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Haryana Power Generation Crop. Ltd.

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Section 5.6.1 - DISTRIBUTED DIGITAL CONTROL AND MANAGEMENT INFORMATION SYSTEM (BASED ON PER UNIT BASIS)
TABLE OF CONTENTS Page Section 5.6.1 5.6.1.1 5.6.1.2 5.6.1.3 5.6.1.4 5.6.1.5 5.6.1.6 5.6.1.7 5.6.1.8 5.6.1.9 5.6.1.10 5.6.1.11 5.6.1.12 5.6.1.13 5.6.1.14 5.6.1.15 5.6.1.16 5.6.1.17 37 5.6.1.18 5.6.1.19 5.6.1.20 5.6.1.21 5.6.1.22 5.6.1.23 5.6.1.24 5.6.1.25 5.6.1.26 5.6.1.27 5.6.1.28 5.6.1.29 5.6.1.30 Visual Annunciation System.................................................5.6.1-38 Sequence of Events Recorder (SER)...................................5.6.1-43 I/O Termination Cabinets.....................................................5.6.1-44 Distributed Processing Unit Cabinets....................................5.6.1-44 Data Highway......................................................................5.6.1-45 Operator Workstations.........................................................5.6.1-46 Processor Characteristics.....................................................5.6.1-47 Input/Output Modules...........................................................5.6.1-48 Monitors..............................................................................5.6.1-49 Keyboards...........................................................................5.6.1-50 System Software..................................................................5.6.1-50 Printers................................................................................5.6.1-52 Engineering Station..............................................................5.6.1-52 DISTRIBUTED DIGITAL CONTROL AND .........5.6.1-1 thru 5.6.1-55 MANAGEMENT INFORMATION SYSTEM General.................................................................................5.6.1-1 Automation System................................................................5.6.1-6 Drawing 114-01-0104: System Architecture Operating Conditions...........................................................5.6.1-10 Redundancy and Partitioning...............................................5.6.1-10 Response Times..................................................................5.6.1-12 Control and Information Functions........................................5.6.1-13 Modulating Controls.............................................................5.6.1-13 Discrete Controls.................................................................5.6.1-16 Unit Protection System.........................................................5.6.1-16 Steam Turbine Control and Protection Logic.........................5.6.1-17 Turbine Vibration Monitoring System....................................5.6.1-18 Steam Generator Control & Protection Logic........................5.6.1-21 Steam Turbine Water Induction Prevention (TWIP) Logic......5.6.1-22 Interlock and Runback Logic................................................5.6.1-22 Information..........................................................................5.6.1-23 Performance Calculations and Plant Optimization.................5.6.1-32 Plant Optimization functions.................................................5.6.1-35 - Performance Requirements for DDCMIS and Control Loops...5.6.1-

2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II /TC 5.6.1-i

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5.6.1.31 5.6.1.32 5.6.1.34

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Diagnostic Station................................................................5.6.1-53 Historical Data Storage and Retrieval System.......................5.6.1-54 Indicators/Recorders/Ammeters..........................................5.6.1.-55

2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II /TC 5.6.1-i

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Section 5.6.1 - DISTRIBUTED DIGITAL CONTROL AND MANAGEMENT INFORMATION SYSTEM


5.6.1.1 GENERAL The DDCMIS and other equipment / instrument should be state of art technology. If any software, hardware, alarm / tripping etc. is not specifically mentioned but are required for safe plant operation shall be provided by Bidder. The fundamental objective of the various control systems provided for the Yamuna Nagar Thermal Power Plant is to facilitate effective plant operations by ensuring the following: Personnel safety. Equipment protection. Ease of operation (automation). Equipment and cycle efficiency. Equipment and system reliability. Equipment and system maintainability.

To implement these criteria, normal control and monitoring of the unit shall be from a Central Control Room (CCR) provided for each unit. The CCR shall employ state-of-the-art control system hardware configured for ease of operator interface. Separate systems shall be provided for each unit . From the Central Control Room, the operators shall be able to start up, load, unload, release for remote dispatch, shut down, and monitor the operation of the steam generator, turbine generator, and associated auxiliary systems. A Distributed Digital Control and Management Information System (DDCMIS) shall be provided as the primary operator interface with each unit, i.e., steam generator, steam turbine, balance-of-plant equipment, and auxiliary electric equipment. Normal operation of the plant is envisaged from monitor and KB. However, it shall be possible to operate the plant by using back-up hardwired A/Ms, ILPBs, indicators, recorders, etc even if the processor has failed and the plant can also be brought to the safe shutdown start/stop/normal operation (in the event of failure of DDCMIS I/O cards, processors, data highway & MMI). The principal functions of the DDCMIS are as follows:a) b) c) Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-1 Provide the control of the steam turbine generator (STG). Provide control of the steam generator, main steam cycle, steam bypass and water cycle.

Provide control of pulverizers, combustion air, burner ignition, and flame management. 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II,

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

d)

In case SCADA for 220 kV Switchyard Circuit Breakers control is not from the same family of DDCMIS, then a gateway shall be provided to monitor switch yard operation. Receive input signals that represent the status of process variables and equipment status; condition the signals; and utilize them for control, protection, monitoring, status display, annunciation and SER. Provide the output signals to modulate and control the final devices, such as control valves, control drives, dampers and pumps. Provide gateways for accepting the inputs for control room monitoring of dedicated control and information systems such as (i) water treatment; (ii) continuous emissions monitoring; (iii) vibration monitoring; (iv) coal handling; (v) air compressor etc; (vi) condenser polishing; (vii) ash handling; (viii) cooling water system including chlorination (if required); and (ix) any other system. Provide alarm logging and sequence-of-events recording (SER) capability with 1 ms resolution. Provide plant and equipment performance calculation, capability and plant optimizing functions. Provide Auto Plant start-up, loading, auto synchronization and shutdown. Perform information processing functions including logging and printout of historical data, trend displays, elapsed time monitoring, and tantalization of fuel and energy usage and generation. Provide a means to coordinate the load control of the prime movers in response to remote dispatch load change requests. All the control packages of turbo-generator, boiler and their auxiliaries shall be the integral part of DDCMIS. Bidder at his discretion may either use DDCMIS system for following packages or use separate PLCs and provide suitable communication/ gateways for monitoring of the data from the central control room:i) ii) iii) Coal handling plant Ash handling plant Water treatment including Chlorination & DM plant

e)

f) g)

h) i) j) k)

l) m) n)

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iv) v) Air Compressors CW pump

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Bidder to note that PLC system shall be from one manufacturer only and Relay based system shall not be acceptable. Above referred packages are common for all units. Information from these systems should be made available to DDCMIS of each unit. o) p) Status of all drives, pumps, tanks, etc should also be available in central control room. For group control of HT/LT drives, local/remote selector switch shall be provided on MCC which shall be used as permissive for operation from central control room. The philosophy shall be as follows:Local Control Indication MCC/Switchgear Control Indication Control Pump Motor (HT) Stop PB (Lockable ) Start PB ON/OFF Ammeter Stop PB L/R switch (Lockable ) ON/OFF Trip Ammeter Start/ Stop DCS Indication ON/OFF RTS Trip Current Control Start PB/ Stop PB Control Room UCP Indication ON/OFF Trip, Current RTS: 1. No electrical fault 2. L/R switch set to remote 3. Availability of control supply 4. Process permission RTS: 1. No Electrical fault 2. L/R switch set to remote 3. Availability of control supply 4. Process permission Intelligent type Remarks

Type of drive

Pump Motor (LT) Fan Motor Blower Motor

Stop PB (Lockable ) Start PB

ON/OFF Ammeter >30 kW

Stop PB L/R Switch (Lockable )

ON/OFF Trip

Start/ Stop

Current (>30 kW or Essential) ON/OFF Trip RTS

Start/ Stop PB

ON/OFF Trip

MOV (Non inching)

Open / Close

Open / Close

--

--

Open / Close

Open / Close Open Fault Close Fault RTS Open Close Position RTS Open Close

--

--

MOV (Inching)

Open Close Stop L/R Switch --

Open Close Position

--

--

Open Close Stop

--

--

Intelligent type

SOV

--

--

--

Open Close

--

--

--

q) r)

Maintenance scheduling & maintenance package shall be quoted as optional.

All HT motor bearings shall have duplex RTDs for remote indication and local temperature gauges for local indication. 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, TURNKEY SPECIFICATION Vol. II / 5.6.1-3

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s)

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

If any software, hardware, alarm / tripping etc. is not specifically mentioned but are required for safe plant operation shall be provided by the bidder.

5.6.1.1.1

Multi tasking of Processors The distributed digital control system is required to address the following tasks:1) 2) 3) Open loop control (binary) Closed loop control (analog modulating) Plant monitoring/signal acquisition and processing

The micro-processor based system has the capability to perform the above tasks either separately or in a combined form. As multi-function processors have a number of control functions and are preferred to be in completely redundant mode, security of control functions including those of protection would be maintained even with the loss of the active processor as well as the functions could be taken over by standby processor. All processors for modulating controls shall have self-tuning facility. 5.6.1.1.2 Signal Acquisition and Processing Modules for Monitoring & Control Functions Primary instruments for monitoring functions are provided separate from those for control tasks. Keeping this segregation of field instruments, the system philosophy could adopt separate processors for monitoring tasks. Monitoring task being less critical compared to control tasks, the processors for monitoring could be non-redundant. Alternatively, as the hardware for monitoring functions is generally similar/identical to those for the control tasks, it is possible to combine the monitoring portions with control tasks. However, in view of the general practice of control engineering, separate non- redundant processors can be provided for this function. All processors for control and monitoring shall be redundant. 5.6.1.1.3 Processor Task Allocations The system shall perform overall control tasks having appropriate redundancy built in for all the system functions both at processor and peripheral level. No failure of any single peripheral or processor leads to any system function or data being lost. The interlock and modulating controls shall be so assigned to the processors that failure of any processor does not lead to shutdown of the entire unit. For the system with multi-function processors, functional distribution is adopted and geographically, the system can be centralised. 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-4

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Each functional group consists of dedicated microprocessors including redundancy and dedicated input and output processing. The redundant multifunctional processors are in a hot back up mode. The back-up processor takes over the function of the failed processor within 50 milliseconds. Following tentative segregation for regulating controls is proposed, however final segregation shall be subject to Owners approval during detailed engineering:a) b) c) d) Coordinated master controls and Fuel feed control Air flow and excess air correction Furnace draft Mill related controls such as air flow/feeder rate/outlet temperature controls; 2 mills (in case of LE bowl mill or two sides of a tube mill) per redundant processor Feed water/drum level Deaerator, hotwell SH steam temperature control (multi variable control) RH steam temperature control (multi variable control) HP/LP heaters Tripple redundant processors for turbine integral controls Tripple redundant processors for BMS (FSSS). Also the cards and Processor for BMS shall be fail safe type.

e) f) g) h) i) j) k)

From a to i, nine controllers shall be dual redundant (18 Nos. total ) and j and k shall be tripple redundant ( 6 Nos. ). Hence, altogether minimum 24 redundant processors are envisaged. During detailed engineering, processor task allocation will be done amongst these processors (and shall be subject to owners approval ) taking into consideration the turbine control, boiler control and the station C&I portion altogether. Segregation further depends upon I/O handling capacity of the processor. Other loops of the plant e.g. miscellaneous loops can be distributed amongst the above processors. 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-5

