SECTION: D 6. power supply and 1/O modules. Contractor shall also furnish the guaranteed process parameters and the acceptable deviations before conducting the performance test.Part(B) Page 46 of 114 4. The trending of control parameters shall be in service during these checks and the over shoot / under shoot of the controlled parameters shall be less than 1%. Following tests to be performed during the PG test: Redundancy checks for processor. During this period. the system shall run with 100% availability.6 4.2 3. the OWNER shall conduct performance guarantee test for a period of 14 days in the presence of CONTRACTOR’s commissioning engineer. TCE. any modifications / repairs as required shall be carried out.3 3.1 After successful trial operation.4 3. During the test.2. communication.2 4.1 TCE FORM NO. Test shall be conducted at site by Contractor’s personnel in the presence of the Owner / Consultant. Test shall be a “Total Integration Test of the whole PLC System” including the testing of communication links.0 4.5 INSTRUMENTATION AND CONTROL TEST AND INSPECTION FOR DCS/ PROGRAMMABLE SYSTEM SHEET 2 OF 4 (i) (ii) (b) (c) (d) 3. These ISSUE R0 Vol V . PERFORMANCE GUARANTEE TEST FOR I&C SYSTEM 3.5 3.4 below. Total interruption period (system outage time) shall be calculated as detailed in 5. 120R2 . the trial operation duration shall be extended by the period of interruption.3. This check shall be conducted in a sequence as mutually decided between the Client and the contractor.

3. Specified serial links shall be established and proven. During the test.1 If the performance of the system deviates from the specification requirements.3.3 4. shall be checked. The total duration for the site acceptance tests i.3. the contractor shall be given a maximum period of 3 days depending on the gravity of the defect as mutually agreed. The specific test shall be repeated for proper functioning.5657A-C-500-002 Volume – V SECTION: D 6. Contractor shall be given maximum of three attempts each not exceeding 3 days for any subsequent defects found. during which period. the contractor shall rectify / modify the system to meet the specified requirements. PG Test Methodology 4. 120R2 .2. After 3 tests for each activity.2.3.TCE Consulting Engineers Limited Spec No.7 4. 50% and 25% and the variation in the process parameters shall be within the limits specified.9 4. any modules / equipment fails.Part(B) Page 47 of 114 TCE FORM NO. Checking of the time activated and on demand reports.2.3 Response time for each type of update as per the specification shall be checked on line by suitably recording each activity.5 4.2.5 INSTRUMENTATION AND CONTROL TEST AND INSPECTION FOR DCS/ PROGRAMMABLE SYSTEM SHEET 3 OF 4 checks shall be logged (removal and relocation of modules/cables) in the system in addition to being made available to the operator in operator station. 75%.2. the contractor immediately within four hours shall replace the faulty module / equipment and the test shall be repeated after extended continuous running of 96 hrs. TCE. if the system still deviates from the specified requirements. The calculations / documents earlier furnished for establishing the specified system availability. the warranty period may be extended depending on the gravity of the defect.2. Functional inter-changeability of the Operator Stations and printers shall be checked. Contractor shall declare the system fit for checking after completing the modification / rectification.2. Guaranteed parameters shall be checked and established as per “Schedule of Performance Guarantees” furnished by the contractor.8 4. Time synchronisation with master clock shall be tested.3. 4.5 ISSUE R0 Vol V . to carryout the modification without disturbing the plant operation.2. The specified MIS functions.2 4.2 4.4 4. Performance Calculations etc.3 4..e site pre-commissioning tests and Trial operation test together shall not exceed 30 days including the repetition of tests and duration for replacement / rectification. The stability tests for the control loops shall be checked for other load conditions viz. 4.6 4.4 4. shall be demonstrated with due consideration for the running plant.

1 The test shall demonstrate the specified guaranteed PLC system availability of 99.5 5.3. the Owner’s engineer shall keep the log of total outage period in a pre-determined format mutually agreed between Owner and Contractor. Any other failure shall be considered as system reliability / availability failure as defined in Section D 6. Equipment repair shall be carried out by Contractor’s engineer by using the spare and as per trouble shooting procedure furnished by PLC System Vendor.6 5.3 5. TCE.3. The last 5% of the total supply payment will be released only after successful completion of PLC system “Availability Guarantee Test”.3% (considering guaranteed availability of 99.TCE Consulting Engineers Limited Spec No.2 4. However. The PLC System PG test shall be carried out to Owner’s satisfaction. The test period shall be a continuous period of 6 months.4 4. The PLC System “Availability Guarantee Test” shall be carried out to Owner’s satisfaction.4 5.0 5.4. the mean time to repair shall not exceed that specified by the CONTRACTOR. PG Test Result Interpretation The failure of any one of the hard or soft copy device shall not be taken as nonavailability of the system.Part(B) Page 48 of 114 TCE FORM NO.5657A-C-500-002 Volume – V SECTION: D 6. tools and tackles required for the successful completion of the PG test shall be provided by CONTRACTOR as part of the total scope of services.4.6 4.7%) of the test duration of 6 months.5 INSTRUMENTATION AND CONTROL TEST AND INSPECTION FOR DCS/ PROGRAMMABLE SYSTEM SHEET 4 OF 4 4. AVALABILITY GUARANTEE TEST FOR PLC SYSTEM 4. During the test period. All the special equipment.3 or as agreed for the project. The Contractor shall depute their representative/ engineer for the total duration of ‘Availability Guarantee Test” covering 24 hrs. Contractor shall ensure that the disturbance to the process is minimum. then a new 6 months test run shall start from the time the system is fully available again. 5.5 5. PLC system availability shall be computed as specified in Section D 6. If the accrued downtime exceeds 0.7 ISSUE R0 Vol V .3.1 During all the above tests. 120R2 . The PG test shall be repeated if the test results deviate from the guaranteed values. of the day. The last 5% of the total supply payment will be released only after successful completion of PLC system PG test. Ready stock of all types of modules / PC boards shall be available as part of the total scope of services for immediate replacement during the period.2 5.7% for a continuous period of 6 months as specified in Section D 6.

valid for the duration of the performance test. shall continuously and intensively instruct and train adequate number of the OWNER's operating and maintenance personnel at site during erection and commissioning of the equipment to enable them to take over the proper operation and maintenance of the equipment after commissioning. The CONTRACTOR shall include in his bid.6 SHEET 1 OF 1 1. operation or maintenance.5 2. 120R2 Vol V . manufactured and supplied by him is under installation. TCE. local transport at place of training etc. These engineers shall be given special training in shop. INSTRUMENTS FOR PERFORMANCE TESTING All instruments required for performance testing to prove the guaranteed performance of the Instrumentation and Control Equipment as specified in Section-D 6. to enable the engineers to become fully familiar with the equipment offered. CONTRACTOR shall include in his bid a detailed description of the proposed training for the OWNER's personnel. test.0 1.0 ISSUE R0 TCE FORM NO.3 1.14. from reputed test house. The CONTRACTOR's personnel at site. the charges for providing training to purchaser's personnel as above which will include lodging & boarding charges.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL OTHER SERVICES Volume – V SECTION: D 6.4 1.2 1.5. These test instruments shall have test certificates. and manufactured and in any other power plant where similar type of equipment designed. shall be loaned to the OWNER by the CONTRACTOR for the duration of the Performance Test. The type of training with number of personnel to be trained and the quantum of training to be provided are detailed in TABLE. 1. undertake to train engineers selected and deputed by the OWNER. laboratory and drawing office of the CONTRACTOR.1 TRAINING OF OWNER'S PERSONNEL The CONTRACTOR shall at no extra to the OWNER. where the Instrumentation and Control Equipment will be designed.Part(B) Page 49 of 114 .Spec No.

PLC SYSTEM CLOSED LOOP CONTROL SYSTEM (CLCS) 2.3 & D 5.3 DATA BUS SYSTEM (DBS) The BIDDER shall guarantee that the data bus system shall not be overloaded (above 50%) even under peak data transfer load. 2. PLC Controller.2 The control system shall be capable of regulating the control devices to achieve the performance guarantees specified below.7 SHEET 1 OF 3 1. The response time as specified in Section-D 6. TCE. as specified in Section-D 5. 120R2 Vol V .1 2. 5.1. INTERLOCK.3 & D 6.0 SOFTWARE PACKAGES The BIDDER shall guarantee the proper implementation and functioning of all Software packages required for different control systems namely. HMI system.Spec No.3 of specification shall also be guaranteed. 2. PLC type control system etc. Interfacings.Part(B) Page 50 of 114 .1 2.4 of specification. 4.1 Accuracy of each instrument shall be as specified in Section-D 5.0 PLC BASED CONTROL SYSTEM(S) The BIDDER shall guarantee the proper functioning of all PLC based control system including all sub-systems namely.3 and D 6. coal or fuel oil or in any combination. protection and sequential control system as specified in Section-D 6.0 AUXILIARY POWER SUPPLY SYSTEM (APSS) ISSUE R0 TCE FORM NO.3 shall be from 15% of full load to turbine control VWO condition. etc. These limits shall be applicable for firing of either fuel namely.0 2. included in the scope. These limits shall also be applicable for various modes of operations of co-ordinated master control specified in the control system.3 & D-5. Control range for the guaranteed limits specified in para 2.2 The BIDDER shall guarantee the proper functioning of interlock.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – PERFORMANCE GUARANTEE Volume – V SECTION: D 6.0 MEASUREMENT SYSTEM (MS) 1. 3.4 of specification.4 of specification.1.1. PROTECTION AND SEQUENTIAL CONTROL SYSTEM 2.4 of specification.4 HUMAN-MACHINE INTERFACING SYSTEM The BIDDER shall guarantee the proper functioning of HMI system & Control Engineer’s interfacing equipment as specified in Section-D 6.

4 of specification. PERFORMANCE The BIDDER shall guarantee that the goods furnished by him shall be in full accordance with the requirements of the enquiry specifications.Part(B) Page 51 of 114 . indicators and switches like pressure switches.0 LOCAL INSTRUMENTS /PANEL MOUNTED HARDWARES/ FINAL CONTROL ELEMENTS All analysers. 8. etc. 9.2 of specification. and final control elements like control valves / control dampers. TCE.7 SHEET 2 OF 3 The BIDDER shall guarantee the proper functioning of auxiliary power supply system as specified in Section-D 6.0 The BIDDER shall guarantee the availability of PLC Based Control systems for minimum 99. 10.. shall be guaranteed for proper functioning within an accuracy as specified. 120R2 Vol V . 11. control switches. 6.4 of specification.0 COMMUNICATION LINKS Bidder shall note and confirm to the successful implementation of all the specified communication links among different Control & Monitoring systems like PLC Controls under the scope of this specification.0 TOTAL SYSTEM AVAILABILITY 11. 13. etc.Spec No. All the links shall be redundant and Bidirectional and shall be implemented through Fibre Optic cables and run in two physically separate conduits.0 QUALITY ISSUE R0 TCE FORM NO.5 of specification.4 of specification.2 12.1 11. selector switches.7% on an annual basis and demonstrating the same. level switches.0 VIBRATION MONITORING SYSTEM The BIDDER shall guarantee the proper functioning of the Vibration monitoring system as specified in Section-D 6.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – PERFORMANCE GUARANTEE Volume – V SECTION: D 6. 7.0 LARGE VIDEO SCREEN / VDU MONITORS All equipment shall be guaranteed for proper functioning as specified in Section-D 6. relays.0 WATER ANALYSIS SYSTEM The BIDDER shall guarantee the proper functioning of water analysis system as specified in Section-D 6. The method of calculating the total system availability shall be as specified in SectionD 6. panel mounted items like digital display unit.

Part(B) Page 52 of 114 . Bidder shall guarantee the specified requirements for microprocessor based systems supplied by him.7 SHEET 3 OF 3 13.Spec No. materials or workmanship.2 ISSUE R0 TCE FORM NO. 13. 120R2 Vol V .5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – PERFORMANCE GUARANTEE Volume – V SECTION: D 6. Bidder shall warranty the same for a period of twelve (12) months from the date of taking over of the plant.1 The BIDDER warrants that the goods are new and of high quality and that the goods will be free of defects in design. TCE.

belt weigher. etc. Of operator station & 1no. dust extraction / dust suppression / ventilation fan.Part(B) Page 53 of 114 .1 1. 1. no.cabling to DCS Cabling for master clock signal from master clock to PLC system UPS for complete I&C system Communication link between DCS and PLC system Redundant fiber optic cables from CHP main PLC to DCS corresponding. bunker level indicators. metal detector.13 BTG BTG BTG BTG 1.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM .7 BOP BOP BOP BOP 1. travelling tripper.0 1. TCE.4 1. Of Engineering station) Remote I/Os at main CHP substation. I&C cabling for entire CHS package including JBs. side arm charger and main CHP PLC Bunker level indicator signals to DCS .9 1. wagon tippler substation. including media converters.12 BTG BTG BOP BTG BTG BTG BOP BTG BTG BTG BOP BTG BTG BTG BOP BTG 1. cable trays. apron feeder. sump pump. 120R2 Vol V .TABLE 1 – TERMINAL POINTS Design / Engineering BOP BOP Volume – V SECTION: D6 SHEET 1 OF 5 Sl. LIUs and patch cords at both ends of the link. bunker floor PMCC room and air compressors.5 BOP BOP BOP BOP BOP BOP BOP BOP 1. Supply BOP BOP Erection BOP BOP Commissioning BOP BOP 1. Local control panel / DB local control panel for magnetic separator.8 BOP BOP BOP BOP 1. Equipment mounted PLC based control systems for wagon tippler & side arm charger and stacker / reclaimer Redundant communication link between a) PLCs of stacker reclaimers and CHP main PLC b) PLC wagon tippler.2 Package / Activity Coal handling system All field devices & instruments PLC system for CHS (With 1nos.Spec No. to OPC link.14 BOP BOP BOP BOP ISSUE R0 TCE FORM NO. Redundant fiber optic cables between PLC and remote I/O Control desk in CHP control room and wagon tippler control room.6 BOP BOP BOP BOP 1.3 BOP BOP BOP BOP 1.11 1.10 1.

9 BTG BTG BTG BTG BTG BTG BTG BTG 3. 1.8 2.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM .Part(B) Page 54 of 114 .4 BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP 3.7 BOP BOP BOP BOP BOP BOP BOP BOP ISSUE R0 TCE FORM NO.2 3.1 3.4 2. etc.0 3.5 BOP BOP BOP BOP 3. of engineering station based local control panel Programming station for the PLC station Control desk DM control room Complete I&C cabling including JB's.6 3.0 2. Cable trays.3 2.15 Package / Activity Cabling between CHS MCC to PLC DM Water plant & Effluent treatment plant Complete filed instrumentation and final control elements Installation hardware for instrumentation equipment PLC System with 1 nos.3 3. Cable trays. etc.5 2. no. operator station and 1 no. corresponding to OPC link including media converter. TCE.6 BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP 2. LIUs and patch cords at both ends of the link UPS for Reservoir intake water PLC based I&C system Cabling between Reservoir intake MCC to PLC Supply BOP Erection BOP Commissioning BOP 2. for the DM plant UPS for DM water plant & Effluent treatment plant PLC based I&C system Cabling for master clock signal from master clock system to PLC Cabling between DM Plant MCC to PLC RESERVOIR INTAKE WATER SYSTEM Complete filed instrumentation and final control elements Installation hardware for instrumentation equipment PLC based local control panel LCD keypad operated Complete I&C cabling including JB's. Redundant fiber optic cables from Reservoir intake water system PLC to DM water system PLC.1 2.TABLE 1 – TERMINAL POINTS Design / Engineering BOP Volume – V SECTION: D6 SHEET 2 OF 5 Sl. 120R2 Vol V .2 2.7 BOP BOP BOP BOP 2.Spec No.

hardwired annunciation system and CW header instruments) Cabling for master clock signal from master clock system to PLC Supply Erection Commissioning 4.0 4. Redundant fiber optic cables from Reservoir intake water system PLC to DM water system PLC. Package / Activity Raw water & pre-treatment system Complete filed instrumentation and final control elements Installation hardware for instrumentation equipment PLC based local control panel LCD keypad operated Complete I&C cabling including JB's.Part(B) Page 55 of 114 .2 4.4 BTG BTG BTG BTG 5. corresponding to OPC link including media converter.3 BTG BTG BTG BTG 5.7 BOP BOP BOP BOP BOP BOP BOP BOP 5.0 5. TCE.4 BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP 4.TABLE 1 – TERMINAL POINTS Design / Engineering Volume – V SECTION: D6 SHEET 3 OF 5 Sl.1 BTG BTG BTG BTG 5. LIUs and patch cords at both ends of the link UPS for Reservoir intake water PLC based I&C system Cabling between Raw water MCC to PLC Circulating water / auxiliary cooling water Field instruments and associated instrument installation hardware except CW header Field instruments and associated instrument installation hardware for CW header DCS operator station and I/O modules in CW / ACW pump house I&C cabling where both ends are BTG equipment (eg. no. Field instruments) I&C cabling where at least one end of cable connects to BTG equipment (MCC.0 Ash handling system ISSUE R0 TCE FORM NO.6 BTG BTG BTG BTG 6.1 4. etc.2 BTG BTG BTG BTG 5.6 4.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM .3 4. Cable trays.5 BTG BTG BTG BTG 5.Spec No. 120R2 Vol V .5 BOP BOP BOP BOP 4.

