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2X660MWSUPERCRITICALTHERMALPOWERPLANT

AT
THARANGAMBADINAGAPATTINAMDIST.TAMILNADU

CONSULTANT

DEVELOPMENTCONSULTANTSPRIVATELIMITED
191,ANNASALAI,CHENNAI600006



BIDSPECIFICATIONNO.:11Z02SPCG001

MAINPLANTPACKAGE

[BOILERTURBINEGENERATOR]

VOLUME:IIE

TECHNICALSPECIFICATIONS
FOR
CONTROLANDINSTRUMENTATION


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
CONTENT DCPL-11Z02

MAINPLANTPACKAGE

[BOILERTURBINEGENERATOR]





OVERALL CONTENTS







VOLUME-I : COMMERCIAL & GENERAL CONDITIONS OF CONTRACT

VOLUME-II : TECHNICAL SPECIFICATION

VOLUME-III : BID PROPOSAL SHEETS [TECHNICAL PART]

























CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
CONTENT DCPL-11Z02


CONTENTS



VOLUME : II TECHNICAL SPECIFICATIONS


VOLUME II-A : LEAD SPECIFICATION

VOLUME II-B : SPECIFICATIONS FOR STEAM GENERATOR & AUXILIARIES

VOLUME II-C : SPECIFICATIONS FOR TURBINE-GENERATOR, AUXILIARIES &
OTHER FEED CYCLE EQUIPMENT

VOLUME II-D : SPECIFICATIONS FOR POWER CYCLE & OTHER PIPING,
VALVES & SPECIALTIES

VOLUME II-E : SPECIFICATIONS FOR CONTROLS & INSTRUMENTATION

VOLUME II-F/1 & : SPECIFICATIONS FOR ELECTRICAL EQUIPMENT &
VOLUME II-F/2 ACCESSORIES [IN TWO VOLUMES]

VOLUME II-G : SPECIFICATION FOR ELEVATORS

VOLUME II-H : SPECIFICATIONS FOR MAIN, AUXILIARY & CLOSED CIRCUIT
COOLING WATER SYSTEMS & ACCESSORIES &
MISCELLANEOUS SYSTEMS.

VOLUME II-I : FLUE GAS DESULPHURISATION (FGD)

VOLUME II-J : TENDER DRAWINGS.

































VOLUME:IIE

TECHNICALSPECIFICATIONS
FOR
CONTROLANDINSTRUMENTATION



CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
CONTENT DCPL-11Z02

CONTENTS



VOLUME : IIE TECHNICAL SPECIFICATIONS FOR CONTROL
AND INSTRUMENTATION


SECTION- I : GENERAL TECHNICAL REQUIREMENTS

SECTION-II : SCOPE OF WORK

SECTION-III : CONTROL AND INSTRUMENTATION FOR STEAM
GENERATING UNIT & AUXILIARIES

SECTION-IV : C&I FOR TURBINE GENERATOR, AUXILIARIES &
FEED CYCLE EQUIPMENT

SECTION-V : CONTROL & INSTRUMENTATION FOR PLANT
AUXILIARIES AND OFF-SITE PLANTS

SECTION-VI : TECHNICAL SPECIFICATION - INSTRUMENTS AND
SYSTEMS

SECTION-VII : STEAM AND WATER ANALYSIS SYSTEM

SECTION-VIII : ERECTION AND COMMISSIONING

SECTION-IX : LABORATORY INSTRUMENTS

SECTION-X : ELECTRICAL POWER SUPPLY SYSTEM (UPS AND
DC BATTERY AND BATTERY CHARGER)




VOLUME:IIE

SECTIONI

GENERALTECHNICALREQUIREMENTS



CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
CONTENT DCPL-11Z02



CONTENT



CLAUSE NO. DESCRIPTION PAGE NO.


1.00.00 INTENT OF SPECIFICATION V.II-E/S-I : 1

2.00.00 GENERAL PERFORMANCE REQUIREMENT V.II-E/S-I : 3

3.00.00 GENERAL DESIGN REQUIREMENTS V.II-E/S-I : 6

4.00.00 GENERAL TECHNICAL REQUIREMENTS V.II-E/S-I : 7

5.00.00 PROVEN PRODUCT V.II-E/S-I : 15

6.00.00 CODES AND STANDARDS V.II-E/S-I : 15

7.00.00 DESIGN CRITERIA V.II-E/S-I : 19

8.00.00 METERING BASES AND CHART UNITS V.II-E/S-I : 31

9.00.00 PROCESS CONNECTION & INSTRUMENT
HOOK UP V.II-E/S-I : 31

10.00.00 POWER SUPPLY SYSTEMS V.II-E/S-I : 34

11.00.00 ENVIRONMENTAL CONSIDERATIONS V.II-E/S-I : 34

12.00.00 SECURITY V.II-E/S-I : 35


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 1 DCPL-11Z02

VOLUME:IIE

SECTIONI

GENERALTECHNICALREQUIREMENTS


1.00.00 INTENTOFSPECIFICATION

1.00.01 This specification is intended to provide the technical guidelines for the fully
coordinated Control & Instrumentation system with auxiliaries and accessories for
Chettinad Power Corporation Private Limited 2x660MW STPP Tharangambadi,
Tamil Nadu. The duty of services specified below and in other drawings and
documents forming part of this specification are considered required for safe,
reliable, trouble free and efficient operation with adequate maintenance facilities
as per modern power station practice and as per terms and conditions
enumerated in this specification.