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Provision is made for geographical distribution of hardware in the proposal as an alternate. Each group has sufficient spare capacity of at least 25% to meet modification/extension of the system. Multi-function processors can incorporate the corresponding interlocks (open loop control tasks of the system). Interlock

and modulating controls are to be so assigned to the processors in such a way that failure of any processor does not lead to shut down of the entire unit. In no case CPU loading should exceed 60% of its capacity. Bidder to submit calculation of CPU loading along with his bid. While allocating control tasks for Interlock Protection, following criteria are also to be satisfied:a) b) c) Left and right air-flue gas paths do not share processors. Left and right water paths do not share redundant processors. Those auxiliaries which are common to both paths (BFP-C) will be resident in the processors of the left/right paths so that both paths will not be lost due to the failure of a processor. The Air and Water paths do not share processors.

d)

The system has capability to provide held contact, maintained contact or a held contact till completion of the control action. Further system has the capability of either torque or position seating of the valves/dampers. 5.6.1.2 5.6.1.2.1 AUTOMATION SYSTEM System Requirement The system envisaged is based on modern network orientation and is totally flexible in its adaptability to process structures, to the safety and availability requirements of main and auxiliary plants and the communication needs of the user. The control system has the following four functions:a) b) Signal Conditioning (I/O System) Control functions

c) Man-machine interface 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-6

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

d) e)

System communication System configuration is as per drawings No. 3628-114-01-0104

2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-7

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

5.6.1.2.2

Operating Stations a) Main Control Console i) The main control console provides the primary man-machine interface through the operator station. DDCMIS shall consist of total twelve (12) sets of utility monitors with dedicated keyboards. Including, one set of monitor and keyboard each for Engineering, Alarm & Diagnostic, SER, Performance calculations & optimisation and shift supervisors shall be offered in both the options. The monitor units are of interactive type, providing the operator with the ability to issue commands via. the keyboards. Overview of the plant systems, complete controls and monitoring of the plant equipment and parameters, including performance of start-up/shutdown, normal plant operation and emergency operations, are accessible from any one of the monitor units. In addition, one PC is provided for vibration monitoring and analysis system. System architecture shall be as per drawing 3628114-01-0104. All operating stations shall be interchangeable and it should be possible to operate the plant from any operator station. Equipment status, start permissive check and step-by-step instructions are displayed on the monitor screens for guiding the operator during various plant and equipment start-up and shutdown operations. On a plant fault, system trouble or equipment mal-function, necessary operating is displayed automatically to direct the operator to alleviate the abnormal conditions. These operator guides are of intelligent, easy to follow and designed to enhance plant availability. Operator station shall be minimum 32 bit processor (with 128 MB RAM). The monitors shall be of 21 inches high resolution (1280x1024) color monitors with minimum 80 GB Hard Disk memory with glare-free screens to provide the operator with sharp, clear and easy-to-read graphic and text displays. The response time shall not be more than 1 second. All keyboards/key pads are of totally enclosed type. Each key entry is confirmed by a sound e.g. a beep. Monitors with 3D capabilities for graphics are preferred. Functional keyboards for plant operator stations shall be of special type adopted to operation tasks and monitor functions. It shall contain all keys necessary for plant operation in an ergonomically manner. Multifunction keys shall be provided with automatic display for modified functions.

2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-8

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

The main control console shall also include a backup section which containing insert panels for FSSS, EHGC, and hard-wired MFT, turbine trip emergency operation devices, etc. ii) b) Main Control Console also consists of operating station for Sequence of Event Recording along with monitor.

Computer Room/Engineer Room: The computer room/engineer room shall be located adjacent to the unit control room to provide easy access for control room personnel. This room shall contain all DDCMIS related equipment necessary for configuring and maintaining the power block and balance of plant systems as follows:i) Engineer workstation/workstations (in case of separate SG & TG integral DCS) with monitor/keyboard console and all programming devices for configuration of the system and graphics shall be housed in computer room. Diagnostic workstation with monitor/keyboard with diagnostic feature shall be housed in computer room. One workstation for performance calculation/efficiency calculations shall be housed in computer room. One SER station with keyboard etc shall be housed in computer room. Four (4) Color laser printers, one (1) Dot matrix printer for alarms & logs; and one (1) colour laser printer (A3 Size) for engineering station, one (1) inkjet printer for SOE recording (no printer shall be mounted on the main control console/control desks). All the printers shall be kept in computer room. PC and printer for vibration monitoring and analysis system shall be housed in computer room. Engineer room/shift supervisor room shall contain one workstation monitor, KB and printer. PC for automatic tube leak detection system shall be housed in computer room.

ii) iii) iv) v)

vi) vii) viii) c)

Shift Supervisor Station: The shift supervisor station consists of one monitor and one keyboard. Necessary arrangements shall be provided for hooking up to respective units.

2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-9

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d)

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Key-boards are of ASCII type with custom keys for dedicated graphics and group displays. These keys are re-assignable by Owners programme personnel. Keyboards are of totally enclosed membrane type with mylar overlay.

e)

Historical Data Storage and Retrieval (HDSR) System. The HDSR shall provide medium and long-term storage of select data points for subsequent retrieval, display, and analysis. HDSR system shall provide storage of status/values of analog and digital inputs. The collected data shall be retained on historical storage device for a minimum period of one month after which the data shall be automatically shifted to CD drive for long term storage. These shall be 2 nos. CD Writer. Master Digital Clock [common for all 2 units]: One (1) number master digital clock is provided mounted in control room. Master clock system is capable of receiving time signals broadcast by National Physical Laboratory or as per GPA and processing it and then transmitting and synchronizing this with other units DDCMIS, PLCs and micro-processor based systems, SCADA etc. Necessary hardware and software requirements for all units shall be met. The slave clocks shall be provided with digital display for each PLC, SCADA etc.

f)

5.6.1.2.3

System Communication The system communication shall be through redundant proprietary data highway transferring data at a speed of 10 Mbps. All the operating stations shall be connected to this data highway for the operation purpose. The engineering station, diagnostic station, performance calculation, SER etc shall be communicating on the Ethernet TCP I/P bus with a transfer speed of 100 Mbps or better.

5.6.1.2.4

Man-Machine Interface Communication takes place between operator, process and the system. Communication consists of monitor observations, operations and plant controls, system configurations, diagnostics and data archiving, reports and logs, X-Y plots, bar charts etc. The monitor based systems have the advantage of not only reporting the plant station and variable values but also the process mimics.

5.6.1.2.5

Control Functions All processing and computational tasks are completed in the processors using standard software modules and procedures. A programme library with built-in macros is used for constantly recurring functions. The processors are built around high performance microprocessor and have a multi tasking operating system. This 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II,

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

facilitates simultaneous processing of relevant programmes with freely selective cycle times. 5.6.1.2.6 Signal Conditioning The signal conditioning is done in order to filter out the process noise and other electrical disturbances of the signal, protect the system against light voltage transients, and convert the analog/binary signal to digital form. The I/O sub system therefore, converts the process signal to a form that the processors can use it to perform computational tasks. Microprocessor based Opto/Galvanic isolation shall be provided. 5.6.1.3 OPERATING CONDITIONS DDCMIS components such as the main control console, operator work stations, the processing unit cabinets, the Engineer/Programmer's Console, I/O module and termination cabinets, and specialized units shall be located in the control room or various control equipment rooms. These rooms shall be air-conditioned as required to maintain room environment within the tolerances of the equipment. DDCMIS electronic equipment shall be redundantly powered from Un-interrupted Power Supply (UPS) AC System at a nominal 240 volts, 50 hertz/24V DC. Any required voltages other than 240 volts shall be provided by power supplies within the DDCMIS equipment. The DDCMIS shall be capable of withstanding power supply interruptions up to a quarter of a cycle in duration without system error. 5.6.1.4 REDUNDANCY AND PARTITIONING In order to establish a high degree of system availability, the various control systems which comprise the overall unit control system shall be configured such that no single component failure, can cause a failure or mis-operation of critical automatic or manual control functions. The failure of a redundant component shall be alarmed to the operator to allow on-line removal/replacement or at the first shutdown opportunity. The systems' redundancy schemes shall be designed such that the transfer from any critical element to its redundant backup shall occur without upset to normal process control or to system displays, data collection, or other normal DDCMIS functions within 50 m sec. The signal distribution from sensors which are shared due to process restrictions between control loops, logics, monitoring purposes and between back-up instruments on the panel shall be as follows:a) In the case of multiple input to a card, input cards used shall be restricted to a maximum of 16 inputs per card for analog input and 16 for digital inputs. 32 channel card shall not be acceptable. All Input / Output cards for OLCS and CLCS shall be hot standby redundant.

2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-11

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b)

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

In case there is either process redundancy (Left, Right) or transmitter or switches redundancy, the inputs shall be routed through independent input cards. No two control loops/interlock loop shall share the inputs (either binary or analog) vide input cards if process signals are independently available. Protective inputs for two drives shall not be allotted to the same input card. Output cards shall be independent for each control loop. For outputs to HT and LT motors, the following shall be adopted : i) Each HT motor and unidirectional drives shall have dedicated output cards. No other drive shall be combined with HT motor drive output card. However indication outputs can be driven from this output card for the concerned logic loop. Not more than two bidirectional drives shall share one output card. For unidirectional drives, not more than one drive will be allotted to one output card. In case inputs/outputs are required from one logic to another, they can be soft wired provided, they are on same processor. For those inputs outputs resident on other processors, the same shall be hardwired.

c)

d)

ii) iii) iv)

e)

For back up instruments on the panel or outputs, not more than two devices shall be driven by one output card. In case the same output is received by two independent devices/systems, the outputs shall be routed through independent output cards. For signal distribution or fanouts, suitable electronic cards (opto couplers) shall be used. Annunciation: The processors shall contain the logic required to group individual process and system alarms into common groups as well as the annunciation sequence logic. Standalone annunciation system shall also be acceptable.

f) g)

Redundant components and equipment within given systems shall be distributed among processors and I/O cards to the extent practical. Critical inputs shall be supplied with redundant sensors/transmitters with each input connected to different input cards. Where redundant inputs exist, the DDCMIS shall be configured to automatically reject erroneous data. Where required, one-of-two, two-of-two, two-of-three, or median select schemes shall be utilized to ensure the integrity of critical inputs. The use of redundant outputs 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-12

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

driving the same final element or equipment shall generally be avoided in favor of failsafe design and redundancy of the plant equipment. The operator stations shall be identical in capability and independently linked to the system. Although these stations shall be normally dedicated to a specific function, any station can replace the function of any other station at any time. All power source and power conditioning equipment in the system shall be redundant.