11 6. LIUs and patch cords at both ends of the link.9 6.7 6.16 BTG BTG BTG BTG 6. including media converters. Cabling for master clock signal from master clock system to PLC PLC / microprocessor based control system for air compressor Communication link between air compressor PLC and AHS PLC system Supply BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP Erection BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP Commissioning BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP 6.10 Package / Activity All field devices & instruments along with Installation hardware AHS PLC (With 1 nos. no.TABLE 1 – TERMINAL POINTS Design / Engineering BOP BOP BOP BOP BOP BOP BOP BOP BOP BOP Volume – V SECTION: D6 SHEET 4 OF 5 Sl.2 6. cable trays. TCE.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM .12 6. Of operator station & 1no.8 6. to OPC link. 6.3 6.15 BTG BTG BTG BTG 6. Communication link between DCS and PLC system Redundant fiber optic cables from AHS PLC to DCS corresponding. Of Engineering station) Slurry system PLC LCPs for Bottom ash handling system LCPs of bottom ash handling system Local control panel for Silo unloading system Local control panel for Coarse ash handling system Remote I/O as required Control desk in AHS control room Redundant serial link between ash water & slurry PLC to AHS PLC Bus cabling between remote I/Os and ash handling system PLC UPS for PLC based I&C systems Complete I&C cabling including JBs. etc.13 6.14 BOP BOP BOP BTG BOP BOP BOP BTG BOP BOP BOP BTG BOP BOP BOP BTG 6.6 6.4 6.1 6.5 6.18 BOP BOP BOP BOP 7.17 BOP BOP BOP BOP 6.Part(B) Page 56 of 114 . 120R2 Vol V .0 GENERAL ISSUE R0 TCE FORM NO.Spec No.

TCE.2 BTG BTG BTG BTG 7. to OPC link. including media converters.1 BTG BTG BTG BTG 7. Package / Activity Cable link between the slave clocks and the PLC system across the plant [BTG & BOP PLC's] including master and slave clock Redundant fiber optic cables from BOP / BTG PLC's to DCS corresponding. Hardwired signal exchange from BOP to BTG DCS cabling I&C cabling where at least one end of cable connects to BTG equipment (MCC.TABLE 1 – TERMINAL POINTS Design / Engineering Volume – V SECTION: D6 SHEET 5 OF 5 Sl.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM .Part(B) Page 57 of 114 .4 BTG BTG BTG BTG BTG BTG BTG BTG ISSUE R0 TCE FORM NO.3 7. no. 120R2 Vol V . etc) Supply Erection Commissioning 7. LIUs and patch cords at both ends of the link.Spec No.

ISSUE R0 TCE FORM NO. TCE.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM –TABLE 2 Volume – V SECTION: D6 SHEET 1 OF 1 Sl.Spec No.Part(B) Page 58 of 114 . 1 2 3 4 5 6 System / Equipment Reservoir intake Water Intake System Raw Water & PreTreatment Plant Coal Handling Plant Ash Handling Plant DM Water /Effluent Treatment Plant Other Utility Plants Control System Hardware PLC Based Control System PLC Based Control System PLC Based Control System PLC Based Control System PLC Based Control System PLC Based Control System Interfacing with Plant DCS Note 1 Note 1 Note 1 Note 1 Note 1 Note1 Remarks Plant common Plant common Plant common Plant common Plant common Plant common NOTES: 1 Communication link between Plant common DCS & PLC control is redundant bi. No. 120R2 Vol V .directional OPC communication link with TCP-I/P protocol.

Charts.1 ISA S 5.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 3 Volume – V SECTION: D6 SHEET 1 OF 1 TABLE-3: CODES AND STANDARDS Instrumentation Symbols and identification. Binary Logic Diagrams for Process Operation Graphic symbols for DCS.Part(B) Page 59 of 114 . Industrial Platinum.02 ISA S 75. Welded & Seamless General Table – Dimensions & Masses / Length Measurement of Fluid Flow by Means of Orifice Plates & Nozzles Pipe Threads Quality Control Standard for Control Valves Seat Leakage Thermocouples Measurement & Control.1 / ASTM E 230-03 DIN 19243 DIN 43760/ IEC 751 ISO 5167 ANSI MC 96. Binary Logic Elements Operating Conditions for Industrial Process Meas. TCE. Electromagnetic Compatibility for Industrial Process Measurement Preparation of Function Chart for Control System Industrial Measurement & Control – Terms & definition Vibration. logic & Comp. Converters for IS two wire DC systems. shared display inst.04 ISA S 75.1 / IEC 751 IEC 529 IEC IEC IEC 62443 ISSUE R0 TCE FORM NO.02 ANSI B 16.2 ISA S 5.Spec No.03 IEC 113 IEC 534 IEC 617-12 IEC 654 IEC 801 IEC 848 IEC 902 API 670 ISO 4200 ISO 5167 ANSI B 2. RTD Measurement of Fluid Flow by Meter Run Temperature Measurement Degree of Protection by Enclosure Electrical Apparatus for Explosive Gas Standards for Cables Process control security requirements ISA S 5. & Control Equipment.1 ANSI FCI 70. Axial Position & Bearing Temperature Monitoring Systems Plain End Steel Tubes.104 ISA MC 96.01 ISA S 75. 120R2 Vol V . Position sensors & Sig. Tables Industrial Process Control Valves Graphical Symbols for Diagrams. Electrical sensors. System Environmental Conditions Control Valve Sizing Control Valve Procedure Capacity Test Uniform Face – Two Face Dimensions for Flanged Globe Style CV Bodies Diagrams.3 ISA S 71. Elec.

NO 1.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 4 Volume – V SECTION: D6 SHEET 1 OF 1 TABLE-4: I&C DATA TO BE FURNISHED WITH THE BID The following documents shall be furnished along with Bid for utility packages.0 16. networking and security features.0 13. Local control room layout Flow diagram / P&ID (Process and Instrumentation drawings) indicating primary and secondary Instruments and the destination/functionality of the signals for main Plant.0 4. graphic capabilities data exchange procedure. Confirmation certificate for the latest version of software and hardware offered.0 6.0 ISSUE R0 Vol V . List of open loop controls included.0 15.0 10. Duly signed schedule of performance guarantees.0 Control philosophy / operation philosophy / Design philosophy / Redundancy philosophy for utility control system. List of closed loop controls included.0 DATA TO BE FURNISHED Reference list with capacity of plant. logs.Spec No. engineering tool. history.0 3.0 5. Evidence that the offered PLC system is upgradable and evolutionary in both hardware and software Letter confirming support of spares for 15 years for the PLC system supplied. List of software. 2. 120R2 . user’s certificate for the PLC system configuration offered. 7. Codes and applicable standards followed for the project. TCE.0 8.0 11.0 9.Part(B) Page 60 of 114 TCE FORM NO.0 12.0 14. year of commissioning & control system implemented along with minimum two (2) nos. reports. etc. Clause wise confirmation / deviation list with respect to I & C requirements specified in sections. SL. system capability such as graphic displays. System Architecture highlighting the applicable standards for control and information domain. archiving. trending. Grouping philosophy of control loops in controllers PLC configuration drawing / system architecture drawings including MMI.

radar type level instruments). of each type 4.Spec No. of each size 1 no.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 5 TABLE.7 1 no. 10% of total quantity 3.0 2. system /marshalling cabinets for Main Plant 5% for each type and range but minimum 1 no 5% for each type and range but minimum 1 no 5% for each type and range but minimum 1 no 5% for each type and range but minimum 1 no 5% for each type and range but minimum 2 nos each 2 nos. ISSUE R0 Vol V .Part(B) Page 61 of 114 TCE FORM NO. whichever is higher.5 4. of each type 1 no.5 2. of each type 1 no.5: ESSENTIAL SPARES Volume – V SECTION: D6 SHEET 1 OF 2 SL. or 10% of each rating of total quantity whichever is higher.2 3. 120R2 . ITEM/DESCRIPTION Field Instruments (Gauges.1 Minimum 01 no.if supplied) – Interfacing modules Solenoid Valve Solenoid Valve Coil 5.1 2.4 4.0 5.3 Fuses of each type and rating MCB of each type and rating Male/female parts of pre-fabricated cables Control valves and Pneumatic Block valves (for each valve): For main Plant Plug and steam assembly 50 nos 10 nos 6 nos.6 4. 2. of each type 2 no.2 2. or 10% of total qty. TCE.1 4.7 PLC CONTROL SYSTEM (Each) Power Supply modules/Cards Network Cards Communication Interface Cards All other electronic modules I/O Cards (Each Type) Controller card Interposing Relay Panels. of each type 1 no. transmitters.0 10% for each type and range but minimum 2 nos. local panels.4 2.3 4. Solenoid Valves QUANTITY / UNIT 1.2 4.3 2.0 3. of each type 1 no.1 3. seat ring packing and gaskets pilot relay actuator diaphragm O-rings Control valves (Electrical operated.0 4. Switches.6 2. NO.

the Contractor shall supply the spares for the supplied system/sub-system/instruments as per the manufacturer’s recommendation.1 7. NO.6 7.3 7. Rotameter. Temperature switch. ITEM/DESCRIPTION QUANTITY / UNIT 6.5 7. NOTE: SPARES requirement for any equipment/system not specified above.1 Vibration Monitoring System Vibration pickups with cable 1 no. 120R2 . Flow switch. ISSUE R0 Vol V . 7.0 6.0 7.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 5 TABLE.Spec No. or 10% of total quantity whichever is higher for each type and range. Pressure indicator.7 Analyser Electronic cards Conductivity cells/ pH cells & electrodes Chemical Reagents Resin Column Sampling system Accessories Pressure Control valve. Minimum 1 no or 10% of total quantity whichever is higher for each type Minimum 1 no or 10% of total quantity whichever is higher for each type 1no for each type and range 1no for each type and range Suitable for 6 charges/usages 2 nos Thermometer.5: ESSENTIAL SPARES Volume – V SECTION: D6 SHEET 2 OF 2 SL.2 7. TCE.Part(B) Page 62 of 114 TCE FORM NO. Solenoid valve.4 7.

IMPULSE TUBE MATERIAL (REF. 2) ANSI RATING ANSI RATING IN SH. MATERIAL & RATING FOR IMPULSE PIPE/TUBE AND FITTINGS SIZE PIPE (REF. 120R2 . 1) SERVICE TUBE SL .34 mm OD 12.NO.NO. 1) IMPULSE PIPE MATERIAL IMPULSE LINE FITTING MATERIAL INSTRUMEN TS VALVES MATERIAL 1.80 21.7 mm 00X1.5657A-C-500-002 A SIZE.NO.Spec No.NO. 1) IN SH. TCE.Part(B) Page 63 of 114 Volume – V SECTION: D6 SHEET 1 OF 5 ISSUE R0 TCE FORM NO.65 MM THK ASTM-105Gr-II ASTM-A-62 BRONZE BODY 150 LBS TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 6 TABLE-7: SIZE. SL. MATERIAL & RATING FOR IMPULSE PIPES / TUBES & FITTINGS Vol V . L. SS 316 3000 LBS WATER SYSTEM ASTM-A-106Gr-B (CARBON STEEL) SCH. N O.

12.40 21.Part(B) Page 64 of 114 3. 120R2 . TCE.3 mm OD ASTM-A105-Gr-II 150 LBS Volume – V SECTION: D6 SHEET 2 OF 5 ISSUE R0 TCE FORM NO.3 mm (PIPE THOUGH OUT) ASTM-A105-Gr-II 3000 LBS TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 6 B.65 mm THK SS 316 IS 1239 HEAVY CLASS (BLACK) SS 316 INSTRUME NT AIR SYSTEM 3000 LBS IS 1239 HEAVY CLASS ASTM-A105-Gr-II ASTM-B-62Gr-II 150 LBS SCH. MATERIAL & RATING FOR IMPULSE PIPES / TUBES & FITTINGS Vol V .65 mm THK (GALVANISED ) 12.Spec No.7 MM ODx1.7 MM ODx1.40 21. SERVICE AIR SYSTEM SCH.5657A-C-500-002 2. SIZE.

Spec No.

TCE.5657A-C-500-002

A SIZE, MATERIAL & RATING FOR IMPULSE PIPE/TUBE AND FITTINGS SIZE MATERIAL MATERIAL PIPE TUBE (REF. SL.NO. 1 IN SH.NO. 1) IN SH.NO. 1) SCH. 40 21.3 mm 0D SS 316 3000 LBS. 12.7 mm 0DX1.65 mm THK ASTM-A-312TP-316 (STAINLESS STEEL) ASTM-A182-Gr-IF6a ASTM-A-182Gr-F6a 150 LBS ANSI RATING (REF. SL.NO. 2 ANSI RATING IMPULSE TUBE IMPULSE PIPE IMPULSE LINE FITTING MATERIAL INSTRUMEN TS VALVES MATERIAL

S L. N O .

SERVIC E

4.

MAKE UP WATER SYSTE M 21.3 MM 0Dx2.77 MM THK * (PIPE THROUG HOUT) SS 316 ASTM-A-312TP-316 (STAINLESS STEEL)

TCE Consulting Engineers Limited

INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 6

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

NOTES: 1.0 IMPULSE PIPE THICKNESS SHALL BE SELECTED AS PER ANSI B 36.10 BASED ON THE SCHEDULE INDICATED AGAINST EACH SERVICE.

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SAMPLI NG SYSTE M

AS APPLICABLE TO SERVICE UNDER SL.NO. 1 TO 12.

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INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 6

Volume – V SECTION: D6 SHEET 4 OF 5

2.0 WHEREVER IMPULSE TUBES ARE PROVIDED, ALL THE FITTINGS REQUIRED FOR THESE SHALL BE SS 316. IMPULSE LINE/TUBE FITTINGS & ACCESSORIES 1.0 NIPPLE SHALL BE PROVIDED FOR ROOT VALVE SIZE MORE THAN ½ INCH AND NIPPLE SIZE SHALL BE SAME AS THE ROOT VALVE SIZE. REDUCER/ADAPTER SHALL BE PROVIDED TO SUIT INSTRUMENT CONNECTION, WHERE NIPPLE, ROOT VALVE SIZE IS MORE THAN ½ INCH. BULK HEAD FITTING SOCKET WELDED TYPE TO BE PROVIDED AT INSTRUMENT RACK/ ENCLOSURE. ALL INSTRUMENT IMPULSE TUBE SIZE SHOULD BE ½” SS. IMPULSE TUBE SHALL BE TIG WELDED FROM ROOT VALVE TO INSTRUMENTS. ANCHOR FASTENERS SHALL BE PROVIDED FOR INSTALLATION OF STANDPIPE WHENEVER REQUIRED.PURGE LINE SHALL BE CONNECTED NEAR ROOT VALVE ONLY. PURGE ROTAMETER, BACKPRESSURE REGULATOR, AIR FILTER REGULATOR FOR PURGE AIR SHALL BE LOCATED NEAR INSTRUMENT. 3.0 3.1 FITTINGS : ALL FITTINGS EXCEPT THE LAST FITTING CONNECTING TO THE INSTRUMENT SHALL BE SOCKET WELDED. THE SIZE OF THE FITTINGS SHALL BE SAME AS THE IMPULSE LINE SIZE. THE FITTING CONNECTING TO THE INSTRUMENT SHALL HAVE A SIZE AND THREAD TO SUIT THE INSTRUMENT CONNECTION. DRAIN DRAIN SHALL BE PROVIDED FOR ALL WATER AND NONINFLAMMABLE / NON-CORROSIVE FLUIDS ONLY. DRAIN VALVE TWO NUMBERS OF GLOBE DRAIN VALVES SHALL BE FOR O PROCESS CONDITIONS OF 425 C OR 62 BAR AND HIGHER. ONE NUMBER GLOBE DRAIN VALVE SHALL BE PROVIDED FOR O PROCESS CONDITIONS OF LESS THAN 425 C AND 62 BAR THE VALVE SIZE SHALL BE SAME AS IMPULSE PIPING/TUBING SIZE. FUNNEL WITH DRAIN HEADER

1.0

3.2

4.0 4.1

5.0 5.1 5.2 5.3

6.0

ISSUE R0
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Volume – V SECTION: D6 SHEET 5 OF 5

6.1

THIS SHALL BE PROVIDED IN THE RACKS FOR BLOWING/DRAINING OUT THE PROCESS FLUID IN THE IMPULSE TUBINGS. THE DRAIN HEADER OF THE RACK SHALL BE CONNECTED TO THE NEAREST FLOOR LEVEL OR PLANT DRAIN.