1.00.02 The technical specifications that follow serve as the guide specification for the
station C & I as well as the proprietary controls like Boiler & its integral control,
Turbine-Generator set & its integral control etc. supplied as part of equipment
packages within the contract and also various stand alone system controls to be
supplied as part of sub-packages, as in case of plant auxiliaries. Interfaces with
BOP and other external systems have also been addressed.

1.00.03 In conformity with the guidelines provided in the specification, the scope of works
shall completely cover all the control & instrumentation equipment, functions,
activities and documentation specified under the accompanying Technical
Specifications and shall not be limited to the following:

a) Detailed design and engineering of the manufactured equipment; system
integration and system engineering.
b) Complete manufacture including shop testing before shipment.
c) Specifying, procurement, quality inspection of bought-out items from sub-
suppliers. Design co-ordination for and integration with bought-out items.
d) Coordination, integration and interface between the station C&I system and
various proprietary and plant auxiliary control systems and also other
systems by Owner and BOP packages such as central load dispatch,
Demineralized Water plant, Water Pretreatment plant, Coal Handling Plant,
ETP etc. for coordinated centralized operation and monitoring.
e) Providing engineering drawings, documents, licensed copy of software and
developmental tools, data, instruction, operation and maintenance manual
etc. for Owners review/ approval / record.
f) Arranging for Owners inspection and testing of manufactured as well as
bought-out items at the respective works.

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 2 DCPL-11Z02

g) Packaging and transportation of instruments, equipment, accessories and
erection hardware from the manufacturers works to the site, including transit
insurance.
h) Opening of site office at location provided by Owner.
i) Receipt, storage, preservation of instruments, equipment and erection
hardware at the site.
j) Fabrication of site-constructed items.
k) Pre-assembly (if any), erection, testing and commissioning of all the
equipment and instruments supplied, in totality.
l) Performing availability tests and Performance and Guarantee tests.
m) Prepare and submit approved & as-built drawings and documents in hard
and soft copies.
n) Furnishing of spares, tools and tackle and test instruments.
o) Fulfilling post-commissioning liabilities.
p) Arranging for the training of Owners personnel of different categories at
manufacturers works as well as plant site.
q) Other activities detailed in subsequent sections of the Specification.
r) Any other activity, not mentioned explicitly, but felt essential by Bidder for
successful completion of work.

1.00.04 Requirements enumerated in this specification are qualitative in nature and are
based on typical configuration of the plant for the purpose of bidding. It shall be
the responsibility of Bidder to offer Control & Instrumentation system to meet the
actual functional requirements of the plant offered.

1.00.05 Integrated microprocessor based Distributed Digital Control and Management
Information System (DDCMIS) shall be supplied for unit and station monitoring
and control. The Complete operation and control of Steam Generator and its
station auxiliaries, Turbine Generator and its auxiliary station equipments, unit
equipments and also the electrical system control, monitoring, mereting and
auxiliary systems shall be carried out from DDCMIS.

In general, no conventional back up indicators & recorders, hard manual stations
and drive control pushbuttons and window annunciation are foreseen for
operation of the units, unless where need for such back-up is strongly
recommended by Bidder for the safe shutdown of the plant in case of total black
out condition of DDCMIS.

However, It may be decided to install hardwired Emergency trip push buttons for
boiler, turbine and unit at the control desk. Back up instruments for safe

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 3 DCPL-11Z02

shutdown, if any recommended, shall be installed at a vertical back up Unit
Control Panel.

Discrete Instruments and control devices related to the electrical system, as and
if required, including Generator manual synchronization stations shall be installed
on the vertical Electrical Control Panel Board.

Bidder shall furnish a list of recommended back up control & instrument devices
for Owners approval with a write up as to how the unit may be brought to safe
shut-down condition in case of DDCMIS black-out situation without damage to
plant, equipment and personnel. In general, emergency protective devices like
DC lube and seal oil pumps, air motors, hydraulic barring system etc, as offered,
shall not depend on DDCMIS for their auto-starting. Cables related to such
devices and equipment and parameters to be monitored under emergency
situations shall be of fire survival type to safely coast down the units under fire
break out situation as well. The critical annunciation windows with annunciation
logic and sequence implemented in DDCMIS shall be provided in the back-up
panel. The number of windows shall be decided during detail engineering

DDCMIS shall be adequate for plant start up, administrative and emergency
shutdown, load adjustment, load throw off and emergency handling like run
backs, run ups, run downs automatically or optionally through operators
intervention.

1.00.06 It is not the intent to completely specify the details of design and construction
features herein. Nevertheless, the instruments / equipment and their installation
shall conform to high standards of engineering design and workmanship in all
respects.