5.6.1.5

RESPONSE TIMES The system shall have adequate speed of response through all regimes of system loadings. The minimum criteria to be ensured are as follows:a) b) Key board command to field equipment shall be executed and its confirmation shall be displayed on the screen within 2 second. The response for operator requested display (time between pressing of last key and appearance of last character on screen) shall be of the order of one seconds under all loading conditions. Dynamic parameters in the monitor displays shall be updated in one second interval. The cycle time for open loop and closed loop controls shall be as follows:i) For critical closed loops like Boiler Drum Level control, furnace draft control & combustion control, the loop cycle time shall be maximum 100 milliseconds. For non-critical milliseconds. closed loops it shall be maximum 250

c) d)

ii) iii)

For all open loops & sequential interlocks it shall be max. 100 milliseconds and for protection it shall be 50 ms. (The loop cycle time is defined as the time taken from change of sensor output to processor command output these response times are to be demonstrated at site during commisioning).

2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-13

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e) f)

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

The time taken to change over to back-up processor on failure of main processor shall be less than 50 ms, preferably 25 ms. All analog inputs to CLCS shall be acquired and data base updated within an interval of 100 milli-seconds. Data for critical loops shall be acquired & data base updated at a faster rate to suit the requirements of (d) above. The digital inputs for SOE shall be monitored at 1 milli-second resolution. The system shall acquire & check all inputs at the input scan rate. If the input is in alarm state (i.e. the input is in an off normal condition) the alarm status shall be annunciated, printed out and displayed within 1 second after the input is scanned.

g) h)

5.6.1.6

CONTROL AND INFORMATION FUNCTIONS The DDCMIS shall provide five primary functions as listed below and discussed in the following sections:Modulating Control Discrete Control Protection Information Annunciation Modulating control and discrete controls for an equipment can be carried out in multifunction processor.

5.6.1.7

MODULATING CONTROLS The modulating controls shall be designed to eliminate the necessity for operator actions except manual/auto selection, set point changes, biasing, and similar actions, during normal operation. Bumpless and balanceless transfers between automatic and manual operation modes shall be provided automatically without need for operator action. The final control element shall operate in automode within 20 to 100%. The modulating control function shall be distributed among a number of redundant processor pairs as described in earlier. Each redundant pair of processors shall 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II,

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

consist of two redundant processors, with one processor normally in a "hotstandby" mode. Failure of the primary processor shall cause a bumpless transfer of control to the standby processor. This transfer shall be invisible to the operator except that failure of the primary processor shall be alarmed. To the extent practical, equipment shall be assigned to processors such that redundant pieces of equipment shall be controlled by separate processor pairs. The primary plant control loop (coordinated control) shall simultaneously regulate the output of the steam generator (steam flow) and the turbine generator (megawatts), in response to changes in unit load demand while maintaining all major operating parameters in the power cycle in safe operating limits. The control system shall be designed for both constant and variable pressure operation. The control system shall be designed to accommodate base load, two shift, and load following operation.

The coordinated control system controls the operation of the steam generator and its auxiliary equipment and, by transmitting load demand signals to the turbine electro-hydraulic control (EHC) system, coordinates the response of the turbine and the steam generator to changes in load demand. This coordinated response is generated through the following distinct control loops:Unit master load control. Turbine load demand. Pulverizer load control. Pulverizer primary airflow control. Pulverizer coal/air temperature control. Fuel oil flow/Fuel oil pressure control. Combustion airflow control. Primary air pressure control. Furnace draft control. Condensate (deaerator level) control. Feedwater flow control. 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-15

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Superheat steam temperature control. Reheat steam temperature control. HP/LP bypass control. Main steam warming control.

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

The coordinated control system shall continuously compare air and fuel flow demand and feedback signals. The system shall always attempt to maintain an airrich atmosphere in the furnace. The fuel-air, cross-limiting programme shall ensure that airflow shall increase before fuel flow on load increases, and that fuel flow shall decrease before air flow on load decreases. Other modulating control loops shall include at least the following: Closed cycle cooling water temperature. Closed cycle cooling water pressure control. Condensate pump recirculation flow control (if required). Level control. Condenser hot well level control. Boiler condensate tank level control. Deaerator pressure. Deaerator temperature. Deaerator level control. Feed pump recirculation control. Feed water heater level control. LP steam header pressure control. Condenser neck spray control. Generator hydrogen temperature control. Generator stator water temperature control. 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-16

Haryana Power Generation Crop. Ltd.


Air preheat temperature control. Steam turbine lube oil temperature control.

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

The modulating control loops shall utilize single, double, triple, and split range measurement systems as required. Selection of the type of measurement system to be utilized for each loop shall be made during detailed design. Following controls shall also be included:Turbine Seal Steam Processor. Cold gas temperature processor generator. Primary water temperature control for rotor cooler. Warm-up control to warm up main steam lines. Lub oil temperature control

5.6.1.8

Secondary Air Damper Control (SADC) PRDS Control

DISCRETE CONTROLS Discrete control logic shall be provided for motors (pumps, fans, compressors, and the like), non-modulating valves, auxiliary electric breakers and starters, switchyard breakers and switches and sequential startup and shutdown control logic. The operator interface with the discrete controls shall be via graphic based operator work stations installed in the Central Control Room. For the DDCMIS, it shall consist of start-stop, open-close, on-off, start-auto-stop, start-standby-stop, and similar control pop-ups which emulate the action of hard-wired control switches and push buttons. The logic provided for each item of plant equipment shall be designed to minimize the requirement for operator interface and shall include permissives and interlocks for protection against the abnormal operation of equipment. Permissive and step displays shall be provided for equipment which requires permissive or interlock logic.

5.6.1.9

UNIT PROTECTION SYSTEM

2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-17

Haryana Power Generation Crop. Ltd.

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

The Unit Protection System shall sense abnormal or hazardous operating conditions and shall automatically initiate shutdown, isolation, or runback of major equipment as required to protect personnel and equipment. The Unit Protection System includes the following components:Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-18 Steam turbine protection logic. Turbo-generator, exciter, and step-up transformer protective relaying. Steam generator protection logic. Steam turbine water induction prevention logic. Interlock and runback logic. ID fans FD fans PA fans Gravimetric feeder control Reheater protection Coal mills BMS/FSSS Regenerative air heaters SH/RH spray - block valves and isolation valves LFO, HFO pumps Emergency drum drain valve Soot-blower control HP/LP heater CW pumps ACW pumps Condensate Extraction pumps 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II,

Haryana Power Generation Crop. Ltd.

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Boiler Feed pumps

The Unit Protection System shall be implemented at two levels. Individual equipment shall be protected by logic contained within its distributed processors. Examples of this type of protection shall be abnormal temperature, pressure, level, flow, and other process interlocks such as pump minimum flow requirements, minimum NPSH requirements, low lube oil pressure, high vibration, and the like. The steam turbine proprietary control system contains the protective logic necessary to guard against potentially dangerous conditions such as high vibration, abnormal oil temperature, low oil pressure, high condenser pressure, overspeed, and other potentially damaging conditions. In addition to the individual equipment protection logic described above, unit protection logic shall be provided in a dedicated pair of microprocessors. The unit protection logic coordinates the tripping of major plant components to prevent dangerous or potentially damaging plant operating modes. The unit protection logic shall also run back or trip major components as required in response to loss of plant support systems and systems which are common between major components within a unit. 5.6.1.10 STEAM TURBINE CONTROL AND PROTECTION LOGIC The steam turbine control shall be based on 2 out of 3 logic. The steam turbine control system shall be equipped with triple redundancy in sensors and processors

employing 2 out of 3 logic for control & operation. The system shall be designed such that the control of steam turbine shall be automatically and safely transferred to second logic control system on failure of the first logic control system. The control system shall be suitable for tying up with the automatic turbine run-up system, the coordinated control system, load frequency control system etc. Following control shall be included: Automatic Turbine Run up System. EHTC/TSE System. Turbine Stress evaluator. Automatic Turbine Tester. HP/LP bypass control. 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-19

Haryana Power Generation Crop. Ltd.

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Protective logic shall also be implemented in the steam turbine generator control system either in proprietary or in DDCMIS (in case there is one control system for SG, TG and Station C&I) to guard against conditions such as those listed below:5.6.1.11 Loss of vacuum. Thrust position. Loss of governing fluid pressure. High vibration. Overspeed. Low lube oil pressure. High bearing temperature. Other abnormal conditions as required by the manufacturer.

TURBINE VIBRATION MONITORING SYSTEM AND HT DRIVES VIBRATION MONITORING SYSTEM a) The Turbine Vibration Monitoring System shall monitor continuously the equipment to avoid its regular operation and, consequently, to damage, sometimes even irreparably, the physical integrity of all the mechanical parts which prejudice the life of the turbine. Complete instruments including sensing elements, converters, measuring module transmitters, indicators supplied by the bidder along with all required accessories for the following turbine vibration instruments shall be provided. Indication of the vibrations shall be local as well as remote. The instruments/equipment shall be of reputed make to the Owner's approval:i) Axial shift of rotor -- Axial displacement in the position of the turbine rotor shall be measured by non-contacting sensors, mounted in the front pedestal. The clearance between the sensor and the collar shall be measured inductively and converted into a voltage signal in the proximitor. The sensor and proximitor shall be located close to each other and form a single unit. The output signal from the proximitor shall be fed to the terminal cubicle, and the signal is displayed in the shaft position monitor. Differential expansion of HPT, IPT/LPT -- These channels shall measure the relative position between the rotor and the turbine casing. Each dedicated input electronic circuit shall receive the signal

b)

ii)

2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-20

Haryana Power Generation Crop. Ltd.

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

coming from the transducer situated in the turbine, the circuitry shall process the data and the result shall be delivered by the relevant output electronic circuit (voltage or current expressed) to external users (i.e. recorder). iii) Casing expansion of HPT and IPT -- This channel shall check the casing movement of the turbine versus a fixed point (floor). The absolute expansion test shall be made using a transducer of LVDT differential transformer type. One dedicated input electronic circuit shall receive the signal coming from the transducer situated in the turbine, the circuitry shall process the data and the result shall be delivered by the relevant output electronic circuit (voltage or current expressed) to external users (i.e. recorder). Shaft eccentricity Bearing vibration Rotor vibration -- These channels shall detect the vibrations of the rotor. Each vibration shall be detected using two parasitic type current transducers (no-contact) mutually bent by 90 and 45 with respect to the vertical axis. The dedicated input electronic circuit shall receive the signal coming from the transducers situated in the turbine, the circuitry shall process the data and the results (amplitudes and phase angle) shall be delivered by the relevant output electronic circuit (voltage or current expressed) to external users (i.e. recorder).

iv) v) vi)

vii)

Turbine speed -- The channel shall measure the actual turbine speed obtained from the DEHC. One dedicated electronic circuit shall receive the signal, processes the data and the result shall be delivered by the relevant output electronic circuit (voltage or current expressed) to external users (i.e. recorder). Control valve servomotor position Turbine metal temperatures Bearing metal and oil temperature Any other measurement recommended.

viii) ix) x) xi) c)

The instruments provided shall be of flush mounted type and of quick response for meeting the control requirements of turbine on rapid load

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Haryana Power Generation Crop. Ltd.