6.2 6.3

THE SIZE OF THE DRAIN HEADER SHALL BE 1”. WHEN INSTRUMENTS ARE MOUNTED LOCAL TO THE TAPPING POINT AND ARE NOT MOUNTED IN THE RACK, OR PANEL OR ENCLOSURE. THE DRAINS SHALL BE CONNECTED TO THE NEAREST FLOOR LEVEL OR PLANT DRAIN. INSTRUMENT TYPE OF THE VALVE SHALL BE NEEDLE VALVE WITH BUILT IN DRAIN VALVE. SIZING OF THE VALVE SHALL BE ½”. RIGHT/LEFT THREADED FITTINGS : THIS SHALL BE PROVIDED FOR INSTALLATION/REMOVAL OF INSTRUMENTS WITHOUT DISTURBING THE TUBING/PIPING. A SUITABLE ADAPTER SHALL BE PROVIDED TO INSTALL THE INSTRUMENTS ON ½” RIGHT-LEFT THREADED FITTING A ½” VENT LINE WITH A ½” ISOLATION VALVE SHALL BE PROVIDED IN THE INSTRUMENT RACK FOR AIR AND COMPRESIBLE FLUIDS OR OTHERWISE IF THE INSTALLATION CALL FOR EG., FOR LIQUID SERVICE WHERE THE TRANSMITTER IS LOCATED AT A HIGHER ELEVATION THAN THE TAPPING POINT.

7.0 7.1

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pr. including on header section. ISSUE R0 Vol V . e. 03(Three) transmitters shall be provided. Pressure Switches shall be provided (a) On all process lines / Equipment where parameter abnormality/status including pre trips alarms to be communicated to the operator in control room.TCE Consulting Engineers Limited Spec No. For all permissive conditions governed by safety operation of the equipment. including on header section if 2 or more fans are employed for the same service. (d) 1. All input and output lines of process equipment.3 Differential Pressure Switches (Indicating type) shall be provided (a) (b) Across filters/strainers for remote monitoring Across condenser for remote monitoring and interlocks 1.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 1 OF 23 TABLE 7: GUIDELINES FOR PROVISION OF INSTRUMENTS AND SPECIFICATIONS 1. Inlet and outlet of filters/strainers.2 Suction and discharge lines of pumps. if two or more pumps are employed for the same service. conditions.4 Pressure Transmitter shall be provided For all control applications and as demand by the process.Part(B) Page 68 of 114 TCE FORM 329 R3 . For all interlock conditions which governs starting of standby equipment or subsequent equipment for safety operation of the system. All Drive/equipment protection trip due to pressure shall be derived from LVM of transmitter signal and not through switches.1 Pressure indicators shall be provided for (a) (b) (c) (d) 1. (b) (c) . adequate.0 GENERAL GUIDELINES FOR PROVISION OF INSTRUMENTS / TAP POINTS Instrumentation and control system shall be supplied in accordance with the various sections of the specification. Suction and discharge lines of fans. TCE. 1. It shall be noted that for all critical control applications.g. Inlets and outlets of heat exchangers and desuper-heaters.

K-type for temperature upto 600deg. Six nos. for winding temperature monitoring.C.TCE Consulting Engineers Limited Spec No.6 Temperature indicators (Thermometers) shall be provided (a) (b) (c) (d ) (e ) On all process lines where local indication is warranted by the system either for monitoring or testing.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 2 OF 23 1. for connection to DCS system. Heat Exchangers & Coolers for both the fluid media. flow. RTDs shall be terminated in the external terminal box. Thermowell shall be provided for all temperature indicators. 1 no. duplex with thermowell assembly. duplex k-type thermocouple shall be provided for each bearing of HT equipment. Differential temperature indicator shall be provided across BFP suction and discharge service Capillary type temperature indicators shall be used in vibration prone areas. (a) (b) All thermocouples and RTDs as required for implementation of control & monitoring shall be supplied The elements shall be duplex type with integral thermowell (except for metal thermocouples). For all alarm and Trip application. pressure.Part(B) Page 69 of 114 TCE FORM 329 R3 . per phase) Resistance temperature detectors (RTD’s) shall be provided for all 6. shall be provided. ISSUE (c) (d) (e) (f) (g) R0 Vol V . a LVM of temperature element shall be used. ( 2 nos.7 Temperature Elements :. level measurement All Drive/equipment protection trip shall be derived from LVM of transmitter signal and not through switches.5 Differential Pressure Transmitter shall be provided For all the requirements of Diff.C and R-type for temperature above 600 Deg. On the inlet/outlet equipment such as desuper-heaters.6 kV motors. 1. 1. Thermowells shall be provided for mounting of all temperature elements. Each element shall be 3 wire type. TCE. All temperature elements shall be supplied with associated junction box Compensating cable shall be provided with all thermocouples (i) From T/C to field junction box and to system cabinets. Temperature switches are not acceptable. For metal thermocouples suitable pads with clamps etc.

1. Suitable platforms shall be provided for purpose of taking measurements and during maintenance.11 Flow Glasses shall be provided at the outlet of the pipe lines and shall be employed under the following conditions: (a) Coolant from the equipment (coolers). combustor. .5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 3 OF 23 (h) 5 to 15 meter long thermocouple (MTM type) shall be provided in high surrounding temperature zone (e. The gauge glasses shall be stacked to cover the complete height of the tanks including over flow level. Sealpot etc) areas. ACW over head tank etc. Continuous level measurement shall be provided for CW forebay. FBHE. g. Necessary mounting clearance with approach platforms shall be provided. 1. Level switches : The instrument shall be provided : (a) (b) On all equipments (storage vessel) where parameter status has to be communicated to the operator in the control room.10 Level Transmitters (a) Level transmitters shall be provided on process equipments where continuous remote monitoring and/or control of level is envisaged.TCE Consulting Engineers Limited Spec No. (b) The instrument will be differential pressure type for other applications for ranges exceeding 32 inches. The instrument will be displacement type for all high pressure and vacuum applications involving two phase media and range of measurement or control is within 32 inches. when more than one level gauge is required. ISSUE R0 Vol V . The termination of the thermocouples shall be at low temperature area. TCE.8 Level gauges shall be provided on all tanks and the maximum length of one gauge glass shall not exceed 1 metre. All permissive. and interlock conditions governed by the safety operation of the equipment. 1. Condensate Storage tank. Clarifier water tank.Part(B) Page 70 of 114 TCE FORM 329 R3 . Steel pipes will be provided with adequate supports. There shall be an overlap of minimum 150 mm.9 The instrument shall be external float type with SW connection with isolation facility for surface mounted tanks and top mounted with steel pipe for all sumps. 1.

Four (4) way solenoid valve shall be provided for operating double acting cylinders.18 R0 Vol V .13 1. Dual coil Solenoid valves shall be supplied for equipment trips and single coil for balance. All bypass valves of control valves shall be motor operated valves suitable for inching operation provided with position transmitters. power cylinders etc. Electro-Pneumatic Converters shall be provided for all pneumatically operated control valves.g. The number of ways for solenoid valve shall be provided as indicated below:(a) On line two (2) way solenoid valves shall be provided. Pneumatically operated control valves shall be provided for all control application. control valves with split range application shall be provided. where the low pressure(below 10Kg/cm2) is admitted or exhausted from a diaphragm valve or single acting cylinder. E. E. For line sizes more than 1” pneumatic block vales shall be used.g.14 The instrument shall be rotary type with glass mounted for indication. TCE. then control valves shall be provided for those applications also. Upto 6 inch on-line flow glasses shall be supplied and above 6 inch bypass type flow glasses shall be provided. Pressure test points & drains shall be provided across each control valve . where variable speed drives are to be controlled from remote .15 1.TCE Consulting Engineers Limited Spec No.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 4 OF 23 (b) (c) 1. If applicable. Speed Measurement shall be provided. where process line of less than 2 inch with low pressure(below 10 Kg/cm2 ) & temperature application is involved.16 (b) (c ) (d) 1.: Pneumatic operated spray water block valve. Flow elements shall be provided as detailed in Table-9. Direct operated solenoid valves shall not be used for the process lines size more than 1”.17 Position Transmitters shall be provided for all control valves and including valves. If the process demands any other control. Position transmitters shall be non-contact proximity type only. for converting controller output of 4-20 mA to 3-15 PSI for interfacing with pneumatic actuators.Part(B) Page 71 of 114 TCE FORM 329 R3 .: Pneumatically operated on-off type dampers.12 1.. ISSUE 1. Where a single control valve can not meet the turned down ratio as dictated by the process. All integrated bypass valves shall be motor operated. Three (3) way solenoid valve shall be provided commonly. 1. Solenoid valves shall be provided for all pneumatic control valves hooked up with process interlock requirements and where direct tripping is involved. control dampers where modulating/inching operation is required.

2Amps. the sampling tap points as called in Table-11 of the specification. Vibration pads shall be provided on all HT equipment for mounting the vibration sensors. Solenoid valve (two relays per valve) .19 Air Filter Regulators along with gauges shall be provided in each of the (a) (b) (c ) Air supply line to valve positioners /power cylinders Air supply line to electric to pneumatic converters Air supply line to pneumatic interlocked block valves 1.20 Interposing relay (To be mounted in IPR panel located at local control room) for interface to the following: LTMCC – Relays with contact rating of 0. shall be provided.23. Termination of Duplex thermocouples/RTDS.Part(B) Page 72 of 114 TCE FORM 329 R3 . The vibration sensors in horizontal and vertical direction and vibration monitors shall be provided for all HT equipment. shall be provided. TCE. 1. position transmitter and ISSUE R0 Vol V . Termination of limit switch. torque switch.1 Junction Boxes shall be provided for a) b) c) d) Shall be Double door type and not of double leaf type with cable entry from bottom.23 1. The vibration signals shall be made available at applicable controls system [PLC] for monitoring and protection purpose.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 5 OF 23 1.21 Analytical Instruments (a) (b) Withdrawal Type Conductivity Analyser shall be provided at condenser hotwell along with necessary mounting arrangements/ accessories as required.TCE Consulting Engineers Limited Spec No.Relays with contact rating of 0. Vibration monitors shall be located in the central control room. For other analytical measurements. Termination of all sensors located equipment wise. 1. HTMCC (two relays per drive) – Relays with contact rating of 2amps. Junction Box (JB) /Field Termination cabinets (FTC) 1. Hardwired signal exchange – as required. two relays per valve) .2Amps (two relays per drive) Integral Starter(for all valves.Relays with contact rating of 2Amps.22 Vibration Measurements: Complete vibration measurement system (microprocessor based) for all bearings on both X-Y directions.

Additional field JB shall be provided where there is a length limitation for the signal cable from sensor. independently for each valve. both the SPDT contacts of switches shall be wired upto the J. The power requirements of the systems shall be estimated and the power supply requirement shall worked out. All power supply in the system cabinets shall be redundant and have auto-change over facility or diode auctioning.TCE Consulting Engineers Limited Spec No. etc. torque switches and position transmitters to their respective field junction boxes. 1. 20% spare terminals shall be provided in each FTC. Turbine and other hot zone area. Prefabricated cable for connecting between system cabinets. 10% spare terminals shall be provided in each JB.25 Auxiliary Power Supply System (APSS) The power supply system shall confirm to the requirements indicated in Electrical specification.24 Instrumentation & control cables and Prefabricated Cables termination guidelines (i) (ii) (iii) To connect field instruments to field junction boxes/Local Panels. Based on the requirement.2 Field Termination cabinets : Areawise termination of cables from JBs. Only spring-loaded terminals shall be used for termination. For switches. 1. Heat Resistant Instrumentation cable (PTFE) with armouring shall be used near Combustor. marshalling cabinet to system cabinet. FTC shall be double door type and not double leaf type with cable entry from bottom. Only spring-loaded terminals shall be used. To connect limit switches. Cabling between interposing relay cabinet to the marshalling cabinet located in MCC room.23. (iv) (v) (vi) 1. Compensating cable shall be supplied for connection between the element and the respective junction boxes / system cabinets as per guidelines.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 6 OF 23 e) f) g) control demand. system cabinet to Relay Rack.B. the power supply scheme along with distribution board shall be designed and provided. TCE.Part(B) Page 73 of 114 TCE FORM 329 R3 . ISSUE R0 Vol V .

1. For pressure switches and temperature switches. All pump suction measurement will cover the negative pressure range also and all vacuum measurements will cover the negative pressure as well as the positive pressure as the case may be. Based on the estimation. alarm and trip levels. Power supply to all the other panels like Vibration Monitoring panel.Part(B) Page 74 of 114 TCE FORM 329 R3 .28 Selection of Ranges for Instruments The ranges of the instruments shall be selected based on the following philosophy indicated below: (a) For pressure and vacuum measurements. Globe valves are to be used for all clarified water tapings. the maximum operating temperature will be within 80 to 90% of the maximum scale range. fittings and air supply and signal piping/tubing shall be supplied for all the instruments under the scope of this specification. All instrumentation Isolation valve should have drain facility. Gunmetal valves are not allowed for any instrumentation applications. TCE.26 Instrument Air Supply System Instrument air requirement shall be worked out for the complete plant.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 7 OF 23 For AC Power distribution. ISSUE R0 Vol V . PLC system shall be redundant with bumpless changeover. (b) (c ) (d) 1. (b) (c) (d) For temperature measurement. compressors along with distribution shall be designed and provided. Instrument isolation valves (needle type SS) before manifold on the impulse line in addition to the root valves for all Instruments. For level measurement. 1. The general specification is given in Table-7. the redundant power supply change over scheme shall only be provided in distribution board and not at the equipment end. the maximum of the range will cover the overflow point or six inches below the top of the vessel and the minimum of the range will be six inches above the bottom of the vessel. Also. the gauge glasses will be stacked with overlap to cover permissive.27 Impulse pipes/tubes & fittings (a) Impulse pipes. the maximum operating pressure will be within 70 to 80% of the maximum scale range.TCE Consulting Engineers Limited Spec No. the set points shall fall within 40% to 70% of the scale range selected.

TCE Consulting Engineers Limited Spec No. For any conveyor.31 1.S. the same switch shall stop the conveyor. From either end of conveyor pull cord switches should not be more than 15m. Belt sway switch shall have C.Part(B) Page 75 of 114 TCE FORM 329 R3 . The speed setting should be adjustable.32 1. Pull cord switch / Belt sway switch identification system The system shall identify the one or more operated pull cord / belt sway switch location and monitor the condition of the cable connecting the switches in series for open and shorted conditions. The system shall comprise sensor modules installed in the field switches and indicator / transmitter module to identify switch operated / cable healthy condition. however. 1. Non contact type zero speed switches Each conveyor shall be provided with a zero speed switch (auto reset type) at the tail end for sequential operation of the system. Enclosure shall be provided for pull cord and belt sway switches.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 8 OF 23 (e) For flow measurement. Pull cord switch shall have C.I. belt sway and zero speed switches A canopy made of 5mm M. minimum two pairs of switches shall be provided. Pull-Cord Switches Pull Cord (manually reset type) emergency stop switches shall be located along both the sides of entire length of all conveyors. TCE. body with additional enclosure to prevent ingress of dust. In case of belt speed falling below the tolerable limit. body with additional enclosure to prevent ingress of dust. Adequate length of PVC coated wire rope and all accessories shall be furnished.33 ISSUE R0 Vol V .29 Pull cord. The degree of protection for all protection switches shall be IP-65. These switches shall be placed not more than 15 m from either end of conveyor. The 1.30 1.I. the maximum range shall be fixed at about 10 to 15% above the maximum operating flow. Also a local trip indication (Cluster of LEDs) shall be provided with each pull cord switch. plate shall be provided over the lever of each pull cord switch and for each belt sway switch so that spilled over coal lumps do not trip the belt by actuating the lever. All switches shall have 2 NO & 2 NC potential free contacts. Necessary provision to be kept in control circuit to by-pass the switch during starting. The spacing shall be at an interval of not exceeding 30 meters. Belt-Sway Switches Belt Sway limit switches (auto reset type) shall be furnished in pairs at periodic intervals of minimum 30m to limit belt sway to permissible extent.