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

changes. The offered indicators shall have an accuracy required for such applications. d) The bidder shall be responsible for complete erection, testing and commissioning of the supervisory instrumentation. All other accessories such as power supply receiver modules, amplifiers, electronic components etc shall be installed on free standing cubicle wired to terminal blocks. Turbovisory logic cabinets containing the protection circuits of axial-shift, condenser vacuum, lube oil pressure, main steam temperature shall be provided. The protection logic shall be designed as 2 out of 3 DC energised to trip system. To accomplish this, triplicate sensors/switches shall be employed for all the parameters associated with the protection circuits. Pretrip alarms shall be provided before the action of the protection. The system shall provide all the alarm interlock/trip contacts properly wired out independently to the terminal blocks for external connection. The contacts provided for interlock, protection and alarm circuits shall have adequate making, breaking and current carrying rating for the circuits involved. Adequate number of contacts shall be provided for use in the circuits to be evolved by the instrumentation contractor. The system shall include turbine lock-out relay and turbine trip solenoid along with necessary hardware for their testing. The system provided shall have necessary self-checking circuit and it shall be possible to test/isolate any protection circuit. The protection scheme shall be furnished by the contractor for approval clearly indicating the equipment outside the scope of the contractor. The enclosure class for cabinets shall be IP-32. The logic hardware shall be housed in a totally dust and vermin proof, sheet steel vertical cabinets of free standing type to match with other panels and shall be wired to terminal blocks. The protection system shall be

e)

f)

self-contained and complete in all respects such as logic hardware, power supply equipment circuit breakers, fuses etc. g) For cabinet interconnections, maxi termim, wire techniques shall be adopted. Signal cables for connections from field devices shall be as per equipment suppliers standards. The details of the cabinets offered showing the complete details of the instruments/control devices coming on them shall be furnished and finalised during detailed engineering stage. All HT motors, fans, pumps shall be provided with vibration monitoring system. This should be for Double axis, DE & NDE side.

h)

i)

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Haryana Power Generation Crop. Ltd.

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

5.6.1.12

STEAM GENERATOR CONTROL & PROTECTION LOGIC The steam generator control & protection logic including BMS (Burner Management System) shall be implemented either in proprietary control system which contain failsafe cards or in the DDCMIS unit protection processors which shall also have failsafe cards. BMS shall not be implemented in DDCMIS if the system does not have failsafe cards. The logic shall be implemented in two trains, with each train receiving process status information through separate input cards. In addition, process status information shall be transmitted to the unit protection processors via the data highway. In case of SG, TG and Station C&I (DDCMIS) separate DCS, the DDCMIS outputs which trip the boiler shall also be from separate cards and shall be configured in a two-out-of-two de-energize to trip scheme. This configuration provides the following benefits:Failsafe protection against loss of power. Failsafe protection against DDCMIS output failure. Protection against inadvertent trips due to single train failure. On-line testing capability without isolation (test) switches. Immediate detection and annunciation of field input failures.

The steam generator shall be protected against abnormal conditions such as the following:Steam flow path not available. Operator trip push buttons.

5.6.1.13

Furnace over/under pressure. Loss of fuel; loss of flame.

STEAM TURBINE WATER INDUCTION PREVENTION (TWIP) LOGIC The turbine water induction prevention logic detects the presence of potential water admission sources, disposes of accumulated water, and isolates the turbine from the water source as required. The turbine water induction prevention logic shall be designed in accordance with ASME Standard TDP-1. 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II,

Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-23

Haryana Power Generation Crop. Ltd.


The TWIP logic serves three major functions: a) b) c) d)

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Prevents water accumulations by inhibiting the use of attemperating sprays at low loads. Prevents the carry-over of water from sources such as the boiler and deaerators. Disposes of accumulations of water in low point drains by forcing drain valves open during low load operations and prior to turbine startup. High level in heaters resulting water ingress inclusion of gland seal condenser.

The TWIP logic shall be implemented in the unit protection processors. The logic shall be implemented in two trains, with each train receiving process status information through separate input cards. In addition, process status information shall be transmitted to the unit protection processors via the data highway. The DDCMIS outputs which act to trip the steam turbine via its proprietary control system shall also be from separate cards and shall be configured in a two-out-oftwo de-energize to trip scheme. 5.6.1.14 INTERLOCK AND RUNBACK LOGIC Interlock and runback logic shall be provided to coordinate the unit response to auxiliary equipment upsets. The logic shall attempt to maintain a balance between steam production and steam consumption within the operable ranges of the equipment in service. Equipment to be considered in the development of interlock and runback logic shall include the following:Condensate pumps. Feedwater pumps. Circulating water pumps. Pulverizers. Steam turbine (load rejections). Combustion air fans. ID Fan. 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-24

Haryana Power Generation Crop. Ltd.


FD Fan. PA Fan.

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Unit trip logic shall also be provided to allow the simultaneous tripping of the steam generator and steam turbine within a unit. The interlock and runback logic shall be implemented in the unit protection processors. 5.6.1.15 INFORMATION The DDCMIS provides the real-time process parameter and equipment status information to the operators which shall be needed to supervise automatic control functions, provide process feedback during manual intervention, allow monitoring of performance trends, and simplify post mortem analysis of equipment or unit trips. Information shall be provided to the operator in several formats as follows and the bidder shall include them in his scope of work:i) ii) iii) iv) v) X-Y Plots, bar chart. All graphic formats and dynamic information to be prepared from the flow diagrams All log formats and report formats. All start-up guidance formats. System Summaries: The system shall have the capability to display/print certain summaries on operator demand. All these summaries shall be available for display on to the utility monitor and the shift supervisor's monitor as well as for print out on the utility and programmer printers. The report format will be designed to take this into account. Single Point Trend: Print/display the value of a single point at a selectable period variable from one to ten minutes.

vi)

vii)

Group Trend: Print/display the values of a selected group of inputs. There shall be available a total of 16 groups of 10 points each from the 75 equipment/system a parameter groups. Groups one through 15 shall have a fixed complement of points, while the points associated with group 16 onwards shall be selectable by the operator.

2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-25

Haryana Power Generation Crop. Ltd.

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

It shall be possible to trend any group at any one time at a selectable period from one to sixty minutes. In addition to the above, there shall be two groups of 8 points each, which will use stored data of past 60 minutes to project future trends and display/print this information. The projection period will be 10 to 30 minutes. viii) Sequential Points Print Out: Print/display once the values of a group of sequentially addressable points (in point number sequence). The operator shall have the capability to select a starting point and the end point to be printed out/displayed. Alarm Summary: Print/display all points (analog, calculated, digital) that are off-normal at the time request is made by the operator. Review of Alarm Limits, Deadbends Scan/Calculation Rates: Print/display for all points the assigned sensor, process and significant change alarm limits, dead bands, and scan/ calculation rates. The printouts/displays shall be in sequence, by point ID number. Off Scan Summary: Print/display all points (analog and digital) that are off- scan at the time the request is made by the operator. Constants Summary: Print/display of all plug-in constants (those normally used as constants and those used as substitutes for input points). Scan Period Summary: Print/display all scanned inputs by point ID number, point description, and assigned scan period. Point Quality Summary: Print/display all points with other than good quality tag by point ID number, point description and quality tag. Trend Log Summary: This summary shall list all groups covered in group trend that are ready for trending or being trended. The display/print out shall include each group identification (group header) and shall list all points associated with each group. Trend Recording Assignment: This summary shall display/print out for each recorder pens the point ID number, point description, current value, alarm limits and engineering units. The scale for each variable should also be indicated. Bar Graph Assignment Summary: Upon Operator/Programmers command, the system shall display/print out listing of Bar graph assignment identifying point ID and point description.

ix) x)

xi) xii) xiii) xiv) xv)

xvi)

xvii)

2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-26

Haryana Power Generation Crop. Ltd.


xviii) xix)

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Group Review Summary: The Group Reviews shall be available for display/print out. Reports & Logs: The system shall print logs/reports as defined in these clauses. The printing of these logs/reports shall be initiated automatically at prescribed time intervals, or initiated on demand or by the occurrence of predefined events. All logs/reports shall be made from stored data so that once a log is initiated it can be completed without interruption. Multiple logs when printed from stored data shall print consecutively without interruption. Programmed log formats shall include but not be limited to all required headings, sub-headings, and word descriptors. The exact format and printer assignments for each log will be defined by the Owner after award of contract. In addition to the logs specifically defined in these specifications, the operator shall be able to create new logs and modify existing logs and reassign them among the printers on-line. Sub-headings, column formats, point number assignments, data collection frequency, and printing intervals shall be produced via. a monitor/keyboard combination. The system shall be capable of handling upto 40 printed pages (30 lines per page and 118 characters per line minimum) of logs in addition to those specified with 10 formatted columns of data per page. These 40 pages shall be subdivided into separate logs by the operator.

xx)

Shift Report: The system shall print at the end of the shift a report which shall have two parts. The first part will include the following:a) b) c) d) e) f) g) Summary of alarms and returns to normal, indicating time and maximum/minimum value of the corresponding variables. Summary of bad inputs. Status changes. Alarm limit changes and substituted values by the operator. Deviation of system/equipment efficiencies. Accumulated data. The second part will consist of 100 points subdivided into 10 groups of 10 points each. The values shall be stored each hour and shall be cumulative, averaged or instantaneous as decided by the Owner/Consultant at a later date. The shift report shall be automatically printed at the end of each shift. It will also be simultaneously stored on magnetic tape.

h)

2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-27

Haryana Power Generation Crop. Ltd.

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Capability shall also be provided to print this report at any time on operator's demand. However the demand print out shall not eliminate the requirement to produce a shift report at end of each shift. xxi) Daily Report: The system shall print at end of each day a report in two parts. The first part shall include the following:a) b) Summary of important alarms (trip and pre-trip alarms): Equipment in service time and number of start- ups for all major equipment Daily fuel statement: The second part will consist of 100 points subdivided into 10 groups of 10 points each. The values shall be stored automatically each hour on the hour and shall be cumulative, average or instantaneous value as selected by the Owner/Consultant at a later date. The report shall be printed automatically at midnight every day and shall also be stored on magnetic tape. The capability shall also be provided to print this report on operator demand. However, this will not eliminate the requirement to produce a daily report at midnight. xxii) Other Reports: The system shall store on bulk memory at suitable time intervals for further processing data to generate the following information:a) b) c) d) e) xxiii) Normalised values of data accumulated. List of all major equipment trips sub-systemwise. Plant and major equipment availability. Fuel statement. Long term performance deterioration trends.

Turbine Run up Log: A log of up to 100 turbine and generator data points shall be collected and automatically printed at either 1, 2, 3 or 5 minutes intervals as selected by the operator. The log shall be initiated by turbine roll-off and shall remain in operation until stopped by the operator. Boiler Start-up Log: A log of upto 100 boiler data points shall be collected and automatically printed at either 3, 5 or 10 minutes intervals as selected by the operator. The log shall be initiated at the start of the boiler for purge sequence and stopped by the operator.

xxiv)

2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-28

Haryana Power Generation Crop. Ltd.

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

xxv)

Turbine and Generator Diagnostic Log: The turbine diagnostic log shall contain upto 100 turbine and generator data points to be used in analyzing possible turbine ad generator trouble. The data shall be printed out once every 24 hours at a time selected by the operator. Once the log printout is initiated, data shall be collected and printed out every minute until four sets of data have been recorded. Turbine Recall Log: The turbine recall log shall be initiated by the occurrence of any one of several alarms and shall consist of all data defined for the turbine diagnostic log. The system shall store information whenever the turbine generator is on-line. The data shall be stored in the computer memory at one minute intervals. A total of 30 minutes of data shall be stored in the memory. Following the initial 30 minutes of operation, the oldest data in the memory shall be discarded and replaced with new data. The log printout shall be initiated by preselected alarm conditions and shall continue at 1 minute intervals after initiation of the log until the alarm conditions has disappeared or until stopped by the operator. Turbine Shutdown Analysis Log: A log of upto 100 turbine data points shall be printed whenever the generator is taken off line. Data, except turbine speed, shall be collected at 2 minute intervals. Turbine speed shall be collected at 1 second intervals, for the first 5 seconds after the shutdown is initiated and at 2 minutes intervals thereafter. The log shall continue until terminated by the operator. Post Trip Analysis Log: The post trip analysis shall be provided to record operating data during the period immediately before and after a unit trip. Upto 100 boiler, turbine and generator analog variables shall be stored every 10 to 60 seconds, selectable at site ( Number of points and time zones selectable) . After the initial 5 minutes of operation, the process shall be continued with the oldest readings being replaced with the new readings. In the event of a unit trip, the post trip analysis data of the preceding 5 minutes shall be frozen in memory. The computer shall continue to read data and store data at one minute intervals for 5 minutes after the trip. The data log shall then be printed on demand.

xxvi)

xxvii)

xxviii)

xxix)

Sequence of Events Log: The computer shall also log the high resolution digital inputs with their point descriptions and event time accurate to one milli-second resolution.

2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-29

Haryana Power Generation Crop. Ltd.

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

xxx)

Maintenance Data Log: Provision shall be made for logging operating information about certain plant equipment for the purpose of scheduling preventive maintenance and routine equipment inspection. The log shall be capable of including all equipment for which an equipment status" digital input has been provided and such other equipment as shall be designated by the owner. The specific equipment included in the log shall be selected from the programmer's/engineer's terminal and shall include but not be limited to the following examples:a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) Soot blowers 6.6 KV breakers Air Compressors (Instrument air service, and air conditioning etc) ID Fan PA Fan Condensate Pumps Circulating Water pumps Auxiliary Cooling Water Pumps Bottom ash water pumps Demineralization system equipment Spray valves Pulverizers Service water system equipment FD fan BFPs ESP

2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-30

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Each item of equipment will have the following operating limits which are specified through the programmer's/ engineer's terminal:a) b) c) Maximum number of cycles or starts. Maximum number of hours of operation (may be weighted to reflect multiple speed or variable speed operation). The system shall count the number of cycles or starts and the number of hours of operation since the previous maintenance or inspection period for each item of equipment included in the log. When either of the above limits is exceeded, a log notation shall be provided with allowable time and accumulated time since the last overhaul. The maintenance data log shall be printed periodically on a daily, weekly or monthly schedule or may be printed on operator demand. The log shall indicate the data on which the previous maintenance or inspection was completed for each item of equipment, the cycles or starts and hours of operation limits, the number of cycles or starts and the number of hours of operation since the last maintenance or inspection and shall indicate whether either of the operating limits has been exceeded. After the required maintenance or inspection has been performed, a push button actuation through the prgrammer's/engineer's terminal shall remove the equipment from an alarm state and reset the cycles/starts and hours of operation counters to zero. The date on which this reset operation occurs shall be retained and included in the log as the previous maintenance or inspection.

d) e)

xxxi)

Special Logs: Several special logs shall be provided by the data distribution control system computer as follows:a) Printing of data shall maintain assigned columns. The engineer's/ programmer's terminal shall include capability to edit logs to move all data columns currently in use to adjacent locations. A log of all vibration inputs shall be made on demand. A summary log of all bad inputs shall be made on demand. A log of temperature devices including, but not limited to bearing temperatures of all 6600 volt motors, stator hot spot temperatures of 6.6 KV motors and bearing temperature of all driven equipment equipped with temperature detectors shall be made hourly.

b) c) d)

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

e)

A log shall be made to provide a record and warning of 6.6 KV motor start limits.

f)

Provisions shall be made for a test log consisting of 50 parameters obtained in a very short time span through a priority interrupt. The program shall be repetitive at the selected standard sample rate until manually halted. The test log shall be printed on the programmer's printer only.

xxxii)

Performance Log: Provision shall be made for logging upto 100 variables which can be used in unit performance calculations. This log shall be initiated and printed on demand by the operator. The log shall consist of averaged data which is accumulated over an adjustable period of time from 10 to 30 minutes. Operator Command Summary Log: The distribution control system shall have the capacity to store all operator requests for a twenty four hours period. Both the nature of the requests and the individual time of each request shall be stored. This information shall be printed automatically once each twenty four hours in the form of a summary log. The log shall also be available for printing upon operator demand.

xxxiii)

xxxiv) Long Term Historical storage and Retrieval: System shall be capable of storing data for historical purposes. It shall be possible to store all the logs including SOE logs and reports. In addition to the logs and reports described above, the historical storage shall provide for storage of status/values of analog and digital inputs. The number of points and the corresponding collection frequency is given below:Frequency 1 sec 6 sec 30 sec 60 sec No. of points 512 512 768 1280

The collected data shall be retained on historical storage device for a minimum period of one month after which the data shall be shifted to magnetic tape for long term storage.

2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-32

Haryana Power Generation Crop. Ltd.


xxxv)

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Process Graphic Displays: The process graphic displays shall provide representations of plant layouts and measurements. The information included on each display shall be matched to the expected operator objectives when selecting that display. Process information and equipment status shall be presented as dynamic text values and symbol colors. For ease of recognition, controllable equipment shall be identified on the display by a consistent means such as specially colored locator codes. Operator control action shall be effected by first selecting the equipment to be

controlled using the cursor or keyboard then initiating the desired control action utilizing the keyboard. xxxvi) Faceplate Displays: Faceplate displays consist of an intelligent grouping of manual/auto station or control switch "faceplates" associated with a given piece of equipment or process. Operator control action shall be as described above, first selecting the appropriate faceplate then initiating the desired control action. xxxvii) Bar Chart Displays: Bar chart displays consist of a grouping of vertical or horizontal dynamic bar graphs associated with a particular process. Bar charts shall provide an analog representation of process parameters for quick operator recognition. xxxviii) Trend Displays: Trend displays shall provide a dynamic graphical representation of at least four analog or digital values versus time. Trend displays shall emulate the function of ink type "strip chart" recorders. Trend displays shall provide the capability to scroll backward in time (viewing historical data) to view performance or process trends thereby assisting in troubleshooting and post mortem analysis. xxxix) X-Y Plots--X-Y plots provide the capability to plot one process variable versus another. An example of this type display shall be a generator capability curve. xl) Permissive Displays & Step Indicator: Permissive displays and step indicator shall group, into a single display, the conditions which must be met for a designated piece of equipment to be started or continue operating. The permissive display and step indicator shall be dynamic to rapidly indicate to the operator sequential start/stop or open/close and the reason a piece of equipment tripped or failed to start. A similar type of display shall be used to serve as a checklist when operating in the semiautomatic or manual startup modes.

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Haryana Power Generation Crop. Ltd.


xli)

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Operator Guidance Messages: Guidance messages shall consist of a single line of text designed to prompt the operator when specific actions are required based on Boolean logic decisions within the DDCMIS. Printed Reports and Logs: Several types of predefined logs shall be provided to maintain a printed record of operating events and operation summaries. Logs to be provided shall include post trip log, periodic logs such as shift and daily logs, tag-out summaries, performance log, startup summaries, and trend logs. The DDCMIS shall provide the capability to define additional permanent and temporary logs as required.

xlii)

The DDCMIS shall provide extensive data control software and input conditioning capabilities. A partial listing of the capabilities follows:i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv) Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-34 P, PI, PID, D, I All standard trigonometric functions. Standard steam tables. Thermocouple linearization and temperature compensation. Input quality checking. Engineering unit conversion. Input averaging, maximum and minimum, summation, difference, integration, median value selection (for analogue), two out of three logic (for digital). Elapsed time monitoring (including high-speed pulses). Square root extraction. Calculation of up to a seventh order polynomial. Standard Boolean calculations. Analog comparisons. Rate of change determination. Input smoothing (rolling average). Biasing

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xvi) xvii)

Manual loading Lead-lag compensation

In addition, the DDCMIS shall contain on-line and on-demand performance calculations to identify equipment or processes which shall be operating in an abnormal condition. 5.6.1.16 PERFORMANCE CALCULATIONS AND PLANT OPTIMIZATION a) Provisions shall be made, including all required custom programmed software, for performing the calculations described in this clause. All

calculations shall use a high level language. Calculations shall be made using floating point arithmetic. These equations shall be changeable on-line at the job site. An extensive set of steam property subroutines based on the 1967 ASME steam tables shall be included. The calculation results shall automatically be quality coded according to the worst quality of any of the inputs to each calculation. The results of these calculations shall be available, through the data base, for appropriate logs and operator displays as determined by the Owner. b) c) Calculations for monitoring the performance of the unit shall be performed. These calculations are categorized into two classes. Class I calculations include those calculations that are made every scan cycle, generally for the purpose of detecting and alarming unit malfunctions. The following class I calculations shall be included:i) ii) iii) iv) v) vi) vii) Cold reheat steam approach to saturation temperature. First stage superheat outlet temperature approach to saturation temperature. Turbine steam metal temperature differences. Turbine metal temperature rates of change. Feed water individual heater terminal temperature differences. Excess air deviation from standard. Feed water leaving each heater temperatures deviation from standard.

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viii) ix) d) e)

Drum water saturation temperature rate of change. Turbine steam supply accounting.

Metal temperature differences for SG-SH and RH region - any specific location w.r.t any specific location. Class II calculations include those calculations that are made to determine the performance of individual items of equipment and the overall unit. Class II calculations shall be performed on-line using averaged data which is accumulated over a period of time. This time period shall be selectively adjustable from 10 to 30 minutes. The system shall also collect this averaged data on magnetic tape. The operator shall be able to input coal analysis data into the computer for the class II calculations. Class-II turbine performance calculations shall comply with the recommendations of ASME Performance Test Code Report PTC 6S-1970, Simplified procedure for Routine Performance Tests of Steam Turbines. The Contractor shall be responsible for altering his standard performance programmes to comply with this specification and to conform to the cycle of these units. Boiler efficiency shall be computed by the heat loss method and the inputoutput method. Percent deviation between the two methods shall be calculated as recommended in the ASME Test Code PTC 4.1-1964, Steam Generating Units. If the test codes require measured data that is not actually available in the process, manually substituted values shall be used. The following Class II calculations shall be performed:i) ii) iii) iv) v) vi) vii) viii) Unit heat rate Turbine heat rate Boiler efficiency Feed water heater performance Air heater performance ESP performance Economizer performance Condenser performance

f)

g)

h)

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ix) x) i)

HP and IP turbine enthalpy drop efficiency LP turbine enthalpy drop efficiency (using dry exhaust)

The on-line performance calculations shall include at least the following:a) b) Steam turbine steam-metal temperature mismatch, and deep-shallow metal temperature differences. Auxiliary power deviation from normal.

j)

The on-demand performance calculations shall be in general compliance with the ASME Performance Test Codes for the steam generator, steam turbine, and other heat exchangers. The on-demand calculations shall include at least the following:-

i) ii) iii) iv) v) vi) vii) viii) k) 5.6.1.17

Unit overall heat rate. Steam turbine heat rate. Steam generator efficiency (heat loss and input-output methods). Economizer performance. Condenser performance. Steam turbine efficiency. Deaerator performance. Thermal efficiency.