29 PG Test Points (a) Pressure. shall be provided by Bidder. field JB’s etc. Stand pipes required for hotwell. Temperature test points shall be provided with thermowell along with a cap and chain. shall have bottom cable entry. 1.31 CABLE TRAY GROUPING Separate cable tray shall be provided for instrumentation cables extension cables. heaters. TCE. Instruments for Performance Testing All instruments required for performance testing to prove the guaranteed performance of the Instrumentation and Control Equipment shall be in Contractor’s Scope. temperature [with thermowell] and flow test points shall be provided in line with performance test code requirements. instrumentation cables shall run through the top most cable tray Minimum distance of 500mm to 1000mm must be maintained between the instrumentation cable tray and the high heat zones where the temperature is 200 deg. 1. MMI cables etc.30 At the discharge of all pumps and fans At the inlet and outlet of the heat exchangers for the fluid media involved At the inlet and outlet of each control valve Pressure test points shall be complete with root valves and shall terminate with a nipple. These test instruments shall have test certificates from reputed test house. valid for the duration of the performance test. The system shall be provided to cover all the conveyors from the mines to the bunker. GSC. pressure and temperature test points shall be provided for the following services: i) ii) iii) (b) (c) 1.C and above.TCE Consulting Engineers Limited Spec No.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 9 OF 23 system output shall be connected to the PLC for identifying the operated switch location / cable condition to the operator on the VDU. deaerator.Part(B) Page 76 of 114 TCE FORM 329 R3 . In addition. flames scanner cables. drain pot. All the control room cabinets . etc. ISSUE R0 Vol V .

pipe mounted Pressure gauges of aluminium casing (epoxy coated) with 4and1/2 inch phenolic dial (white dial with black numerals). TCE. 2. Accessories like snubbers for pump discharge applications and chemical diaphragm with 15 m PVC covered SS armoured capillary for corrosive and oil services. Pressure Indicators Direct reading. IP 65 or equivalent degree of protection. AISI 304movements and micrometer type adjustable aluminium pointer an accuracy of +0. Auto reset micro switch with internal adjustment For set values with 2 SPDT contacts rated for 0.Part(B) Page 77 of 114 TCE FORM 329 R3 .2 Pressure Switches Non indicating type.TCE Consulting Engineers Limited Spec No.2 A at 220 V DC. external zero and span adjustment. 2. Armoured capillary of 15 M shall be provided as required. etc.1 SPECIFICATIONS FOR INSTRUMENTS TO BE SUPPLIED ARE AS FOLLOWS. temperature sensor for compensation. and 316 SS element and accuracy of +1% of span. output signal of 420 mA DC.4 Differential Pressure Indicators ISSUE R0 Vol V . 2. 316 SS sensing element. Aluminium housing with epoxy coating.2% of span. Over range protection will be 50% above maximum pressure.0 2.5% of span including accessories like siphons for steam services. snubbers for pump discharge applications and chemical diaphragm for corrosive and oil services and name plate.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 10 OF 23 High heat resistant instrumentation cables (PTFE) with armouring Shall be used in and around the combustor. rack mounted with accuracy of +0. Power supply 24 V DC. including accessories like siphons for steam services. Calibration facility shall be provided via HART communicator .3 Pressure Transmitters (Smart) Micro-processor based indicating type (LCD display). 316 SS Bourbon tube. Material of accessories will be SS. IP65 or equivalent degree of protection for enclosure. field mounted Pressure Switches of aluminium casing (epoxy coated). IP 65 or equivalent degree of protection for enclosure. 2. Material for accessories will be SS. main Turbine & other hot zone areas in the plant. snubbers for pump discharge applications and chemical diaphragm for corrosive and oil services. HART protocol output shall be available in each transmitter. Scale for setting shall be provided. etc. name plate & mounting brackets. Over range protection 50% above maximum pressure. self diagnostics. Material of accessories will be SS.

5 Differential Pressure Switches Bellows or diaphragm operated indicating field mounted type. Linearity :+0. external zero and span adjustment. filled system with ten (10) metres SS capillary with SS armour and six (6) inch dial (white dial with black numerals with micrometer pointer) housed in aluminium casing (epoxy coated) with an accuracy of +1% of span. response time of 2-4 seconds. Remote communication with field communicator/ control system. Repeatability : +0. Material of accessories will be SS.6 Differential Pressure Transmitters (Smart) Micro-processor based indicating type (LCD display). name plate & mounting brackets.TCE Consulting Engineers Limited Spec No. linear calibration over the range and SS bulb with 316 SS thermowell having a process connection of M33 x 2 thread or 150 RF flanged. Hystersis: +0. HART protocol shall be available in each transmitter. rack mounted with accuracy of +0. auto temperature calibration. chemical diaphragm with 10 m PVC covered SS armoured capillary for each limb for corrosive and oil services and 5 way manifold & name plate.7 Thermometers Indicating type. Auto reset micro switch with tamper proof external adjustable set values with 2 SPDT contacts rated for 0.Part(B) Page 78 of 114 TCE FORM 329 R3 . aluminium casing (epoxy coated) with six (6) inch dial (white dial with black numerals).2 A at 220 V DC.5% FSR.05% of FSR or better. Over range protection will be 50% above maximum pressure. etc. bellows or diaphragm operated differential pressure indicators. Aluminium housing with epoxy coating. haste alloy sensing element. TCE. an accuracy of +0. temperature sensor for compensation. 2. 316 SS pressure element nylon movement. Calibration facility shall be provided via HART communicator. 2. chemical diaphragm with 15 m PVC covered SS armoured capillary for each limb for corrosive and oil services and 5 way manifold & name plate. chemical diaphragm with 15 m capillary for each limb for all corrosive and oil services and 5 way manifold. aluminum casing (epoxy coated). mounting brackets. IP 65 or equivalent degree of protection over range protection 50% above maximum pressure. etc. etc.25% of FSR or better”.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 11 OF 23 Direct reading type. Material for accessories will be SS. an accuracy of +1% of span within adjustable contact including accessories like snubbers for pump discharge applications. mounting brackets.2% of span.1% of FSR or better. Repeatability shall be + 0. IP 65 or equivalent degree of protection. field mounted. Power supply 24 V DC. etc. output signal of 420 mA DC. pipe mounted. 316 SS pressure element. IP 65 or equivalent degree of protection. Accessories like snubbers for pump discharge applications. 2. with micrometer type pointer.1% of FSR or better.) will be SS. IP 65 or equivalent degree of ISSUE R0 Vol V . Accuracy : +0. Material of accessories (name plates. Self diagnostics. Material of accessories will be SS.5% of span including accessories like snubbers for pump discharge application.

Spring loaded mineral insulated thermocouple assembly with 316 SS thermowell housed aluminium casing (epoxy coated) having a process connection of M33 x 2 thread or 150 RF flanged.9 Thermocouple Assembly Duplex type with accuracy of +0.) will be SS. IP 65 or equivalent degree of protection for enclosure. In case flanged wells are required for any specific application. Material of accessories (name plate. Thermowell shall be hex head of barstock assembly.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 12 OF 23 protection for enclosure. The thermowell construction shall meet the ANSI 19.02%. etc. Spring loaded mineral insulated three (3) wire RTD assembly with 316 SS Thermowell housed in aluminium casing (epoxy coated) having a process connection of M33 x 2 thread or 150 RF flanged. Insulation resistance at 540oC shall not be less than 5 M ohms. shall be provided. etc. All bed thermocouples shall have solid tungsten carbide or SS440 protecting sheath.TCE Consulting Engineers Limited Spec No.3-1994 (latest) requirements. IP 65 or equivalent degree of protection for enclosure. Element lead size will be 18 AWG. Thermowell with hex head (with screwed cover & SS chain) bar stock assembly with ungrounded junction. Material of accessories will be SS. etc. response time of 2 to 6 sec. For metal temperature measurement. The thermowell construction shall meet the ANSI 19. The thermowells shall be hardfaced/sterlited to avoid erosion for boiler area applications.5% of span. response time 1-2 seconds. RTDs shall be ungrounded.Part(B) Page 79 of 114 TCE FORM 329 R3 . barstock assembly.5% of span. Material of accessories (name plate. Thermocouple termination head shall be 300 mm above the pipe insulation to avoid cable damage in hot zones. Accessories like name plate. The thermowell construction shall meet the ANSI 19. the same shall be supplied as required.3-1994 (latest) requirements. 2.) will be SS. Thermowell with hex head with screwed cover & SS chain. 2. Element size shall be 18 AWG. RTD shall be supplied as an assembly complete with thermowell meeting ANSI 19. The insulation resistance at 540oC shall not be less than 5M ohms. ISSUE R0 Vol V . All pent house thermocouples shall be supplied with 15mts flexible extension length. Thermowell with Hex head bar stock assembly. thermocouple pads weldable to MS pipes shall be provided with 15 m thermocouple extension wires.10 Resistance Temperature Detectors (RTD) Duplex PT-100 type with accuracy of +0. TCE.3-1994 (latest) requirements. 2. Repeatability over full range shall be better than 0.8 Thermowells Pipe/equipment mounted temperature test wells of 316 SS with a process connection of M33x2 thread or 150 RF flanged. Temperature devices provided with thermowell shall be calibrated with the associated thermowell as an assembly.3-1994 (latest) requirements. plug with chain.

isolated and ungrounded electrical circuits. The top mounted level switches shall be supplied with steel tubes to suit Purchaser’s requirement. The material of accessories will be SS. IP 65 or equivalent degree of protection for enclosure. etc.13 Displacement type Level Transmitter Displacement type level transmitters of float length of 14 inches or 32 inches with an accuracy of +0. 4-20 mA DC output (2 wire system). +24 V DC supply. Displacer /float material of 316SS. Tubular glass OD will be 5/8”. pyrex / borosilicate glass. bolts & nuts. IP 65 or equivalent degree of protection for enclosure. 220 V DC. mating flanges with gaskets (neoprene). drain valve for external case type level switches.12 Level Switches External float operated level switches for tanks and vessels and top mounted level switches and underground tanks. bolts & nuts. etc. 2. Enclosure shall be IP65. 2. mica shield.2 A. mating flange. brass guard rods & brass holders.TCE Consulting Engineers Limited Spec No.14 Flow Glasses Online flow glasses for pipe size up to 6" with a rotary wheel (not a flapper type) suitable for installation on vertical or horizontal pipe lines. zero adjustment (100% of sensing element) for control application and measurement purposes for all services of Condensate and drains. The material of accessories will be SS. Enclosure shall be IP 65. Body material will be carbon steel.Part(B) Page 80 of 114 TCE FORM 329 R3 .5% of span. TCE. Vent & drain valves shall be provided. Upto 50 NB size. 150 RF. Material of accessories (name plate. etc. illuminator (240 AC). Conductivity type electronic Probe type level switches shall be supplied for Drain pots and for sump level. Accessories like name plate. material Pyrex tempered glass. IP 65 or equivalent degree of protection for enclosure. fasteners.ANSI. Accessories like name plate. shall be supplied. shall be supplied.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 13 OF 23 2. 2.11 Level Gauges Tubular type level gauges for low pressure upto 7 kg/cm2 & reflex type for high pressure water & steam services & vacuum services with automatic ball check valves. ISSUE R0 Vol V .) will be SS. connection shall be screwed & above 50 mm NB size it shall be flanged . The required pressure vessel assembly for mounting probes are included in the scope. Micro switch with 2 SPDT contacts rated for 0. Connection shall be screwed or flanged (ANSI class 150 RF). Material of float & float chord will be 316 SS & cage material shall be fabricated steel and the material of accessories will be SS. gaskets (asbestos). rotor & wetted parts will be bronze. particularly where two phases of steam and water are present.

Orifice plate shall not be less than 3 mm thick for nominal pipe diameter upto 300 mm & not less than 6 mm thick for pipe diameter > 300 mm.19 Bunker level Indicator ISSUE R0 Vol V . 2. IBR certification for tube & fittings to be provided for pressure greater than 3. welding adapters. shall be provided to place CRTs. The Processor shall be housed in the bottom section of control desk. IBR certification shall be provided. B ratio of 0. 2.18 CONTROL DESK Indoor located. The material of accessories will be SS. Material of the inner tube shall be inconel 600/316 SS and material of outer tube shall be AISI 316SS. bolts & nuts.5 standards.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 14 OF 23 2. 316SS flow orifice plate assembly for all water services with flange tap connections. TCE. key boards etc. coil in coil type sample coolers with counter flow operation shall be provided. shall supplied. Performance Guarantee flow elements shall be provided separately. root valves as required. 2. nipple. Accessories like name plate.TCE Consulting Engineers Limited Spec No. indoor located. The Profile of control desk with the layout arrangement shall be subjected to OWNER/ENGINEER approval. gaskets.15 Flow Elements SS 316 flow nozzles for all steam and feed water services with D and D/2 pressure tappings.17 SAMPLE COOLER Indoor located. etc. Refer to Table-7 for provision of flow elements. 2.Part(B) Page 81 of 114 TCE FORM 329 R3 . reservoirs (condensing chambers). Isolating valves shall have SW end connection. construction material of steel/channel.16 SAMPLING RACKS Enclosed panel style.5 & 0. 6 nos. desk type control desk with 3 mm thick sheet metal of cold rolled steel. The flow elements shall be supplied as assemblies with High/low pressure tappings. Butt welded edges shall be prepared as per ANSI 16. bolts & nuts.7. All the flow elements shall have 3 pairs of differential pressure tappings complete with root valves. shut off valves per assembly. Element material of SS 316.25 & flanged connections shall be as per ANSI 16. Indoor located. Guidelines for provision of steam and water system analysers is enclosed in Table-11.5 kg/cm2 and corresponding saturation temperature. Orifice assembly complete with nipples & valves to be supplied by Bidder shall be one metre long with ANSI class 150 RF SS flanges at the ends including gaskets. Sliding drawers shall be provided above the Processor compartment and below the desk portion all along the control desk for storing operation log books. free standing panel type unit control panel shall be mosaic grid type.

Switch – 2 nos. The material of accessories will be SS.04”. air supply lines and header will be provided with bulk head fittings to receive impulse lines. of FTCs at MCC shall be provided. All relays shall be mounted in IPR cabinet & relay base (silver plated) ISSUE R0 Vol V .2A 220 V DC. 2. Linearity ±0. 4-20mA output with HART protocol. Terminal size shall be suitable for 0. JB shall have single lockable door with gasket. name plate & metal tag. IP 65 or equivalent degree of protection for enclosure. of SPDT contacts (1 NO and 1 NC) rated for 0. the material of accessories will be SS. lock & key. Resolution 0. Free wheeling diode across relay coil (copper) and self reset type status indicator flag (electronic) shall be provided.JB material shall be acrylic fiber. All JBs shall be provided with individual canopies to avoid ingress of water. Transmitter rack with continuous purging arrangement shall be provided in boiler area. coil rating 24V D..01%. Separate JBs for different voltage levels shall be supplied. All the field Junction boxes shall have double doors.Part(B) Page 82 of 114 TCE FORM 329 R3 .20 Pressure and Differential Pressure Transmitter Racks Open type transmitter racks with canopy to mount all pressure.C. with common keys. Accessories like integral cable between sensor and transmitter unit with connectors on both side.21 Junction Boxes (JB) and Field termination cabinets(FTC) Wall/column mounted junction boxes having 32 (2x16) terminals and cable entry only at the bottom and sealed with fire proof compound. Beam angle <20º. digital panel meter.TCE Consulting Engineers Limited Spec No. suitable for channel/rail mounting in cabinets. 4 nos. shall be supplied.5 mm2 to 2. JB shall have provision to add 10% additional terminals. 2. 220 V DC. Painting inside will be glossy white & outside . Separate terminal blocks shall be used for analog and digital signal signals. IP-65 protection. 2.2 A.22 Interposing Relays (IPR) Electro magnetic type IPRs with plug-in type connections. All should be of bottom cable entry type . gasket and cable gland. TCE. gaskets (neoprene).5 mm2 wire. Screwed terminal type. fixtures. Shield bus for screw connection shall be provided. FTCs in Boiler. able to open side ways.04”.FTC material shall be 3 mm sheet steel. Accuracy ±1%. clamps. etc. Also provided with blow down/drain header. Accessories like metal tag (SS). fire proof compound for sealing. bolts (SS). differential pressure and flow transmitters with vibration dampener (Keldur).IS-5 shade 631. The grouping of instruments in JBs is subject to Purchaser’s approval. Repeatability ±0. +24 V DC supply. Removable gland plate shall be supplied. Minimum 5 nos. Air filter regulator and purge rotameter shall be used at boiler side. FTCs in TG side. Terminal blocks shall be vertical. nuts (SS). 2 set of silver plated charge over contacts rated for 0.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 15 OF 23 Radar type level transmitters top mounted with LCD indicator shall be provided. 02 Nos. Drains shall be connected upto suitable drain header.

free standing vertical type marshalling cabinets with IP-42 enclosure and with 2 mm thick sheet metal of cold rolled steel. Status/amps shall be provided. The racks in system cabinets shall have provision along with plug in sockets/back plane to house at least 20% additional cards. a fault lamp shall be provided on the first or last (based on the control room layout to be decided during detailed engineering) cabinet. relay base mounting rail/channel. on the side to help the operator. Wiring connection shall be screwed & termination shall be suitable for 0. input/output cards. Smoke detector shall be mounted in each system panel and shall be connected to the plant Fire detection and Alarm system. A stainless steel metal tag (plate) shall be fixed to the inside of the door & the layout of the racks. Doors shall have concealed type of hinges and swing of 100 degrees.Part(B) Page 83 of 114 TCE FORM 329 R3 . Prefab cable connectors shall be used for connecting signals between system cabinets. antivibration pads of 15 mm thick. Accessories like name plate (SS) with tag & service inscription.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 16 OF 23 internally wired to the external cabling termination block in IPR cabinet. ISSUE R0 Vol V .TCE Consulting Engineers Limited Spec No. Three nos. Alternatively system cabinets with lift off type doors can be offered. free standing vertical type system cabinets with IP-42 enclosure and with 2 mm thick sheet metal of cold rolled steel. All electronics shall be mounted & wiring connections at these hardware shall be terminated by vendor. fluorescent lighting. fire proof compound (50 mm thickness) for sealing cable entry (bottom).5 mm2 size wiring. blower & louvers in each cabinet with brass mesh. double doors with neoprene gaskets.24 Marshalling Cabinets Indoor located. 2. The colour of the cabinets shall be indicated at detailed engineering stage. slots & details of the card type/service shall be inscribed on this metal tag. etc. Cabinet shall be delivered totally wired. to accommodate for engineering flexibility or future expansion. shall be supplied. Facility to simulate relay operation manually shall be provided. processor cards & associated power supply units. change over contacts shall be wired to external TB with screwed terminations only. nuts & bolts. Relays of different contact interrogation voltages shall be separated by a barrier in IPR cabinet. racks in system cabinets. protections. etc. In addition to Beacon Lamp provided for each cabinet to monitor fault. Indoor located. 2. Quantity shall be as required. fire detector for each cabinet. antivibration pads of 15 mm thick.23 System Cabinets These cabinets shall house signal conditioning cards. The cabinet shall have space provision to mount at least 20% additional cards to provide for future expansion. Each cabinet shall be provided with one each 3 pin receptacles for 240 V. TCE. The doors shall be provided both at the front and rear. Beacon lamp shall be provided in each cabinet to indicate the cabinet having fault condition. The system cabinets. slots in the racks & the terminals shall have identification numbers. double leaf type with neoprene gaskets. Power supply distribution shall be provided on per cabinet basis with all associated MCBs. 1P 50 C/S and receptacles for +24V DC.5 mm2 to 2.