Life cycle calculations for steam turbine.

PLANT OPTIMIZATION FUNCTIONS Plant optimization should include the following:a) Thermal cycle optimization. This should compute the entire turbine and regenerative cycle heat balance and simulate the plant so that operator can examine the improvements in heat rate and changing a cycle parameter.

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b) c)

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Compute the boiler efficiency and simulate boiler parameters such that operator can examine the improvements in boiler efficiency. The use of appropriate plant models to generate set points for the processor in such a way that the performance of the plant is optimized in relay time data 2 secs for graphics. This requirement is valid and applicable for the total no. of graphics specified. Boiler tube life fractions and stress calculations.

d)

The plant optimization functions shall be based on model based software. The system must compute controllable losses related to plant parameters not being maintained at their design points based on actual loads. The model must also be able to identify equipment cleanliness for various heat transfer sections within the plant. The software shall also identify what if scenarios, i.e in case the operator wants the plant parameters to be changed, the model will be executed to simulate the new requirements and display the modified plant parameters. The optimization software shall also identify the actual sequence of soot blowing so that costs of heat loss due to unclean heat transfer sections and the costs of soot blowing are minimized.

The boiler model shall be developed for the following sections:a) b) c) d) e) f) Economizer Water walls Superheaters Reheaters Airheaters Pulverizers

The radiative heat transfers, convective heat transfers and heat and mass balance equations shall be used to generate the above models. A suitable combustion model shall also be built for the boiler. The above models shall be used to generate the set point for excess air loop such that stack losses and unburnt fuel losses are minimized. For soot blowing optimization, the heat transfer coefficients in the corresponding models are set to clear values one by one. The cumulative reduction in loss is compared to the cost of soot blowing to identify which individual section should be cleared by soot blowing. 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-38

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The above model shall also be used to generate optimum condition of burner tilt and superheater and reheater spray flows. The turbine and regeneration cycle shall be modelled such that any change of boiler parameters can be examined in relation to the overall heat rate of the plant for what if-scenarios. The calculable losses should identify the losses associated with equipment degradation and those associated with non-maintenance of design parameters independently. Graphical presentation of results shall be furnished as a part of the optimization guides provided to the operator. These shall be in the form of bar charts, X-Y plots, and plant mimics. Bidder shall detail the optimization package offered with model approaches proposed to be adopted and simulation techniques envisaged. Bidder shall indicate separately the price for this package under options and not include this package price within the base price.

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Performance Requirements for DDCMIS and Control Loops

S.No.

Load Range (% of MCR)

Rate of Load change (% of MCR per minute)

Maximum deviation of parameters from Set point for Constant Throttle Pressure Mode Throttle Flue Gas Drum Furnace SH RH pressure O2 level pressure temperature temperature deviation deviations deviation (mmWCL) deviation deviation ( C) ( C) (kg/cm2) (% of O2) (mm)

A. 1. 2. B. 3. 4. 5. C. 6. 7. 8. 9.

Steady State Conditions 5 to 25% (25% to MCR) 0% 0% +1 +1 (***) +0.25%, -0-0% +15 +15 +2 +3 (**) +2 (**) +2

Ramp of Constant Load change for maximum duration of 5 minutes (25% to MCR) (25% to MCR) (25% to MCR) Step-Load Change From 65% From 65% From 80% From 100% to 5% +20% -20% +20% Fastest run back rate -3.5 +2.5 +3.5 Upto safety valve pressure +2.5%, -0.0% +2.5%, -0.0% +2.5%, -0.0% +3% +100 -100 -100 -200 +5 +5 +5 +10 8 8 8 10 8 8 8 15 +3% +5% +10% (*)+1 (*)1.5 (*)2.0 +0.5%, -0.0% +0.5%, -0.0% +1.0%, -0.0% +25 +30 +80 +3 +3 +4 +3 +3 +3.5 +3 +3 +3.5

Note:

1. (*) 2. (**) 3. (***)

pplicable for coordinated control mode within boiler steam temperature control range. Below boiler steam temperature control range. Air flow pegged at 30% of MCR flow.

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4. Maximum duration of ramp/constant load change signal will be 5 minutes. 5. Control systems limit the transient disturbances within the specified limits and shall return the controlled variables to the set points within the shortest possible time without undue hunting.

5.6.1.18 5.6.1.18.1

VISUAL ANNUNCIATION SYSTEM Hardwired alarm annunciation system in conventional luminous windows following proper ANSI/ASA sequence has been envisaged for limited number of important alarm points. Alarm Annunciation System with 480 conventional individual alarm facia windows has been envisaged (including 20% spare windows). In addition, there shall be 4 channel 40 group alarm cards (to accommodate 160 annunciation inputs). Wherever the contact is required for SOE, DDCMIS and annunciation, the same shall not be diode auctioneered. Three independent contacts shall be generated for these purposes. However, this will be decided during detailed engineering stage.

5.6.1.18.2

Visual Annunciation System shall be on the lines of guidelines and stipulations given in:a) b) Specifications and guides for the use of general purpose annunciators ISA RP 19.1 - 1979. Surge withstand capability tests - ANSI C37.90a - 1974 and IEEE std. 472-1974.

5.6.1.18.3

Standalone Visual Alarm Annunciation System shall consist of requisite electronic cabinets, marshaling cabinets,input sharing networks,remote annunciator logic cabinets with input/output logic cards, redundant power supplies, panel mounted LED box assemblies, set of operator interface devices such as push buttons & audible devices. Prefabricated FRLS interconnecting cables with connectors for signal transmission from electronic cabinets to LED windows as per actual length as required shall be provided. Requirement of annunciation system are specified on a system basis. Bidder shall be fully responsible for engineering and furnishing a fully operational system complete in all respects meeting the intent and requirements of this specification. All equipment and accessories required for completeness of the system shall be furnished by the bidder within the quoted price, whether these are specifically mentioned herein or not. 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II,

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Annunciation system offered shall be from reputed, experienced manufacturer of specified type and range of equipment whose trouble free performance has been proven. Logic cards shall be complete with contact interrogation, contact bounce filtering with typically 15 ms duration and lamp driver circuits. Drivers to lamps shall be with current limiting feature and be provided with current regulation and short circuit protection. In the case of group annunciation windows, the group alarm shall be annunciated every time any of the inputs associated with the group go into alarm status. Facility shall exist in the system to specifically identify the particular input in alarm state within the group. Group alarm card can be upto 4 channel. Visual display of alarm messages in the VAS shall be through panel mounted individual annunciation windows. The annunciator components shall be designed for 50 deg. C ambient temperature and 90 percent highest average monthly humidity. The arrangement on the panels will be decided and advised when panel layouts are finalised. Each window shall be 50 mm high and 75 mm wide and shall be provided with LEDS of high intensity. LED wired in parallel, and capable of replacement from the front. The life expectancy of these LEDs shall be minimum of 100,000 hours. Electronics Cards shall be mounted separately in cabinets. Jumper switch shall be provided on each card so as to make it suitable for NO or NC contacts. Logic cards shall preferably be single channel, however Dual channel cards shall also be acceptable. Sets of push buttons, namely, Silence, Acknowledge, Reset, System Test and Lamp Test etc. shall be provided for mounting as follows: One set for each section of supervisory control panel in main control room.

Each set shall be dedicated to number of windows approximately grouped panel section wise. The system shall be so designed that during the lamp test, the existing fault annunciation is automatically disconnected from the lamp test circuit. Also any 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-42

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

additional fault occurring during the lamp test shall automatically be isolated from the lamp test circuit & annunciated in the normal way.

5.6.1.18.4

Annunciation Sequence The sequence of annunciation for main control panels shall be as follows:Sl.No. 1. 2. 3. 4. Condition Normal Alarm Silence PB actuated Return to normal: a) b) 5. before acknowledgement after acknowledgement Slow Flash Slow Flash ON (different tone) ON (different tone) Visual OFF Fast Flash Fast Flash Audible OFF ON OFF

Alarm acknowledge: i) ii) before return to normal after return acknowledge Steady ON Slow Flash OFF ON (different tone) ON OFF Fast full operational sequence ON

6. 7. 8.

Return to abnormal Reset System Test

Fast Flash Steady ON Flash

9.

Lamp Test

--

Note: Pitch and volume of the tone generators for the audible alarms shall be adjustable. The hooters, buzzers, beacon lamps etc. shall also be provided 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-43

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above the same section. Each audible device shall be driven by separate tone generator.

Sequence of annunciation for local panels shall be as follows:Sl.No. 1. 2. 3. 4. Condition Normal Alarm Acknowledge Return to normal: a) b) 5. Test Before acknowledgement After acknowledgement Steady OFF Flash OFF OFF ON Visual OFF Flash Steady Audible OFF ON OFF

Note: Pitch & volume of audible tone shall be adjustable.

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

5.6.1.18.5

LED box assemblies LED boxes shall have removable impact polystyrene windows of snap ON type. Inscriptions shall be black lettering on white background/film inserts with character height of typically 5 mm with 16 characters per line and 4 lines per window. Window lighting shall ensure clear readability at an ambient illumination level of 500 lux. High density LEDs having minimum light intensity of 100 MCD at 20 mA shall be envisaged.