Interconnection schedule (ICS) between marshalling cabinets. fire detector for each section. Channels.5 m. The terminals for field cables shall be arranged in a logical order of equipment/system wise and shall be worked out by vendor. fire proof compound (50 mm thick) for sealing cable entry (bottom. IP 65 degree of protection for enclosure.Part(B) Page 84 of 114 TCE FORM 329 R3 . 1P. black background with white lettering & shall be fixed to the panel by stainless steel screws (counter sunk).26 Vibration Monitoring System ISSUE R0 Vol V . subject to approval by Purchaser/ Consultant. shall have identification numbers. Removable cover plates with locking facility shall be provided along the bottom of the front desk continuously to facilitate maintenance work. The type of terminals for terminations from cabinets/panels shall match with the pre fabricated cables and pins supplied. bolts & nuts shall be zinc plated and passivated. Each cabinet shall be provided with one each 3 pin receptacles for 240 V. rear). The type of terminal shall be WAGO make only. blower & louvers in each section with brass mesh. The doors shall be provided both on the front and rear. the terminal blocks. Double doors with neoprene gaskets at every 1. 50 c/s and receptacles for +24V DC. 1P 50 c/s & 110 V. Door shall have concealed type o hinges and swing of 180 & lockable. A system cabinet and associated cabinets shall be supplied on a skid to avoid outside interconnecting cables. fluorescent lighting. fire proof compound (50 mm thick) for sealing cable entry (bottom). These shall be phenolic overlays (1. Quantity shall be as required. space heater with thermostatic control for each section (strip type). fire detection for each cabinet.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 17 OF 23 blower & louver in each cabinet with brass mesh. 50 c/s. Two coats of premier paint and black colour paint shall be applied. antivibration pads of 15 mm thick. Panel shall be delivered totally wired. The length of each cover plate shall not exceed 1 m. Fused Terminals are to be used in the marshalling cabinets for analog signals to protect the DCS cards from short circuit/grounding 2.6 mm thick). 1P. Cabinet shall be delivered totally wired. TCE. Fluorescent lamp of 40 W shall be provided from one end of the panel to the other end at continuous length and shall be operated by the door switches as well as by manual switches. 2. The colour of the cabinets shall be indicated at detailed engineering stage. & short description of service engraved.TCE Consulting Engineers Limited Spec No. All instruments. front. Each section of the panels shall be provided with one each 3 pin receptacles for 240V. Fluorescent lamp of 40W shall be provided and shall be operated by the door switches as well as by manual switches. The marshalling cabinets. No. Name plates shall be provided for all instruments/inserts with Tag. the terminals and the electronic hardware if any. inserts and annunciation windows shall be mounted & wiring connections at these hardwares shall be terminated at site by vendor. FTCs and JBs shall be prepared by Contractor and the format of ICS will be decided during detailed engineering stage.25 Local Panels Indoor/Outdoor located. free standing vertical type local panels with 3 mm thick sheet material of cold rolled steel.

SPDT alarm contacts for high and v. Material of construction will be 2mm thick CRCA. air lock device. Vibration pickups shall be provided for X and Y directions..high conditions. Ammeter and voltmeter will be provided for the incoming feeders to the distribution boards.27 230 VAC DISTRIBUTION CABINETS The function of the 230V AC distribution is sub distribution of 230V AC power supply from UPS to all the utilities viz. Material of construction will be 2mm thick CRCA. 230 V AC to 24 V DC distribution system shall be designed with the complete redundancy and the scheme is subjected to approval of OWNER/ENGINEER. In addition. degree of protection IP65. solenoid valve. vertical cabinets designed for indoor location. All the other voltages such as 24VDC shall be derived from UPS system. 2. modulating. Microprocessor based control room mounted vibration monitors (dual channel) shall be provided. Redundant feeders shall be provided. Pneumatic positioners. Fourier analysis etc in as available in Bentley latest system for analysing & diagnosis of machine faults. TCE. fire detector and space heater will be provided for each cabinet.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 18 OF 23 Vibration pickup with sensitivity of minimum 15 mv/mm/ second.TCE Consulting Engineers Limited Spec No. Ammeter and voltmeter will be provided for incoming feeders to the distribution boards. Fluorescent lighting. Fluorescent lighting.Part(B) Page 85 of 114 TCE FORM 329 R3 .29 CONTROL VALVES Multistage. limit switches and position ISSUE R0 Vol V . anticavitation. diaphragm type of actuator with hand wheel. Redundant feeders shall be provided through diode auctioning using diodes of high peak inverse voltage. cage guided. 24V DC supply tolerance shall be +25% and – 20%.28 24V DC DISTRIBUTION BOARD The input to this board shall be from 230V AC UPS system. The cabinets will be free standing. and all other 24V DC requirements. designed for indoor location. air filter regulator. 230 V AC to 24 V DC distribution system shall be designed with the complete redundancy and the scheme is subjected to approval of OWNER/ENGINEER. 2.. operator station/Engineering station & other peripherals located at Control room. Isolating switches and HRC cartridge fuses will be provided for individual feeder isolation. DCS system cabinets. The vibration system shall provide isolated one (1) 4-20 mA DC output and 2 nos. the vibration system shall perform vibration analysis like signature analysis. Isolating switches and HRC cartridges fuses will be provided for individual feeder isolation. single ported. The function of the 24V DC distribution board is sub distribution of 24V DC power to all the utilities viz. Balanced. 2. velocity pickup for low speed. fire detector and space heater will be provided for each cabinet. any other requirement at Field. The cabinets will be free standing vertical cabinets. accelero-meter pickup for high speed. globe type.

Either extended type bonnet or cooling fin type bonnet shall be provided for o service above 200 C and for other service the bonnet type shall be standard. Wherever the required turndown is not possible with a standard single valve. Position transmitter shall be non-contact type.05%.5 M from the valve. with suitable rubber lined interfaces. ISSUE R0 Vol V . specially designed trims shall be customised and used.01%. The control valve design shall be suitable for the required fail-safe conditions. Noise level shall not exceed 85 dB at a distance of about 1..Part(B) Page 86 of 114 TCE FORM 329 R3 . Local position indicator & LVDT type position transmitter with 2 wire. Pneumatic (copper) tubing complete with accessories. In case of predicted noise level above 85dBA. and single seated valve shall not exceed 0. The valves shall be supplied and commissioned as per the fail-safe philosophy required for the process. Generally stem and guide material(trim) shall be SS 316 sterlited. except for specific applications like DM water. TCE. and plug and seat material will be 17-4 PH SS. positioners shall be provided with input/output/bypass gauges. Flanged connection shall be provided for DM water services. adjustable minimum and maximum stops. 420mA DC output. Water seal shall be provided for valves that could be subjected to below atmospheric conditions. Pneumatic actuators would be provided with air failure lock and remote release.TCE Consulting Engineers Limited Spec No. All actuators would be sized so that the final control elements operate properly even when the upstream pressure exceeds 110% of maximum value. Control valves shall be sized to have an opening of 15% at minimum flow condition and 85% at maximum flow condition. of process / equipment. In Vibration prone areas. The noise abatement shall be obtained by valve body and trim design and not by use of silencer. fittings. The end connections shall be socket welded for sizes below 50 NB and butt welded for sizes 50 NB and above. suitable low noise trim shall be provided. All limit switches/position transmitters. shall be wired out to external block of actuator and respective junction boxes. All final Control elements (Control valves & control dampers) shall be with pneumatic or electric actuators. Pressure regulators upstream of control valves would not be envisaged. Refer to Table-6 for selection of control valve body material and actuator type. HP bypass services. limit switches.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 19 OF 23 transmitters completely tubed with junction box. The trims supplied shall be suitable for quick changing. E/P converters suitable for accepting 4-20mADC signal. Leakage class for double seated valve shall not exceed 0. positioners shall be located away from the control valve/damper and location shall be approved by OWNER/ENGINEER. E/P converter signals etc. Actuator housing shall be of pressed steel construction.

30 Instrumentation & Control Cables Individual pair shielded & overall shield twisted pair copper cables shall be used for analog signals & only overall shielded cables shall be used for digital signals.mm cross section with seven strands. Used for panel internal wiring. 2.32.5 mm2 PTFE insulated copper braiding & PTFE outer jacket will be considered for turbine area. positioners.mm cross section with seven strand and twisted pair with 20 twists/metre. 1.1 Instrument wires : Wires carrying 4-20 mA DC or any other low voltage or current signals.5 sq. thermo electric characteristics. shall be as per ANSI STD-MC.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 20 OF 23 load position indicators. TCE. tinned copper conductor of 0.3 Prefabricated cable : Used for interconnection between system/marshalling cabinets. non-contact type electronic position transmitters and solenoid valves in accordance with the system requirements. 1975.mm cross section with seven strands twisted pair with 20 twists/metre.32 Wiring. 2. + 24V etc.5 sq. FRLS 1.5 mm and voltage grade will be 1100V. 240V AC. Features such as colour coding. Colour coding shall be as per standard. PVC insulated.2 Control Wires : Wires used for power supply like 110V AC. heat resistant with flame retarding properties. 2. voltage grade will be 1100V. Used for panel internal wiring. Ferruling indicating terminal numbers on termination side shall be followed. heat resistant with flame retarding properties with thickness not more than 0. 220V DC.TCE Consulting Engineers Limited Spec No. tinned copper conductor of 1.mm copper control cable would be used for cabling between MCC and control system. aluminium nylar tape shielded/PVC jacketed/ armoured & overall PVC jacketed/FRLS. All the insulation including overall sheath will be FRLS quality. 2. All these cables shall be armoured.5 sq. 2. The wire size shall be 0. Insulation material shall be PVC. Termination and Accessories 2. thermocouple extension wires.32.32.31 Thermocouple Extension Cable 600 V twisted pair (20 twist/metre). 2.5 mm2 dia. Each prefabricated cable shall have a minimum of 5 cores as spares and these should not be connected to end connectors. Insulation material shall be PVC.32. etc.4 Terminal Block (TB) Screwed type for marshalling panels and spring loaded terminals for FTC and JBs shall have following features : ISSUE R0 Vol V .5mm.5 mm2. tinned copper conductor of 0. Voltage grade will be 600V. Alternatively thermocouple extension wires with 600 V twisted pair 0.5 sq. Used for panel external wiring. Insulation material shall be PVC.96-1. heat resistant with flame retarding properties with thickness not more than 0.Part(B) Page 87 of 114 TCE FORM 329 R3 .

Clearance between TBs will be 150 mm and between TB and bottom plate will be 250 mm. 2. decarbonised. Wiring raceways. E/P converters and shut off valves. control damper. 4SCFM capacity etc.5 Termination Details Maximum of 2 wires shall be terminated per terminal.mm to 1. transmitter purging lines etc. High voltage and low voltage signals shall be provided on separate TBs which are mounted separately.Power supply and signal TB shall be separate. All accessories shall be SS. Direct/reverse acting. TCE. Material of accessories shall be SS. All wiring shall be ferruled.5 sq. Field Termination cabinet (FTC) and any other field termination cabinets. etc. Housed in cast aluminium casing (with polyurethane paint). AFR shall have automatic drain feature. Degree of protection shall be IP65 2. inlet pressure range of 5-8 kg cm2 and suitable spring ranges (AFR) for use with positioners in control valves. Signals shall be grouped in TBs in the same order as that in junction box so as to provide neat cable layout and wiring. cable support fuses. The output shall be linear.33 Air Filter Regulator (AFR) Constant bleed type AFR with an accuracy of +0.1%. Filtering particles above five microns having phosphor bronze filter element. size of 0.25% accepting 4-20 mA dc signals from control system and converting to 0. range adjustment and zero adjustment to be provided. WAGO make spring loaded terminals shall be used for termination of the instrumentation cables at Field JB.2 to 1 kg/cm2 air pressure to operate valve positioners of all final control elements. Wires carrying power and signal wires shall be routed in separate raceways. shall be supplied. flame resistant.TCE Consulting Engineers Limited Spec No.35 Position Transmitters 24VDC operated Non contact LVDT type with 4-20 mA DC 2 wire system with an accuracy of ±1%.mm to 2.32. Built in blow down valve shall be provided. IP65 degree of protection for casing. Accessories like MCB. All accessories shall be supplied. strapes shall be flame retardant. vertically mounted.36 Solenoid Valves ISSUE R0 Vol V .Part(B) Page 88 of 114 TCE FORM 329 R3 .mm for control wires.mm for instrument wires and 1.5 sq. non-hygroscopic. 2. Insulation between adjacent terminals or between terminals & frame work and will be 2 kV RMS for 1 minute .34 Electro-Pneumatic Converters (E/P) Two wire type E/P converters with an accuracy of +0.5 sq.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 21 OF 23 600 grade. IP65 degree of protection for enclosure. 2. Material of accessories will be SS. 2.5 sq. Cable entries shall be cemented with fire proof compound.

solenoid valve. Touch control facility on the indicator for checking the rate/volume and diagnostic messages. 2. located in flue gas/air area with damper shaft bearings mounted externally. required for the positioning of control damper drives shall be provided. Non-contact type positioner transmitter shall be supplied. Positioners with all required accessories. etc. Trim : Cage guided. Bearings are grease lubricated. pilot operated for higher sizes with shut of class (leakage) VI. body material of bronze.1% of flow rate/volume flow. 2. plunger material of 316 SS rated for continuous duty. Shall have diagnostic capabilities. shall be supplied.5% of flow rate or volume flow. Solenoid valve shall be rated either for 220V DC or 24 V DC only. Bonnet: Std. plug.37 Pneumatic block valves Balanced. gate valve. shall be supplied. Spare cams for accommodating any change in characteristic to achieve better process control during commissioning shall be supplied as required. IP 65 class for enclosure. on-off. Body material shall be ASTM A 216 GR WCB with end connection socket welded for sizes 50 NB and below & butt welded for sizes above 50 NB and flow direction will be horizontal. position locks. Data storage shall be in EEPROM. In vibration prone areas . type of material ASTM A 216 GR WCB & packing material GRAFOIL. metal seated with flow characteristic of quick opening with stem. Actuator : Diaphragm (Nitrile) type with handwheel & travel indicator and adjustable stop.TCE Consulting Engineers Limited Spec No. Body ratings shall suit the pressure and temperature conditions. Blades(SS) shall be linked together. Insulation class of 'F' for the solenoid. limit switch with Nema4 & enclosure. It shall be sized for shut off differential pressure. plug type. Transmitter shall be smart with LCD display and superimposed HART on 4-20mA DC output. Actuators & accessories requiring tubing shall be mounted and tubed.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 22 OF 23 Direct operated solenoid valves. Accuracy: 0. limit/torque switches. single ported. Accessories like position transmitters (2 wire) with 4-20mA DC output. TCE. seat and guide material of SS 316. etc.Part(B) Page 89 of 114 TCE FORM 329 R3 . positioners should be located away from the control damper and the location finalisation subject to OWNER / ENGINEER approval. Accessories like air filter regulator. Repeatability 0. 2. Position indicator.40 MAGNETIC FLOWMETER : Inline type with indicating top mounted transmitter with flange connection.38 Control Damper Drives Pneumatic actuator type. ISSUE R0 Vol V .

1 of actual value or better. Explosion proof certificates to be furnished by Vendor. changeover contacts and both shall be wired to JB. The flow rate shall be available in DCS/PLC and flow integration shall be implemented in DCS/PLC to indicate volume flow. All JBs. Instrument accessories shall include fittings for welding.5657A-C-500-002 Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 7 SHEET 23 OF 23 Material: Case-Al. All the switches shall be provided with 2nos. The material of the sensor shall be SS 316. located precisely for measurement of average flow velocity. local gauges need not be provided. Online retracting facility and flushing arrangement shall be provided. 2. Accuracy shall be +/ . The specification of DP transmitter is specified elsewhere.1% of the actual value or better.TCE Consulting Engineers Limited Spec No. 3. The sensor shall be supplied with complete mounting hardware and support plugs and valve manifolds ( ½” NPT) for DP transmitter connection. Repeatability shall be + /. All instruments located in outline area shall be provided with canopy. Welding procedure is subject to Purchaser’s approval. Dedicated distribution boards shall be provide for solenoid valves with adequate number of spare terminals to loop the interposing relay contact to the respective feeders. ISSUE R0 Vol V . All instruments provided on piping/equipment on HFO/LDO/Lube oil/Control oil services and in Fuel oil pump house shall be explosion proof.0 General Wherever indicating type transmitters are provided. Local panels and similar equipment shall not have top and side entry to avoid dust entry.0.alloy with corrosion resistant. TCE. flow tube and extension pipeStainless steel (SS 304) and Lining-fluro carbon.Part(B) Page 90 of 114 TCE FORM 329 R3 . insert type with minimum four impact ports facing upstream direction.41 ANUBAR ( IMPACT HEAD TYPE): Element shall be tubular. For all Local panels required transformers shall be included to provide the required power supplies. All VFDs shall be located in air-conditioned environment. prior to welding.

>=30 Kg/cm2 OR TEMP >100° C < 3 INCH BW 4 WATER FOR ALL PIPE SIZES EXCEPT VERY LARGE DIA PIPE BW BW i) HP BYPASS STEAM FLOW ii) AUX. TCE. <=100 ° C PIPE SIZES SUITABLE FOR FE APPLICATION TYPE OF CONNECTION FOR ALL SIZES EXCEPT VERY LARGE DIA.Spec No. <=30 Kg/Cm2 AND TEMP. <=30 Kg/cm2 & TEMP <=100° C PR.>30Kg/cm 2 OR TEMP >100° C 6 ORIFICE WATER (CW) PR.<=30 Kg/cm2 AND TEMP. PIPE i) CEP DISCHARGE FLOW ii) CONDENSATE AT DEAERATOR INLET iii) MAKE-UP FLOW TO HOTWELL iv) DM WATER FLOW TO CST BW BW FLANGED FLANGED 2 ORIFICE PLATE WATER PR. 120R2 . CONDEN SATE. TEMPERATUR E OF FLUID SUITABLE PR.5657A-C-500-002 TCE Consulting Engineers Limited Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 1 OF 1 SYSTEM – TABLE 8 TABLE-8: GUIDE LINES FOR SELECTION OF FLOW ELEMENTS SL.<=100°C FOR ALL PIPES CONDENSER COOLING WATER TO ASH COOLERS FLANGE 7 AIR FOIL/ VENTURY AIR ALL DUCT SIZES i) PRIMARY AIR ii) SECONDARY AIR FLOW BW BW ISSUE R0 Vol V .. STEAM FLOW BW BW 5 FLOW NOZZLE STEAM PR.>100° C ALL PIPE SIZES i)SH/ RH SPRAY WATER FLOW ii) HP/LP BYPASS SPRAY SOOT BLOWING STEAM FLOW i) BFP SUCTION FLOW (FOR ONE EACH BFP) ii) FW FLOW BW 3 ORIFICE PLATE FLOW NOZZLE STEAM FOR ANY CONDITION PR. DM WATER) PRESSURE. NO TYPE OF FLOW ELEMENT 1 ORIFICE PLATE FLUID MEDIUM WHERE USED WATER ( FEED WATER.Part(B) Page 91 of 114 TCE FORM NO.>+30 Kg/Cm2 TEMP .

WATER SERVICES CONDESATE WATER SERVICES DM WATER SERVICES AIR SERVICES LUBE/CONTROL OIL/FUEL OIL SERVICES ANY OTHER SERVICES AS REQUIRED CONTROL DAMPERS/VALVES FOR AIR AND FLUE GAS SERVICES WC6 WCB SS316 WCB WCB P P P P P 6. 4. NO.Spec No. WCB P * MATERIAL IS SUBJECT TO PURCHASER’S APPROVAL DURING DETAIL ENGINEERING.Part(B) Page 92 of 114 TCE FORM NO. MAX •C PRES S STD BODY MTL. Kg/Cm2 TEMP. ACTUAT OR TYPE 1. DESCRIPTION PR. 5.5657A-C-500-002 TCE Consulting Engineers Limited Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 1 OF 1 SYSTEM – TABLE 9 TABLE 9: GUIDE LINES FOR SELECTION OF CONTROL VALVES MATERIAL AND ACTUATOR TYPE SL. 120R2 . TCE. ISSUE R0 Vol V . 2. 3. * P 7.

part 1I. part ICS-109) ANSI C39. All these tests shall be witnessed by OWNER or his representative. TCE.51/UL 508.9A/ IEEE 4721 BE MMA 219.Part(B) Page 93 of 114 TCE FORM NO. 120R2 .0 Data bus system :Functional test for the complete system (Both hardware & software) simulating worst condition. Table 13. Dielectric strength test (high pot tests as per NEMA ICSI. Bidder shall furnish in his proposal the test facility and details of the simulation test available in their factory including their previous experience.0 Central Processing Unit for Man Machine Interface Main memory test of 12 hours duration to demonstrate the capability of memory Read-Write function under worst pattern at various voltage levels Main memory parity detection test of 12 hours duration to demonstrate that parity detection feature performs properly to the purchaser's satisfaction Logic tests for 12 hours duration to demonstrate the hardware commands. reading and wrong transfer indications Voltage and speed variation checks Bulk memory parity detection test of 12 hours duration to demonstrate the proper ISSUE R0 Vol V .Spec No. 2. Damp heat cycling test as per is 2106. Radio frequency interference test as per SAMA PMC 33. Factory acceptance test as per Section D 2.PLC 1.1. Burn in test & temperature rise test for 120 hrs. Continuity test & short circuit test for current limiters. Immunity to noise test as per IEEE SWC test 587. 2.1962 or equivalent. Noise test-surge withstand capability test as per IEEE. Quality assurance and tests shall be as per latest BS-5750 and ESS-1980 or equivalent.( Refer Note-2) Notes :1. 3.0 Measurement and Control systems / PLC Functional test (simulated) for the complete system (Refer Note-1&2) System performance & tests for monitoring functions (Refer Note-2) Surge withstand capability test as per ANSI C37. Simulation test for all control loops (Refer Notes-1 & 2). Under voltage and over voltage test (Refer Note-2). interrupt structures and hardware failure detection Count down registers and pulse counter test of 8 hours duration to demonstrate the accuracy of all time count down registers Bulk memory Data transfer test of 36 hours duration to demonstrate possible combinations of transfer from/to bulk memory including checks for illegal writing.5657A-C-500-002 TCE Consulting Engineers Limited Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 1 OF 4 SYSTEM – TABLE 10 TABLE-10: TESTS TO BE PERFORMED FOR PLC / PROGRAMMABLE CONTROL SYSTEM PROGRAMMABLE CONTROL SYSTEM . Table 13. Factory Acceptance Test as per Section D2.

finishes and testing of electronic equipment as per EES-1980 (General specification of electronic equipment) or equivalent Factory Acceptance Test as per Table 13 5. construction. construction components materials. Design.Part(B) Page 94 of 114 TCE FORM NO. components.0 Keyboard :Test for satisfactory operation of keyboard controls.0 Floppy/Tape Drive Unit/Bulk Memory Unit/CD drive Unit ISSUE R0 Vol V . Design. construction. components.1980 (General specification of electronic equipment) or equivalent Factory Acceptance Test as per Table 13 4. materials. 6.0 Printers : Noise level test for the printer Test of interlock performance and error detection feature. Factory Acceptance Test as Table 13 7. TCE. components Materials finishes and testing of electronic equipment as per EES-1980 (General specification for electronic equipment) or equivalent Factory Acceptance Test as per Table 13. construction. Quality Assurance as governed by BS 5750 or equivalent.0 Colour Graphic Video Display Unit (CRT) Functional tests Test for capabilities of CRT including error detection for the complete system (Both Hardware & Software) simulating worst conditions Noise test Surge withstanding capacity as per IEEE or equivalent Quality assurance as governed by BS 5750 or equivalent Design. finishes and testing of electronic equipment as per EES1980 (General specification of electronic equipment) or equivalent Functional tests for the complete system (Both hardware and software) simulating worst conditions. finishes and testing of electronic equipment as per EES .5657A-C-500-002 TCE Consulting Engineers Limited Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 2 OF 4 SYSTEM – TABLE 10 TABLE-10: TESTS TO BE PERFORMED FOR PLC / PROGRAMMABLE CONTROL SYSTEM functioning of parity detection feature Functional test for complete system (Both hardware and software) simulating worst conditions Noise test . 120R2 . Quality assurance as governed by BS 5750 or equivalent. push buttons and all associated functions Quality assurance as governed By BS5750 or equivalent for functional test for the complete system simulating worst conditions Design.Spec No.surge withstand capability test as per IEEE.

construction.0 11. (b) Flammability/Test for acid gas generation/Test for water absorption (*)/Wet dielectric test. Keyboard 12. Wiring Termination and Accessories Routine test Conductor resistance test (*) / High voltage test (*)/Impulse dielectric test/Insulation test/Humidity test/Temperature rise tests on power circuits/Short time current tests on power circuits.3 Test for terminal blocks Test for moulding for flame resistant. Type test Annealing test (*) / Test for insulation and sheath (*)/Flame retardance test – (a) Oxygen index.2 11. Factory Acceptance Test as per Table 13 8. VDU. Printer. 120R2 . Design. System cabinets Verification of degree of protection / Electrical tests as detailed under “Wiring.0 10. Marshalling Cabinets Verification of degree of protection / Electrical tests as detailed under “Wiring. materials.1 11. Non-hygroscopic and Decarbonised / Insulation test between terminals / Insulation between terminal block and frame Tests For Auxiliary Plant Monitoring Systems Vibration Monitoring & Analysis System (a) (b) Simulated Functional test (Note-1) Tests for Server. finishes and testing of electronic equipment as per EES1980 (General specification of electronic equipment) or equivalent Functional tests for the complete system (Both software and hardware) simulating worst conditions Test of Control unit and drive for all features. components.Spec No. Terminations & Accessories”/Type tests & routine tests as per relevant Indian standards. Terminations & Accessories”/Type tests & routine tests as per relevant Indian standards.0 Local Panels Verification of degree of protection / Electrical tests as detailed under “Wiring. Date checking features. Terminations & Accessories”/Type tests & routine tests as per relevant Indian standards.Part(B) Page 95 of 114 TCE FORM NO.0 11.5657A-C-500-002 TCE Consulting Engineers Limited Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 3 OF 4 SYSTEM – TABLE 10 TABLE-10: TESTS TO BE PERFORMED FOR PLC / PROGRAMMABLE CONTROL SYSTEM Noise test Surge withstand capability as per IEEE or equivalent Quality assurance as governed by BS 5750 or equivalent.0 12.1 ISSUE R0 Vol V . Note (*) – As per IS-1554 9. TCE.

4 CMMS System (a) (b) Simulated Functional test (Note-1) Tests for Server.3 PADO System (a) (b) Simulated Functional test (Note-1) Tests for Server.Part(B) Page 96 of 114 TCE FORM NO. Printer. Keyboard Note-1: Test to be witnessed by Owner or Owner’s representative. Printer. Keyboard Note-1: Test to be witnessed by Owner or Owner’s representative.2 Flame Monitoring & Analysis System (a) (b) Simulated Functional test (Note-1) Tests for Server. Printer. VDU. Keyboard Note-1: Test to be witnessed by Owner or Owner’s representative. VDU. TCE. 12.5 MIS System (a) (b) Simulated Functional test (Note-1) Tests for Server. 12. VDU.5657A-C-500-002 TCE Consulting Engineers Limited Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 4 OF 4 SYSTEM – TABLE 10 TABLE-10: TESTS TO BE PERFORMED FOR PLC / PROGRAMMABLE CONTROL SYSTEM Note-1: Test to be witnessed by Owner or Owner’s representative. ISSUE R0 Vol V . Printer. VDU. 12. 120R2 . 12. Keyboard Note-1: Test to be witnessed by Owner or Owner’s representative.Spec No.

NOTE -2 7 8 9 10 11 12 13 14 15 16 17 18 TOTAL SYSTEM CONFIGARATION DRAWINGS 19 FAT PROCEDURE CONSITING OF : 20 (i) TEST EQUIPMENT 21 (ii) TEST ENVIRONMENT 22 (iii) TEST CONFIGURATION 23 (iv) TEST PROCEDURE 24 (v) TEST SCHEDULE 25 (vi) TEST VENUE 26 (vii) TEST REPORTS.MMI. FAT PROCEDURE SHALL BE PREPARED BY VENDOR AND TO BE SUBMITTED FOR PURCHESER'S/ CONSULTANT'S APPROVAL WELL IN ADVANCE PRIOR TO THE COMMENCEMENT OF FAT PPRELIMINARY TEST DOCUMENTS TEST REQUIRMENTS TEST SHALL BE PERFORMED WITH THE COMPLETELY ASSEMBLED SYSTEM AND ALSO WITH COMPLETELY ASSEMBLED SYSTEM OF AUTOMATION EQPT. ALL SYSTEM SOFTWARE & APPLICATION SOFTWARE TO BE LOADED AND OPERATIONAL ON THE SYSTEM PRIOR TO FAT REFER RELEVANT SECTIONS.Part(B) Page 97 of 114 TCE FORM NO. TERMINAL ARRANGEMENT AND EQUIPMENT IDENTIFICATION CHECK 34 POWER SUPPLY VOLTAGE LEVEL CHECK & POWER 'LEDs -ON CHECK 35 COOLING FAN OPERATION CHECK 36 GROUNDING NETWORK CHECK 1. 2. THE INTENT OF THE FAT IS TO DEMONSTRATE AND ENSURE THAT THE I&C SYSTEM MEETS ALL THE FUNCTIONAL REQUIREMENTS AS INTENDED IN THE SPECIFICATION / CONTRACT. A COMPLETED INTEGRATED TEST OF THE SYSTEM SHALL BE CARRIED OUT AT VENDOR'S WORKS IN THE PRESENCE OF PURCHASER/CONSULTANT. TCE.Spec No. 120R2 .SOE AND PERIPHERALS I&C SOFTWARE AND PERFORMING ALL FUNCTIONS EXPECTED OUT WHILE IN ACTUAL SERVICE AND WITH STSTEM CONFIGURATION AS FINALISED. ISSUE R0 Vol V . PROCESS INPUT/OUTPUT CONDITIONS AND OTHER LOAD ON THE SYSTEM ARE TO BE STIMULATED EITHER BY HARDWARE/SOFTWARE.SPECIMEN COPIES 27 FUNCTION DESIGN SPECIFICATION FOR EACH EQIPMENT / SYSTEM 28 29 30 GENERAL APPEARENCE CHECK & BILL OF MATEIRALS CHECK 31 CONSTRUCTION CHECK AS PER OVER ALL GENERAL ARRANGEMENT DRAWINGS 32 DIMENSTIONAL CHECK 33 LABELLING .5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 11 Volume – V SECTION: D6 SHEET 1 OF 2 TABLE 11: FACTORY ACCEPTANCE TESTS FOR PLCs 1 2 3 4 5 6 GENERAL FACTORY ACCEPTENCE TEST (FAT) :REF NOTE-1 FACTORY ACCEPTENCE TEST (FAT) PROCEDURE:REF. The SHIPMENT OF I&C EQUIPMENT TO SITE WILL BE EFFECTED ONLY AFTER THE FAT HAS BEEN CONDUCTED AND THE RESULTS ARE ACCEPTED BY PURCHASER/CONSULTANT BY THE PURCHASER/CONSULTANT.