5.6.1.18.6

Logic Cabinet Panel type logic cabinet/cabinets to be furnished under this specification, shall receive cables from all contacts. This cabinet shall contain the required electronic cards. The necessary contact interrogation and contact bounce filtering to provide a delay of 15 milliseconds shall also be provided. Modular construction shall be employed. All printed circuit boards shall be of epoxy fibreglass construction. All contacts shall be gold plated. The driver circuits for LEDs shall be provided with current limiting features to protect against short circuits in the lamp circuit. Spurious alarms shall not be generated when system is switched ON. The circuit components for the individual windows shall be mounted on plug-in PCB. The PCB shall be mounted in the annunciator logic cabinets. The logic cards shall be provided with optical isolation feature for all input signals. Solid State Logic circuits shall be capable of meeting surge withstand capability in accordance with ANSI C37.90a or IEEE Standard 472-1974. The logic cabinet shall be constructed of 3 mm MS sheet. Cable entry shall be from the bottom. The logic cabinet shall be provided with anti-vibration mounting. 20% spare completely wired in slots with all internal and external cabling shall be furnished. The system shall require facility for adding additional logic cards only for these 20% spare capacity to be implemented. To utilise this expansion capacity, prefab cables with requisite connectors to windows shall also be furnished as part of the system. The packing density of the cabinet shall be such as to ensure ease of maintenance, free accessibility to cards and terminals without hindrance and temperature rise in the cabinet is restricted to less than 10 deg.C above ambient. The temperature rise shall be further limited to be safe for trouble free continued operation of the system component even under worst case condition. Bidder shall furnish the packaging details and justify the density. In the event, forced cooling of the cabinet is adopted, bidder shall equip cabinets with 100% redundant blowers/fans. Cabinets shall be adequately ventilated for the design ambient conditions. 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II,

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The flash frequencies among annunciation windows distributed in various panel sections shall be highly regulated to offer uniform flashing rate throughout the control room. The flasher module for this function shall also be uniformly distributed within the logic cabinet to approximate the finally decided window distribution in control panel sections. Generally not more than 30 points are expected to be hooked up to one flasher module. 5.6.1.18.7 Terminals and Wiring Separate terminal blocks with twenty (20) percent spare terminals shall be provided for contact input termination and power supply. Terminals for each point shall be suitable for maxitermi connection/cage clamp system. Wiring inside panels shall be of copper, 650V grade PVC insulated, flexible conductor. Both ends of wiring shall have numbered ferrules for identification. Required marshaling cabinets as may be necessary shall be envisaged. 5.6.1.18.8 Power Supplies The cabinet shall be furnished with a system of duplex receptacles fed from the UPS control power supply. Two receptacles which are accessible from the front side of the cabinet shall be furnished, and two from the rear side. The logic and other power supplies requirements shall be derived by the Contractor internally in the logic cabinets. Redundant solid-state power supplies shall be furnished for the logic levels, contact interrogation, and LED drives. The outputs of the supplies shall be short circuit proof and diode auctioneered to ensure continuity of power within the system even with one power supply failure. Bidder shall ensure that the interrogation voltage levels for Visual Annunciation System of the Distributed Digital Control System are matched. 5.6.1.19 SEQUENCE OF EVENTS RECORDER Sequence-of-events recording shall be an integral part of the DDCMIS to minimize parallel wiring of inputs, to allow integration of steam generator, STG, and balanceof-plant events into a common time base, and to provide maximum reporting flexibility. Special sequence-of-events inputs which time-tag the event at the input 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-46

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

card level shall be utilized. Depending on the DDCMIS supplier selected, the sequence-of-events function may be implemented in a "stand-alone" system if the

DDCMIS does not support SOE functions ( In case of stand alone SOE system, all the SOE points shall be available in DDCMIS and the SOE shall have redundant Processor). Sequence-of-events recording shall be limited to those conditions which can directly cause a steam generator, steam turbine, generator, and auxiliary electric system trip for which one millisecond time resolution shall be required for post trip analysis. To facilitate post-trip troubleshooting, the SER system shall be designed such that any SOE input may be selected as a trigger point. The system shall generate a SOE report recording the status changes of all SOE points following a status change of the trigger point. The recording shall stop after the trigger point reverts to the normal condition or on a command by the operator. The SER system shall be sized to accept the inputs described above and provide at least 20 percent spare capacity for future modification. Sequence-of-events Recorder shall be for 512 points including spares. 5.6.1.20 I/O TERMINATION CABINETS The I/O termination cabinets house the equipment which provides the DDCMIS interface to the process sensing equipment and process control equipment. 5.6.1.21 DISTRIBUTION PROCESSING UNIT CABINETS The distributed processing unit cabinets shall be free-standing cabinets housing the DDCMIS distributed processing units, data highway communication equipment, and power supplies. Redundant distributed processing units, data highway communication equipment, and power supplies shall be provided to maximize system reliability and mitigate the impact of component failures. Multiple cabinets shall be provided and located in the plant control equipment areas. It is anticipated that processing unit cabinets shall be located in the central equipment room, water treatment area equipment room, coal handling control equipment room, coal unloading control equipment room, compressor room and water treatment area. The construction of the distributed processing unit cabinets and the components housed within the cabinets shall be the manufacturer's standard design. The distributed processing units shall be microprocessors of similar size and capability. Each microprocessor shall be programmed with only the control logic functions required for the process control equipment assigned to be controlled by that distributed processing unit. The number of microprocessors housed within any dis2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-47

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

tributed processing unit cabinet shall be dependent on the quantity of process control and data acquisition I/O and logic dedicated to the functional equipment group being controlled and on the DDCMIS supplier selected.

The distributed processing unit cabinets shall be large enough to house the required processors, power supplies, and communication equipment with sufficient space for troubleshooting and maintenance. In addition, the size of the processor cabinets shall allow 20 percent spare space for expansion should it become necessary in the future. 5.6.1.22 DATA HIGHWAY The data highway shall provide the means of transmitting data between the various components of the DDCMIS. The data highway shall be comprised of redundant cables formed into buses or loops between the components of the DDCMIS. Each cable of the data highway pair shall be routed separately to minimize the likelihood of a single event damaging both data highways. The data highways shall be deterministic bus with minimum 10 Mbits per second speed which may be coaxial cable, twisted pairs, fiber-optic cable, or a combination of cable types. Communication between the operator stations and the functional groups of control microprocessors will be by means of redundant data highways. The system will be fully operational with one highway out of service, with no degradation in performance. The data highways will be effectively immune to the types of electrostatic and electromagnetic interference that can be expected in power plants. The bidder must state, in detail, the precautions which must be observed in installing his highway in order to minimize interference and shall also state whatever precautions must be observed to avoid ground loops due to differences in ground potential throughout the plant. For remote multiplexer units envisaged in various plant areas as detailed elsewhere, requisite electrical isolation should be provided by bidder where the data highway extends outside the station building. The protocol employed will be the vendor's standard provided that it meets the following minimum requirements:a) b) Mastership of the highway will not reside in a single device. No single failure will prevent the orderly and timely transmission of data. Check before execute will be employed for all changes in plant status transmitted over the data highway. As a minimum this will include set point

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changes, control drive bias changes, transfers between automatic and manual, changes in control drive positions, start, stop, open and close instructions. c) It shall be possible for any station on the highway to fail or to be physically removed without interrupting full communication of all other stations.

d)

Both redundant highways will operate at all times. There will be no need to "Fail Over" and initialize to a standby cable. Diagnostics to check the status of both highways will run continuously. Failure of a data highways or of one of the stations of the highway shall be alarmed and reported on an appropriate video screen display. The data highway transfer rates will be a minimum of 10 megabaud. Hot repair capability of the highway will be furnished.

e) f)

Apart from the main data highway, there shall be redundant Ethernet TCP I/P at the higher level with 1 GBps speed. 5.6.1.23 OPERATOR WORK STATIONS The operator workstations provide the normal operator interface with the DDCMIS. Using the operator work stations, the operator may control and monitor processes and equipment, view and acknowledge alarm summaries, access historical and trend data, and request or create printed logs. In addition, the operator workstations provide many of the tuning and troubleshooting functions available through the engineer's workstation. The operator workstations shall be intelligent monitor-based stations with mouse cursor control devices, data highway communications equipment, and support electronics. The operator workstations shall be located on the main control consoles in the Central Control Room, in the Water Treatment Control Room, Coal Handling Control Room, Coal Unloading Control Room, and Compressor Control Room. The intelligent monitor-based workstations shall consist of microcomputers, selfconverging, high resolution color monitors. All active information displayed on these monitor displays shall be updated once every second. System response time to an operator request for a new display shall be no longer than two seconds for displays routinely accessed. It is anticipated that multiple operator workstations shall be used for control and monitoring of the boiler, steam turbine, and balance-of-plant systems. Additional 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-49

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operator workstations shall provide monitoring as required for the stand-alone control systems (coal handling, compressor, water treatment, etc) and miscellaneous monitoring functions (trending, alarm, etc). To provide maximum operating flexibility and reliability, the operator workstations within a unit shall be identical with respect to the graphic displays, database, and keyboard assignments. This shall allow the operator to utilize any operator workstation within a unit to perform any required function. Each operator workstation shall have the capability to provide alarm summary information and serve as host to the alarm and report printers.

5.6.1.24

PROCESSOR CHARACTERISTICS As used in this specification, the word processor refers to any combination of microprocessors, associated memory data acquisition and output devices which may be configurated to perform a set of control functions. Redundant communication processors shall be provided to couple process control stations to the data highway. The processors will have the following features:a) b) c) d) e) Self monitoring and diagnostics Easy to modify control functions Redundant power supplies Word length of 32 bit as a minimum 16 MB RAM as a minimum

Means shall be provided to assure that loss of power in processor does not result in loss of powers in processor does not result in loss of memory such that it must be reconfigured on restoration of power. The system will maintain system configuration without error for power outage of at least 24 hours. Processor functional criteria: If power is lost to the processor the associated control loop/loops shall be automatically transferred to manual. Hardwired manual back-up stations will be available on backup panels for operator intervention and control with an alternative power source and no motion of the associated final control element shall result on such a transfer. This condition shall be alarmed. Transfer to manual will also take place on transmitter failure and analog input exceeding preset limits. This condition will also be suitably alarmed. 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-50

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For applications requiring accuracy level higher than available on fixed point arithmetic, floating point arithmetic will be furnished. Memory furnished will have at least 255 reserve capacity. The processors shall have the following features:i) ii) iii) iv) v) vi) Power fail/auto start Watch Dog Timer Real Time Clock Memory protection Direct memory access Time Synchronizing Clock

It shall be possible that all tuning, configuring and reconfiguring of processors shall be accomplished through monitor/KBD combination, utilizing a convenient set of displays specially designed for that purpose. The system shall include three nonvolatile bulk memory devices which can retain a record of the system configuration. These data shall be the true configuration that is actually stored in each processor. Simply listing the instructions to the file will not meet the requirements. Means shall be provided to permit the engineer to restore the configuration data to any processor from the central memory devices. Updation carried out on processors by the engineer shall automatically update non-volatile bulk memory. The detail specifications of bulk memory shall be found elsewhere in the specification. The processor shall be freely configurable and will have no restrictions on how many times a particular algorithm can be used. It shall be possible to perform both computations and logic functions within the processor file. Where processor or loop redundancy is required by the specification, the automatic back-up shall be dedicated to the specified function. Upon detection of a failure, transfer to the back-up processor will occur within one scan cycle and shall be transparent to the operator. Failure either of the processor file, or occurrence of the transfer shall be alarmed. Transfer to the back-up processor shall be done with completely solid state equipment and shall be bumpless. Electro-mechanical relays will not be permitted. Whenever the configuration or status of a back up processor is changed, the backup file will be automatically changed. 5.6.1.25 INPUT/OUTPUT MODULES

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

The analog/binary input/output modules, drive control module for close loop control/open loop control, function group control module etc shall form part of the process station. Multi-purpose input module and control module shall also be acceptable, where the input module shall accept all sorts of analog and binary inputs and control module shall perform all drive functions, group control functions and process control functions. Maximum number of inputs for analog and binary shall not be more than 16 per module. The analog input/output modules shall have high accuracy of A/D conversion, minimum 12 bits plus sign bit.