OPERATOR GUIDENCE MESSAGE CHECK CRT/ BACKPANEL ‘OPERATION PRIORITY’ CHECK CRT. SYSTEM CLOSED LOOP CONTROL SIMULATION CHECK OPEN LOOP CONTROL SIMULATION CHECK CONTROL LOOP RESPONSE CHECK BUMPLESS AUTO MANUAL TRANSFER CHECK CRT – GRAPHIC OVERVIEW CHECK CRT.Spec No.CHECK FOR OPERATING CONTROL DIRECTLY FROM MIMICS CRT.REAL TIME TREND CHECK CRT. 5.ANALOG CONTROL DISPLAY CHECK CRT. FAT SHALL BE CONDUCTED WITH THE DISTANCE BETWEEN THE PROCESSOR AND OTHER SUPPORTING PERIPHERIALS AS PER THE FINAL LAYOUT IN THE CONTROL ROOM.SEQUENCE CONTROL DISPLAY CHECK CRT. TCE.ALARM MANAGEMENT FUNCTION CHECK CRT LOGGING FUNCTION CHECK CRT / RESPONSE / UPDATING CHECK KEYBOARD LOCK FUNCTION CHECK CRT INTERCHANGEBILITY & ASSIGNABILITY CHECK PRINTER ASSIGNABILITY & BACK-UP FUNCTION CHECK FLOPPY DISK/ STD / OPTICAL DISK UNIT STORAGE & RETRIEVAL CHECK CRT ASSIGNABILITY CHECK FOR HARD COPIER FUNCTION PLANT PERFORMANCE CALCULATION CHECK COMMUNICATION INTERFACE TO OTHER’S SYSTEM SIMULATION CHECK SER INTERFACE DATA DUMP FUNCTION CHECK DATA BUS DISTANCE BUILDING CHECK (REFER NOTE. DURATION OF FAT SHALL BE MINIMUM THREE(3) WEEKS.3) CONTROLLER ENGINEER NOTES MAINTENANCE 35 GRAPHIC DISPLAY BUILDING FUNCTION CHECK 36 CLOSED LOOP CONTROL SYSTEM MODIFICATION CHECK 37 OPEN LOOP CONTROL SYSTEM MODIFICATION CHECK 38 ALARM DISPLAY PRIORITISATION CHECK 39 SYSTEM SECURITY CHECK 40 SYSTEM ALARM CHECK 41 SYSTEM DIAGNOSTIC FUNCTION CHECK 42 POINT DETAIL CONFIGURATION CHECK 43 CONTROL LOOP TUNING CHECK 44 SYSTEM SELF DOCUMENTATION CHECK 3. 120R2 . ISSUE R0 Vol V .TREND CHECK CRT. 4. THE FAT PROCEDURE SHALL BE SUBJECT TO PURCHASER’S APPROVAL.MIMICS CHECK CRT. FOR CLOSED LOOP CONTROLS VENDOR SHALL ALSO DEMONSTRATE THE PERFORMANCE USING SIMULATION SOFTWARE TO COVER THE RELATIVE PERFORMANCE OF THE BOILER PARAMETERS AND TURBINE PARAMETERS.Part(B) Page 98 of 114 TCE FORM NO.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 11 Volume – V SECTION: D6 SHEET 2 OF 2 TABLE 11: FACTORY ACCEPTANCE TESTS FOR PLCs 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 POWER SUPPLY UNDER VOLTAGE AND OVER VOLTAGE CHECK (± 10%) PROCESSOR & MAIN DATA BUS NETWORK REDUNDANCY CHECK COMMUNICATION COUPLER IF APPLICABLE REDUNDANCY CHECK COMMUNICATION MODULE OF THE CONTROLLER TO NETWORK REDUNDANCY CHECK POWER SUPPLY REDUNDANCY CHECK HARDWARE ON-LINE MAINTAINABILITY CHECK .FUNCTION KEYS CHECK CRT.

5 times max. Resistance temperature detector assembly Calibration/Material test/Accuracy test/Bore concentricity test/Insulation test (<500 M at 500 V. 12. 3. 6. 13. Temperature switch Calibration test/Material test//Accuracy test/Bore concentricity : 1.5% of wall thick/Hydrostatic test for TW (1.5657A-C-500-002 TCE Consulting Engineers Limited Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 1 OF 3 SYSTEM – TABLE 12 TABLE-12 TESTS TO BE PERFORMED FOR INSTRUMENTS 1.5 times max.). 11.5 times max. Thermocouple assembly Calibration/Material test/Insulation test (<500 at 500 V. DC) as per ISA. pr.)/Contact rating test. pr. Differential Pressure Switches Calibration test/Hydro test/Leak test/Over range test/Accuracy test/Repeatability test.) More concentricity ±5% of wall thick Temperature transmitters Calibration test/Accuracy test/Ambient temperature error test Thermowells Material test/Bore concentricity : ±5% of wall thick/Hydrostatic test for TW (1. 7. 9.) Pressure switches Calibration test/Hydro test/Contact rating test/Accuracy test/Repeatability Pressure Transmitters Calibration test/Hydro test/Leak test/Over range test/Accuracy test/Repeatability test. 5. 10. Differential Pressure Transmitters Calibration test/Hydro test/Leak test/Over range test/Accuracy test/Repeatability test. DC) as per ISA. TCE FORM NO. Accuracy test. 120R2 . Thermometers Calibration test/Material test//Accuracy test/Bore concentricity : ±5% of wall thick/Hydrostatic test for TW (1. pr.Part(B) Page 99 of 114 4.pr) Interposing relay Functional test/temperature rise test/high voltage test/limits of operation ISSUE R0 Vol V . 2.5 times max.5 times max. Hydro static test (1. Differential Pressure Indicators Calibration test/Hydro test/Leak test/Over range test/Accuracy test/Repeatability test. Pressure indicators Calibration Hydro test (1. Bore concentricity : ±5% of wall thick. 8. Hydro test for TW. TCE.Spec No. Pr.

21. 20. 18. 120R2 . 14.34 special class h) Calibration and Hysteresis test (Refer note-1) i) Actuator leakage test (Ref.34 ISSUE R0 Vol V .34 special class g) Liquid penetration test : As per ANSI B 16.5 time max.34 Seat leakage test : As per ANSI B 16-104 (Refer note-1) CV test : As per ISA procedure Magnetic particle test : As per ANSI B 16.34 special class (applicable for pr.34 c) Seat leakage test : As per ANSI B 16-104 (Refer note-1) d) CV test : As per ISA procedure e) Magnetic particle test : As per ANSI B 16.34 special class f) Radiography test : As per ANSI B 16.Part(B) Page 100 of 114 22.5 time max.> 70 bar & tem < 4000C Liquid penetration test : As per ANSI B 16. 15. pr)/function test Flow glasses Material test/Hydro test/ (1. 16. pr)/function test Variable are flow metes Calibration test/Material test/Hydrostatic test (1. Level gauges Hydrostatic test/Material test/Seat leakage test/Ball check test Level switches (magnetic) Material test/Contact rating test/Hydro test/Calibration test Level gauges (Probe) Material test/Contact rating test/ Hydro test/Calibration test Flow switch Material test/Hydro test/ (1.34 special class (applicable for pr > 70 bar & temp < 4000C Calibration and Hysteresis test (Refer note-1) Note-1: These tests shall be witnessed by PURCHASER / CONSULTANT Pneumatic Block Valves: a) IBR certificate : Form IIIC b) Hydrostatic test : ANSI B 16. 17.5 time max. Note-1) Note-1: These tests shall be witnessed by PURCHASER / CONSULTANT Pressure Regulating Valves: a) IBR certificate : Form IIIC as applicable b) Hydrostatic test : ANSI B 16. TCE. 23.Spec No. TCE FORM NO. pr) Flow element 100% Radiography test/Hydro test/Calibration test/IBR certificate Control valves IBR certificate Form III C Hydrostatic test : IBR/MSS-SP-61/ANSI B 16.5657A-C-500-002 TCE Consulting Engineers Limited Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 2 OF 3 SYSTEM – TABLE 12 TABLE-12 TESTS TO BE PERFORMED FOR INSTRUMENTS test/insulation test. 19.

Compensating cable Thermo-emf characteristic/Continuity test/Measurement on capacitance. inductance and loop resistance / insulation resistance /high voltage test as per latest IS/Tensile and elongation test/Oxygen index test /Any other test applicable. 27. 28. Position transmitters Calibration/hysteresis and Accuracy test Electro Pneumatic converters Calibration test/Accuracy Solenoid valves Hydro test/Seat leakage test/CV test/coil insulation test Air filter regulators Calibration test/Accuracy test Junction boxes Test for degree of protection/Material test Transmitter racks Hydro test.34 special class h) Calibration and Hysteresis test (Refer note-1) i) Actuator leakage test (Ref. ISSUE R0 Vol V . tubes and fittings of all steam & water services Transmitter racks Verification of degree or protection. Test for enclosure type. Type tests & routine tests as per relevant Indian standards.5657A-C-500-002 TCE Consulting Engineers Limited Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 3 OF 3 SYSTEM – TABLE 12 TABLE-12 TESTS TO BE PERFORMED FOR INSTRUMENTS c) Seat leakage test : As per ANSI B 16-104 (Refer note-1) d) CV test : As per ISA procedure e) Magnetic particle test : As per ANSI B 16.34 special class f) Radiography test : As per ANSI B 16. Note-1) Note-1: These tests shall be witnessed by PURCHASER / CONSULTANT 24. 29. 31. 30. 26. TCE. IBR certificate required for impulse pipes. Air leak test for tubing/Piping & fittings.Part(B) Page 101 of 114 TCE FORM NO.34 special class g) Liquid penetration test : As per ANSI B 16. 120R2 . 25.Spec No.

pull out torque. in CD’s in addition to hard printout for each revision. Control cable gland size. Type / Form : Type (Refer electrical data sheet M4-203-01) (*). The engineering documents shall have all fields as listed under ‘Details of Fields’ in this table and the CONTRACTOR shall furnish all the engineering documents. Data required for instrumentation & control Type of control (interlocked / noninterlocked).5657A-C-500-002 TCE Consulting Engineers Limited Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 1 OF 5 SYSTEM – TABLE 13 TABLE 13: FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES) CONTRACTOR shall prepare the engineering documents in this table & submit for PURCHASER / CONSULTANT review & approval. Enclosure. starting current %IFL (*). SL. Integral starter wiring diagram no. TCE. Terminal box : Cable size (mm2). 120R2 .Part(B) Page 102 of 114 TCE FORM NO. manufacturer’s dwg. Data required for electrical engineering : (a) (b) (c) (d) (e) 4. reference standard (*). Rating (kW) Performance at rated volts & Hz : Rated current (IFL) Amps (*) starting % IFL (*). Space Heater : Number provided. local control panel operation. Sl. Type of operation. Integral starter. no. location. 2. power factor (*). actuator wiring diagram no. No. elevation. coupling method (*). status / position feedback. ISSUE R0 Vol V .Spec No. full load speed (RPM) (*). NO 1. co-ordinates. General Data (a) (b) Bidder : Motor (Bidder’s name) (*). Rating : Output (kW) (*). No. control system scope. TYPE OF DOCUMENTS Drive List DETAILS OF FIELDS 1. voltage. (*).. winding insulation class. starting torque %IFL. TCE tag number.. Finally CONTRACTOR shall submit as installed and commissioned drawings / documents. starting method. Indoor / Outdoor. (c) (d) 3. cable OD(mm). Mounting. drive equipment (*). direction of rotation. Type of actuator. Motor Equipment Location : Layout dwg.

120R2 .Part(B) Page 103 of 114 3. -. (Service Status condition to be indicated for contact signals). Sl. signal location in BIDDER’s system. No. Sl. signal type. purpose. No. no. Reference dwg. Signal description. terminal no. TCE tag no. No. signal range / set value. NC) Reference dwg.. Remarks.. Inputs to Bidder from Purchaser’s System Sl. Junction Box Schedule 5. no. signal category (analog / digital). terminal block no. Incoming cable type. Size : Pipe. source equipment tag no. TCE.. VENDOR JB No. (Indicator / Switch / Transmitter. of signals required by BIDDER. Incoming cable no.. No. signal category (DI / DO). terminal no.. signal range / set value. Outputs from BIDDER’s System to PURCHASER’s System 4. signal description. (E/DE). of signals available to PURCHASER.. service description. source equipment. signal destination in BIDDER’s system. etc.5657A-C-500-002 TCE Consulting Engineers Limited Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 2 OF 5 SYSTEM – TABLE 13 TABLE 13: FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES) 5. signal type (isolated 4-20 mA DC / NO / NC / CO). 3 way. VENDOR tag no. -/ com.. Coil # 2 (E/DE) Coil : Single coil Voltage “ 110V AC. 220V DC. No. Reference dwg. signal type (RTD/T/C-4-20 mADC)... TCE tag no. No. Scope. VENDOR tag no.. Body. Inrush. terminal numbers (+. reference dwg.Spec No. VA : Normal.. TCE tag no. SH). Sl... terminal numbers (NO. Schedule of Instruments with Settings (b) TCE FORM NO. Terminal details – Digital 7. signal description. contact type (NO / NC / CO).. No. no. Terminal Details – Analog 6. SH / NC. Instrument type. contact rating. No. signal category (AI / AO).. quantity (*) Type : 2 way. 4 way. Remarks. JB location. Orifice Operating conditions : Pressure – (kg/cm2) CV : Selected. source equipment. Solenoid Valve Data (*) (a) (b) (c) (d) (e) (f) (g) (h) (i) 2.. Remarks.) General Data ISSUE R0 Vol V . Rated/ Action : Coil # 1. VENDOR tag no. fluid (*). instrument / signal tag.. Sl. terminal block no. VENDOR tag no. no. Service. signal category. No. C. signal description. purpose. Remarks (a) Sl. No..

remarks. Accessories. TCE tag no. maximum operating temperature. 10. unit shall be mm wcl for sub-atmospheric pressure) : Normal operating pressure. design temperature. viscosity. design temperature. normal flow (m3/hr). Location in elevation/rows/ columns. design pressure. engineering units.). pipe size. instrument range. Temperature (0C) : Type of element (For RTD – PT100. location. remarks. qty / unit. design flow (m3/hr). / unit. width (mm). power dissipation (walts). qty..R. No. equipment. maximum operating pressure.. width (mm). power dissipation (watts). VENDOR tag no. flow diagram reference (c) Design Data : (i) Pressure : (Kg/cm2. No. reference dwg. depth (mm).S. speed-normal. body rating (ANSI). vibration alarm value VRMS (mm/Sec. no. maximum : vibration range VRMS (MM/Sec). dimensions-height (mm).Part(B) Page 104 of 114 TCE FORM NO. TCE tag. description.) normal operating temperature. weight (kg).. of bearings / equipment type of bearing.. TCE. No. No. vibration frequency-normal. remarks (redundancy of instruments to be indicated here). Level : Normal level. weight (kg). vibration trip value VRMS (mm / sec.. 120R2 . No. no. maximum level. List of bearing vibration measurement (to be furnished for all HT drives in BIDDER’s scope). depth (mm). control room layout reference. ISSUE R0 Vol V . Flow : Fluid.5657A-C-500-002 TCE Consulting Engineers Limited Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 3 OF 5 SYSTEM – TABLE 13 TABLE 13: FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES) VENDOR tag... maximum flow (m3/hr). total no. DP at maximum flow (mmwcl).).Spec No. reference dwg. showing mounting details.. scope. panel / cabinet. 9. of bearing.J. maximum pressure loss. No. control room mounted tag no. Sl. description. For panel mounting dwg. (ii) (iii) (iv) (v) 8. velocity (mts/sec). showing external wiring. showing external wiring. location. reference dwg. scope. List of panels / cabinets & Sl. equipment dimensions – height (mm). etc. C4-53 & for T/C – K. 3rd party instrument list Sl. of equipment. maximum.

The loop drawing shall indicate the field instrument tag no.Spec No. (i) (ii) (iii) All motor operated unidirectional and bi-directional drives. ISSUE R0 Vol V . remarks.. NOTES : APPLICABLE TO ‘DRIVE LIST’ This drive list shall comprise of the following equipment in BIDDER’s scope. source location. equipment code. The field width for all the field of dbases. remarks. The information to be furnished under ‘Data required for Electrical Engineering’ is required for : (i) Electrical Auxiliary system finalisation by PURCHASER.0 B..0 2. 13. Solenoid valves / Pneumatic block valves.0 6. 12. Loop drawing shall be prepared for each & every signal going to BIDDER’s system. source. The VENDOR tag number shall match exactly with VENDOR flow diagrams. Balance information shall be furnished during detailed engineering. Loop Drawings A. cable no.0 5. INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 4 OF 5 SYSTEM – TABLE 13 TABLE 13: FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES) Equipment List Equipment. equipment location. cable length in metres.. service description. (to which the instrument is connected). field JB no.0 4. destination location. as finalised by PURCHASER during detailed engineering shall be incorporated.0 NOTES : APPLICABLE TO ALL THE DOCUMENTS LISTED ABOVE : Wherever ‘*’ is indicated. 120R2 .0 2. 1. Data called for in each field of the engineering documents shall be explicitly filled & not referring to some other drawing. TCE tag no. The drawing shall also indicate the terminal numbers. All control valves / control dampers.5657A-C-500-002 TCE Consulting Engineers Limited Volume – V SECTION: D6 11.. The ‘details of fields’ listed in this table is preliminary only.0 All drives shall have the facility for manual operation. will be given by PURCHASER during detailed engineering. signal tag no.0 3.Part(B) Page 105 of 114 TCE FORM NO.. information shall be furnished along with the bid. cable type. CRT / CPU indicator / to PURCHASER’s system. 1. Cable List (For all cables in BIDDER’s scope) Cable scope. will be furnished at the detailed engineering stage. service. polarity & cable numbers for all junctions & hardware / components forming the loop. 3. There shall be no duplication of VENDOR tag nos. Loop Drawings shall be submitted for all signals between the field instruments & system cabinet / local panels in BIDDER’s scope of supply. destination. TCE. Any additional field (column) requirements of PURCHASER. system cabinet no.

1.. BFP lube oil pump – 2. positively.0 Valve actuator make Valve actuator model DC Starter Valve actuators Local Panels Motor terminal boxes for winding Any other service as applicable. The specified format is applicable for the following : ISSUE R0 Vol V . the information marked * shall be furnished with the bid. Ex. the following details shall be added : (a) (b) 3. Three (3) nos. TCE. cable glands shall be provided for each Actuator for PURCHASER’s control & instrumentation cables. etc. For each source equipment.0 C.Spec No.0 7.Part(B) Page 106 of 114 TCE FORM NO.0 5. Wherever more than one drive of same type is there.. then a column shall be added and the reference of the unit shall be indicated. Drives shall be listed in the order of the process flow path.5657A-C-500-002 TCE Consulting Engineers Limited Volume – V SECTION: D6 INSTRUMENTATION AND CONTROL EQUIPMENT SHEET 5 OF 5 SYSTEM – TABLE 13 TABLE 13: FORMAT FOR ENGINEERING DOCUMENTATION (LISTS & SCHEDULES) (ii) 4.. each shall be listed. Hence. in addition to cable gland for power cable. BFP– lube oil pump – 1. Where there is multiple branches of identical system.0 6. 120R2 . If some of the drives are supplied by any of the subunits of the Main VENDOR.0 2.0 MCC procurement / finalisation by PURCHASER. terminal details. etc.0 8. NOTES APPLICABLE TO ‘TERMINAL DETAILS ANALOG / DIGITAL’ All terminals including spares shall be listed. drives of a particular branch (say – 4) shall be listed first followed by identical listing for the second branch.

5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 14 Volume – V SECTION: D6 SHEET 1 OF 1 TABLE-14: TRAINING TO BE PROVIDED FOR OWNER’S PERSONNEL SL.2 I&C Engineers In PLC System Hardware & Software For All Other Instruments/ Systems 6 4 2 Weeks Each Adequate Training ISSUE R0 Vol V .Spec No.1 2.0 PLANT OPERATION TRAINING 1. OF PERSONS DURATION OF TRAINING 1.0 2. 120R2 .1 Each Type Of Plant auxiliary through PLC OS-Training for Control Engineers SYSTEM MAINTENANCE TRAINING 12 4 Weeks each 2.Part(B) Page 107 of 114 TCE FORM NO. NO. TCE. TYPE OF TRAINING NO.

desk. After first commissioning.1%. All the instruments shall be calibrated for the entire range of the instrument for which it is designed. abuse due to unusual service conditions from sources other than those due to pressure. In addition. Proper documentation in this regard shall be maintained and handed over to the Purchaser.4 2. Hanger and supports shall be so installed as not to interfere with free expansion and contraction of the piping and tubing between anchors. The Bidder shall get prior approval as per approved quality assurance plan of the Purchaser / Purchaser’s Representative before any installation work starts. The Bidder shall follow the standard procedures for calibration of various instruments and as set by the manufacturer of instruments and as instructed by the Purchaser including any requirements of field calibration. then the work shall be redone by Bidder without any cost / material implications to the Purchaser / Purchaser’s Representative. care shall be taken that the arrangement of impulse / sampling piping.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 15 Volume – V SECTION: D6 SHEET 1 OF 6 TABLE-15: ERECTION. air supply and pneumatic tubing from detrimental sagging.Spec No. shall be provided wherever necessary. FIELD TESTING AND COMMISSIONING REQUIREMENTS 1. the instruments shall be tested for calibration again to check whether the instrument maintains its zero and maximum of the range.1 2. junction boxes and other instruments shall be decided by the Bidder depending on the site conditions considering the layout and maintenance aspects. etc. Suitable vibration dampners. TCE.. mechanical injury. 1. The calibration equipment shall cover complete range and shall have the desired accuracy of not less than 0. First. Impulse / sampling piping shall be provided with adequate slope. cabinets supplied by the Bidder shall be welded or bolted to the floor channel.3 ISSUE R0 Vol V . air supply and pneumatic tubing. Supporting clamps shall be provided atleast at every one metre distance for better rigidity. temperature and vibrations.2 1. TESTING REQUIREMENTS The Bidder shall set up his own instrument laboratory. 120R2 . cable trays and equipment shall be supported rigid enough to prevent vibration and anchored sufficiently to prevent strains on equipment installed. Argon arc welding shall be employed. (preferably 1:10). All impulse lines of joints shall be welded type unless otherwise specified.0 2. Impulse / sample piping.3 1. All the calibration equipment shall have the certification from National Physical Laboratory (NPL) or ‘IDEMI’ for the duration of Contract Period.Part(B) Page 108 of 114 TCE FORM NO. If any work is carried out by the Bidder before prior approval from Purchaser / Purchaser’s Representative and modification is sought by Purchaser / Purchaser’s Representative later.0 ERECTION REQUIREMENTS 1. the calibrations shall be carried out independently by the Bidder and later in the presence of Purchaser who shall certify the same. Calibration shall include test for repeatability. All the panels.2 2.1 The actual location of transmitter racks.

2.1 Prior to taking the instruments in service. tools and tackles including test pressure gauges. etc. Necessary equipment such as portable compressor.Spec No. miscellaneous fasteners. materials such as temporary gaskets.. sampling lines and air supply lines shall be blown as required with the establishment of adequate line pressure and temperature conditions to keep the lines thoroughly clean.4 TCE FORM NO. are to be provided by the Bidder.2 3.. All the required software and hardware changes shall be incorporated as required for successful commissioning to Purchaser’s satisfaction. COMMISSIONING REQUIREMENTS 2.4 All instruments and control equipment shall be calibrated to read correctly to the satisfaction of equipment supplier / Purchaser. For all electrical actuators of the valves.e. Pre-commissioning checks. trouble shooting final solutions to application and / or instrument problems. FIELD TESTING AND COMMISSIONING REQUIREMENTS 2.0 3. air supply and pneumatic lines.9 2.10 3. setting and performance of limit switches / torque switches of various positions shall be checked before and after installation of the actuators. For such tests.8 2. On-line i. Hydro test shall be performed for all other impulse lines / sampling lines.. etc. The position transmitters for inching applications shall also be calibrated. cables and test gauges shall be provided by the Bidder. necessary testing set up required shall be arranged by the Bidder. TCE. Necessary equipment such as hydro test pumps and temporary piping to the required point. without removing control valves from the pipe. all impulse lines. functioning. Pneumatic actuators shall be calibrated at site.3 3. is Bidder’s responsibility.7 2. verification of system functioning.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 15 Volume – V SECTION: D6 SHEET 2 OF 6 TABLE-15: ERECTION. connecting pipes. All the float operated level switches shall be tested for the movement of the float and linkages to make to break the switch contacts by filling up with water before installation.6 2. fill pump etc.Part(B) Page 109 of 114 3. 120R2 . Any other tests as may be directed by the Purchaser/Purchaser’s Representative. calibration of the positioners and stroking of control valves / control dampers shall be carried out as required during control system tuning. power initialisation. materials. individuals loop checks.5 All switches shall be tested for the actuation of both normally open and normally closed contacts at the desired set points and also for the fixed / differential settings. ISSUE R0 Vol V . etc. All the conductivity type probes and switches shall be tested for performance before installation. Air leak tests shall be performed on all flue gas impulse / sample lines.

5 After delivery of the equipment.4 4. the Bidder shall locate all the equipment including electronic cards in its final position. TCE. blowers and other necessary equipment for timely efficient erection and testing. semiskilled and unskilled labours including instrument tube fitters. The Bidder shall furnish a detail erection schedule. erection materials required for the complete installation. licensed cable jointing mechanics etc. ISSUE R0 Vol V .5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 15 Volume – V SECTION: D6 SHEET 3 OF 6 TABLE-15: ERECTION. The erection work shall include but not limited to the following: (a) Transportation of the tested and calibrated equipment to the place of installation without any damage. all in accordance with manufacturer’s recommendations.2 4. CALIBRATION AND COMMISSIONING 4. cabinets as required and providing general trouble shooting and final solutions to application and / or instrument problems. SCOPE OF WORK FOR ERECTION 4. tuning of control loops. grounding and interconnection cables. TESTING. 120R2 .Part(B) Page 110 of 114 4. FIELD TESTING AND COMMISSIONING REQUIREMENTS 3.5 4. (b) Installation of PLC equipment as per bill of material and as per relevant approved G.1 The Bidder shall be required to erect all cabinets. the Bidder shall select and adopt methods and procedures for equipment erection to suit the nature of equipment and erection. However..0 of Section D3. hydraulic jacks.6 TCE FORM NO.2. implementation of any configuration changes including hardware. field loading of system configuration / software and data base. desks. demonstration of system functionality to verify conformance with manufacturer’s instructions and specifications.2 4. skilled.2. check all the power wiring.2. The Bidder shall provide all supervisory.A and disposition drawing. which shall be finalised along with the offer keeping in view the overall erection and commissioning schedule.3). The erection schedule as agreed with the PURCHASER shall be strictly adhered to by the Bidder. welding sets. consumable.3 4.2. mobile cranes. conduits. The Bidder shall maintain proper record of the materials at the place of storage for quick identification as and when required. software and additional tappings / instruments. transport vehicles. tools and tackles. consoles. involved according to the best modern practice and his own experience. The Bidder shall perform initialisation of system power. all cables.Spec No. The Bidder shall carry out all repairs to damages that might have suffered during transit or in subsequent storage and replacement of all lost parts. SPECIFIC REQUIREMENTS FOR ERECTION.2. equipment of PLC etc required for completion PLC package covered in this specification.1 The erection of instrumentation system shall be carried out generally conforming to General Technical standards (clause 24.0 4.2.

Installation and termination of electrical.3. from the available / to be erected marshalling cabinets to I/O cabinets System cabinets as per relevant interconnecting and terminating drawings prepared by the successful Bidder.1.3. brackets. The cabinets and desks shall be cleaned by blowing air to remove dust or foreign particles. the necessary openings and inserts required to be made on the floor by the Bidder shall be checked and then after proper alignment. TCE.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 15 Volume – V SECTION: D6 SHEET 4 OF 6 TABLE-15: ERECTION.3.2. Providing identification of cable by engraved Aluminium tag plates at both ends inside the cabinets.2 4. pipes required for supporting cable trays complete with bolts and nuts.3. The Bidder's scope of work and supply shall also include tightening of wires. Cable shall be pulled into the pipes in such a way that there shall ISSUE R0 Vol V . All necessary civil work to be carried out for this shall be in Bidder’s scope of supply.3.3 4. The entry to and exit from pipes shall be smooth and free from burr where cables are run through pipes.2 4. Preparation of separate earthing pits as recommended by the PLC system supplier.3. power supply. and signal lines.1 4.1. consoles as per cable schedule. measuring.Part(B) Page 111 of 114 TCE FORM NO. If any damage is observed before handling. 4. The Bidder's scope of work and supply shall also include tightening of wires. 120R2 .1 4. FIELD TESTING AND COMMISSIONING REQUIREMENTS (c) (d) Installation of the necessary cable and racks with posts. This includes laying of all control cables.3 Cables. replacement of broken items and retouching of damaged painted surface of cabinets those has taken place during transport from store to work site and during installation. control.1 Cabinets and desk The Bidder shall arrange for the transportation and handling of cabinets and desks from stores to work site suitably without any damage.3.1.3.2 4. fabrication and erection of structural steel plates. cables trays and conduits All electrical work shall conform to the rules and regulations of Indian Electricity Act. (e) (f) (g) 4.1. Supply. the cabinets and desks shall be installed on the floor by the Bidder. All cables shall be tested for insulation level.Spec No. compensating cables etc.1.4 4. angles. this shall be brought to the notice of the PURCHASER.3 ERECTION 4.2. and fasteners.3. laying and connection of the earthing cables from different equipment to the respective earthing pit. Before installation of cabinets and desks.5 4.3.2. Cable ends shall be properly cleaned. replacement of broken items and retouching of damaged painted surface of cabinets those has taken place during transport from store to work site and during installation.

4 4. 75% and 100%.Part(B) Page 112 of 114 TCE FORM NO. GI perforated covered trays. 120R2 .5 4. reset and rate action) are at nominal value.3. insulating tapes.3.4. TCE.3. GI flexible conduits.5 ISSUE R0 Vol V .8 4. Thermocouple cables shall be run completely independent of all other cables with minimum separation as per relevant standard and with cross over at right angles. conduit fittings.2.2.3. and cadmium plated trays & cable glands.3.6 Flexible conduits shall be provided wherever necessary. FIELD TESTING AND COMMISSIONING REQUIREMENTS be no damage to the cables.4. 50%. supports. 4.2.7 4. splicing materials.3. the action shall be simulated by disconnecting the wires / shorting the terminals and the function of the associated system shall be checked.4 LOOP TESTING The action of the controller is set as prescribed. 25%. 50%. cable support grips. accessories.2. Each tray shall be filled with a maximum of two layers for instrument and control cables and one layer for power cables providing 20% spare space in the number of layers specified. For field mounted switches for alarms / interlocks. 4.4.2.Spec No. For temperature loops with thermocouples.3. For temperature loops with RTDs.4. Instrument Cable Trays. Cable in hot areas shall have proper heat protection. a known resistance shall be injected in the control cable through decade resistance box and output display shall be checked for 0%. a known milli volt signal shall be injected and the output display shall be checked for input signals of 0%.11 4. 4 – 20 mA shall be injected and checked the loop for 0%. 4.2. 25%.1 4. 75% and 100%. crimping tools. 50%.3 4.4 4. shall be erected vertically as far as possible to avoid dust accumulation. The cabling accessories shall include cage-clamp type terminal blocks.10 4. 25%. Controller settings for various modes of operation (Proportional band. All the cables laid shall be tied individually to the Tray.4. For current signals. 75% and 100% of fullscale inputs. A minimum distance of 400 mm shall be kept between instrument / signal cables and power cables.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 15 Volume – V SECTION: D6 SHEET 5 OF 6 TABLE-15: ERECTION.3.2 4.9 4.2.2.

Spec No. calibration and commissioning shall be brought by the Bidder at site. Bus Worst loading conditions calculation shall be proved at the time of commissioning. COMMISSIONING 4. alarms / interlocks. supervision and maintenance of the system shall be the scope and responsibility of the Bidder. 4.5. all the system and auto control loops shall run satisfactorily for at least one month at varying loads without disturbing any adjustment. The list of set points.3 4.5.4.1 The Bidder shall take care to complete all pre-commissioning activities and simulation tests after erection to suit the over all start up of respective plant equipment.2 4. The performance test shall be carried out for the system offered and certificates to these effects shall be approved by the PURCHASER.5.5. Before taking over of the plant by the PURCHASER. FIELD TESTING AND COMMISSIONING REQUIREMENTS 4. Control loops shall be put in auto mode as per the operational requirement of different phases.6 4. During this period.6 Any equipment required by the Bidder for testing. The pre-commissioning activities of the system shall be completed at least two (2) days in advance as per the schedule of plant start-up.4 4.5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM – TABLE 15 Volume – V SECTION: D6 SHEET 6 OF 6 TABLE-15: ERECTION.5.5 4.Part(B) Page 113 of 114 TCE FORM NO. TCE.5.7 ISSUE R0 Vol V .5.5 4. settings for the controllers shall be furnished in the standard format and handed over to the PURCHASER. The controllers shall be tuned as per the process requirement. The list of such equipment shall be furnished along with the offer. 120R2 .

5657A-C-500-002 TCE Consulting Engineers Limited INSTRUMENTATION AND CONTROL EQUIPMENT SYSTEM –TABLE 16 Volume – V SECTION: D6 SHEET 1 OF 1 ISSUE R0 TCE FORM NO. 120R2 Vol V .Part(B) Page 114 of 114 .Spec No. TCE.

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