The binary input/output modules shall have high insensibility against noises, overvoltage and the disturbances. The contact interrogation voltage shall be 48V DC. The I/O modules shall have LED indication at the front for signal status indication (it is preferred). There shall be 20% spare I/O (10% modules completely wired and terminated in the cabinet and 10% in each module distributed). In case of failure of one channel from working I/O card, the redundant card will take over function of working I/O card. Analog cards shall have galvanic isolation and Digital cards shall have optical isolation. 5.6.1.26 MONITORS Alarm, utility, programmer and supervisor's monitors shall be panel mounted. monitors shall be furnished with black bezels. Control monitors shall have a fast cursor control device like a mouse. All monitor's shall be capable of displaying 128 colours. All the monitors shall have minimum of 16 MB main memory and 80 GB hard disc memory. monitor's located on the main control panel shall be of 21" nominal diagonal dimension. The monitors shall be equipped with non glare polarized glass filters to minimize glare from external lighting. All operator/utility monitors shall be equipped with non glare polarized glass filters to minimize glare from external lighting. All operator/utility monitors shall be capable of performing all the functions and high resolution graphic displays. Further it shall be capable of inter-changeability in all respect. Programming function need not be provided on utility monitor. The 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-52

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

utility monitor's shall have display resolution pixel addressability to provide graphic facility (1280 x 1024 display resolution). monitor character formations shall be 80 characters per line, with 24 lines per display. monitor's designated as "alarm" shall be capable of displaying all generating unit alarms. Alarm monitor's shall be capable of presenting alarms in any of three equally spaced horizontal regions. The selection of a display and display region shall be based upon the first two letters of the point name as designated by the owner. Alarm point name as designated by the owner. Alarm monitor character formation shall provide for 80 alarm characters per line with 24 lines per display. Character display shall be in any one of 128 colors with the alarm easily readable from a distance of four metres.

Control monitors shall be identical as utility monitors with additional feature of a cursor control device for operator interaction. The cursor control device can be a mouse. Touch screen feature should be available in control monitors. Maintenance shall be easily accomplished and convergence alignment shall be performed without removal of the unit from its mount. Radiation shall not exceed 0.5 millirods/hour for each display. Processors and all other electronics necessary to provide a complete working monitor system shall be provided. 5.6.1.27 KEYBOARDS Keyboards shall be 128 key ASCII type. Keyboards shall be of the standard typewriter configuration. The system shall permit the operator to initiate or cancel system services through the keyboard, enter information into the computer, and request information from the computer. Each keyboard shall include a keylock which, when operated, shall unlock selectable subsets of operator functions. In addition to these keyboards, the bidder shall propose his standard panel mounted sets or push buttons which will be used as an adjunct to the keyboards. the bidder shall explain the functions and adaptability of these push button panels. To enable/disable specific sections/groups of control stations in UCB. Keylock feature shall be provided adjacent to the standard function keyboard in the unit control console. The control monitors and utility monitors shall have suitable functional keyboard associated with it. The bidder shall submit the keyboard layout diagrams as part of the offer. The keyboard shall permit easy call up of displays through minimum number of key strokes and control functions as required for the system. 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-53

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Operator keyboards shall have a QWERTY style key layout for text and data entry. Operator keyboards shall have variable rate ramp keys for set-point/output changes. Keyboard shall optionally be available in a membrane style (spill proof). A multi-purpose use-configurable keyboard featuring upto 48 assignable keys shall be available to provide for dedicated display call up and provide miscellaneous discrete inputs for control of software programs. This keyboard shall have LED's for each key to annunciate high and standard priority alarms associated with the display called by that key. An audible annunciator shall also be integral to the keyboard. Key labels shall be easily changeable. 5.6.1.28 SYSTEM SOFTWARE Software to be supplied under this specification shall include but not be limited to the following to perform all the functions specified under this specification. all software shall be in ENGLISH. Software for distributed microprocessor based system shall include the following software packages:i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-54 Real time operating system. Input scanning, processing and alarm monitoring. Open and closed loop control software. Graphic utility. Communication between process modules through data bus. On line diagnostics. Man-machine communication. Input data base generation and maintenance, etc Log generator. Utilities for software development. Background executive for software development in a time sharing mode. Visual C (Fortran) or equipment compiler. Screen editor for software engineer

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

xiv) xv) xvi) xvii)

File handling utility. Library facility for object modules. On-line debugging facility for the purpose of software development. Utility of data transfer from magnetic tape to disk and vice versa in EBCDIC and ASCIT mode.

xviii) Software for communication with systems supplied by others. xix) xx) Full scale steam/water property routines conforming to ASME 1967 steam tables. Any other software as required to meet all the specification requirements.

The vendor shall have the total responsibility for the design, development and implementation of software for the I&C system. The bidder shall include in his scope of work the following:a) b) All computations for alarm cutouts, variable alarm limits. Class I and Class II performance calculations. The owner/consultant shall furnish all data/curves etc required for the above. The formulae etc will be developed by the bidder subject to the approval of the owner/ consultant.

The application software for implementing control algorithms, interlocks, generation of mimics shall be using a graphics editor and graphic tool kit and not using a programming language approach. Graphic blocks, engineering blocks etc shall be used to configure the software. 5.6.1.29 PRINTERS The printers provide a hard copy record of operating logs and reports, alarm logs, sequence-of-events logs, and miscellaneous system events. The colour laser printer shall produce a color hard copy of the image displayed on the work station monitors on request. Number and type of printers shall be as follows:a) b) Inkjet printers (1 No.) for shift supervisor room Dot Matrix printer for alarm (1 No.)

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c) d) e) Colour laser printer (4 Nos.) One colour Inkjet printer for SER (1 No.) Colour laser printer (A3) size one (1) No.

Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

The printers shall not be located in the Central Control Room but in the adjacent room. With each PLC system, printer shall be supplied and this will be located near the respective PLC e.g. Water Treatment Control Room etc. One printer shall be designated as an alarm logger, one printer as a sequence-of-events and post trip review logger, and one printer shall print scheduled and on-demand reports. The printers shall be identical and may be rotated to equalize wear if desired. Additional printers shall be provided with the engineer's work station and the vibration monitoring system as per system architectural drawing. 5.6.1.30 ENGINEERING STATION The function of the Engineering Station (ES) is to provide a means to initially programme, subsequently modify, and produce hard copy documentation of the DDCMIS control logic configurations, graphic displays, logs, reports, and databases. The ES may also serve as an operator workstation, and may be used for control loop tuning and system diagnostics. This shall mounted in computer Room. ES shall consist of a colour monitor, operator keyboard, standard (QWERTY) computer keyboard, mouse, processing unit, application software, disk drives, and printer. The ES shall have security provisions to prevent access by unauthorized personnel. The ES shall provide the capability to archive the system configurations to floppy diskettes for future retrieval. A complete ES shall be provided for each unit and shall be located in a programmer's room in the vicinity of the control equipment room. The ES shall be capable of creating DDCMIS configurations which can be directly downloaded into the distributed processors. In addition, the ES shall provide the capability to either upload configurations from the processors or verify the processor configuration against the configurations created on the ES. This capability ensures that the logic residing in the processors is an exact duplicate of the "master" configuration files and hard copy documentation. The ES shall be equipped with a laser printer to produce hard copy documentation. The printer shall be specified to accept paper sized as required to produce easily readable drawings when an entire page of configuration is printed. The printer shall have sufficient memory to allow printing the maximum paper size at not less than 300 dpi resolution. The ES shall be capable of on-line monitoring of processor configurations to assist in startup troubleshooting and shall include provisions for control loop tuning. The ES shall be specified to include complete on-line or off-line software designed to 2 x 250 MW Yamuna Nagar Thermal Power Plant Stage-II, Phase-I TURNKEY SPECIFICATION Vol. II / 5.6.1-56

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

prevent or detect inconsistencies between the processor logic, operator work station graphic displays, and databases. The ES shall provide mass storage media sized to contain the master version of all system configuration files, graphic files, and databases in uncompressed format while providing ample working file capacity. 5.6.1.31 DIAGNOSTIC STATION The diagnostic station shall assist in detection of system faults and malfunctions and faults in field inputs along with identification of their locations. It shall provide automatic display and recording of such disturbances and thereby enhance the system availability. Sensors, binary switches, transmitters, input/output processing modules, processors, peripherals and multipurpose bus communication system etc shall be fully and comprehensively monitored. Disturbance message shall be printed out on the printer attached to diagnostic station. The diagnostic station shall consist of one monitor, keyboard, mouse, processing unit, floppy drive, disk-drives, application software and printer.

The station shall have extensive diagnostic software to identify all failures upto I/O channel level as well as field inputs. This shall include failure of power supplies, I/O cards, peripherals, processors etc. The field input faults/failures shall be reported with nature and type of fault/failure clearly identified. 5.6.1.32 HISTORICAL DATA STORAGE AND RETRIEVAL SYSTEM The Historical Data Storage and Retrieval (HDSR) system shall provide a means for storage and retrieval of selected analog and digital data points, SOE alarms, logs, and operator journals from the operator work stations, the ES, or any other remote interface drop connected to the DDCMIS data highway. The HDSR system shall provide short-term nonvolatile storage for minimum one week of data and provide a means to automatically archive the data to long-term storage media. The system shall alert the operator to insert a new disk when the blank space remaining on the disk is insufficient to accept the next day's data. The HDSR system shall catalog the time period archived on CD drive to simplify retrieval of historical data. There shall be two (2) CD Writer.

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

The HDSR system shall be specified to provide the capability to export historical data to a neutral format (DOS based) to enable importing data to commercially available software packages for further manipulation and analysis. The historical data storage CD drive unit shall be provided to utilize the largest cost-effective hard disk drive having capacity of 12 GB minimum. 5.6.1.33 Redundant data links shall be provided for communication between the DDCMIS and rest of off-site PLC systems and Turbo Supervisor systems. The data links shall utilize RS-485 or similar communication means, The specific interface hardware shall be dependent on the control system. Typically a third party communication protocol such as MODBUS shall be offered. The data link hardware shall be selected to allow transmission of all required data points plus 20 percent spare points within approximately 2 seconds. The fastest reliable data transmission rate shall be utilized to minimise transmission delay and maximise the number of data points per data link (typically 19.2 K Baud). Multiple data links shall be provided if necessary to meet the above criteria. The data link layer shall utilize the Control System manufacturers standard foreign device communication hardware. The communication protocol shall be mutually agreed between the manufacturer with emphasis placed on previous relevant experience with the chosen protocol.

5.6.1.34 5.6.1.34.1

INDICATORS/RECORDERS/AMMETERS Indicators Vertical Bargraph indicators with four digital display on top or bottom of the indicator shall be provided. Single channel indicator shall be 20 nos. and dual channel 30 nos. Indicators should accept universal input signal (TC/RTD/4-20 mA, voltage) range shall be configurable and programmable with measurement accuracy +0.2% of span or +1 count. Requisite mounting accessories and mounting bins shall also be provided.

5.6.1.34.2

Recorders The recorders shall be microprocessor based, chart less.

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Vol. II: Section 5.6.1 Distributed Digital Control And Management Information System

Minimum twelve (12) nos. recorders (a) 3 Nos. 4 pen, (b) 6 Nos. 6 point, (c) 3 Nos. 12 point shall be offered. The recorders shall have accuracy of +0.2%. 5.6.1.34.3 Ammeter Taut Band type Ammeter with 0-270 display shall be provided for each HT motor. Taut Band Ammeter shall be 96x96 with flush panel mounting arrangement accuracy +1 percent, over range capacity 6 times which shall be marked in red colour for 10% of its scale and input signal shall be 4-20 mA

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