1.00.07 In case of any conflict or contradiction between any two or more sections of this
specification the more stringent condition shall generally be applicable. Owner,
however, reserves the right to relax this condition at his discretion.


2.00.00 GENERALPERFORMANCEREQUIREMENT

2.00.01 Iinstruments and control equipment shall be guaranteed to meet the
performance, functional and accuracy requirements enumerated in the
specification.

2.00.02 Instruments and control equipment shall be guaranteed against manufacturing
defect for at least one year from the date of handing over to Owner.

2.00.03 The guaranteed performance criteria shall be met in full during the guarantee
period.

2.00.04 Any predictable or planned deterioration and / or obsolescence of equipment
shall be clearly brought out in the Bid.

2.00.05 Instruments and control equipment shall be capable of maintaining the specified
performance and accuracy standard over the complete regime of operation of

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 4 DCPL-11Z02

main equipment, taking into account the excursion of parameters during
emergency or malfunction of main equipment.

2.00.06 Control & Instrumentation system shall not impose any limitation or constraint on
the operation of the main equipment. It shall be possible to utilize any in-built over
capacity in design of an equipment with complete controllability and observability.

2.00.07 The control system shall be designed to prevent abnormal swings due to loss of
control power, instrument air, failure of any system component, open/short
circuits or any other such failure or degradation in the system and shall drive the
plant and equipment to fail safe condition.

2.00.08 All modulating devices shall be in stay put condition during any of the above
failures.

2.00.09 Mean Time Between Failure (MTBF) of the instruments shall be considerably
higher than the equipment they shall cater to in order to avoid shutdown on
account of instrumentation failure.

2.00.10 Bidder shall introduce redundant control equipment or instruments wherever it is
felt that the introduction of the same may lead to reduction of downtime of plant
and equipment, in addition to the cases clearly identified in the specification.

2.00.11 In cases where continuous monitoring of performance of equipment is envisaged,
Bidder shall supply instruments of suitable accuracy class to meet the accuracy
requirements of the calculation as per ASME standard.

2.00.12 All instruments and control equipment shall ensure high reliability, low downtime
and ease of maintenance.

2.00.13 Protective systems and their safety features shall be guaranteed to ensure the
main equipment safety in the event of tripping, maloperation and malfunction.

2.00.14 The performance guarantee shall be on complete system basis as well as on the
basis of isolated, individual instrument or component.

2.00.15 Bidder shall replace all instruments failing to meet the performance stipulations of
the specification at any stage of the project.

2.00.16 All instruments / equipment shall be capable of performing satisfactorily in
continuous commercial operation conforming to all relevant codes and regulatory
requirement under the specified environmental conditions.

2.00.17 In general, equipment located in air condition environment shall be capable of
operating without any degradation of performance or damage for at least twelve
(12) hours to keep the plant in running condition in case failure of air conditioning
units. For any equipment or component that cannot conform to this requirement,
Bidder shall consider back-up packaged split type air conditioning unit/s.

2.01.00 TRIALOPERATION


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 5 DCPL-11Z02

The trial operation shall be conducted by Contractor as per the stipulation of this
specification which shall be witnessed and signed off by Owner.

2.02.00 PERFORMANCEANDGUARANTEETEST

Contractor shall perform the tests for performance and guarantee as per the
stipulations of this specification.

2.02.01 PerformanceandGuaranteeTestProcedure

A. NormalLoading&Unloading

During the test Contractor, shall bring the unit to 100% MCR load and
change the load in the range from 50% to 100% MCR typically at the rate of
() 3% and () 5% per minute or as dictated by the allowable ramping rate of
major equipment and contractually agreed, for maximum duration of 20
(twenty) minutes from unit master kept in fully automatic coordinated mode.
Observe the deviation from the set point for the parameters for excursion
limits stated in the table furnished below.

B. SuddenLoadingChanges&Runback

01) Drop 50% of maximum load capability from approximately full load at
a rate of 10% per minute or more as permitted by the main equipment.
02) Drop load from full rated output to the lowest load run-back limit upto
house load, at a rate corresponding to the fastest runback rate.
03) Pick-up 50% of the maximum load capability from approximately 50%
load at a rate of 10% per minute or more, as permitted by the main
equipment.

Contractor shall guarantee that the Control System shall be responsive and
stable and shall maintain the deviation of controlled variables from set point
within the limits specified in the attached table. Contractor shall operate the
unit fully in automatic mode with no intervention from the operator.
Contractor shall successfully demonstrate the performance of the Control
Systems as per attached table before acceptance and taking over by Owner.

NOTE : Control System shall 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 oscillation,
overshoot or undershoot.
For sliding pressure mode of operation, the performance criteria shall be
separately agreed during detail engineering.





CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 6 DCPL-11Z02




MAXIMUMDEVIATIONOFPARAMETERSFROMSETPOINT(Constant Pressure Operation)
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Steady State Condition


1. 50% to MCR (+) 0 () 2.0 () 0.5 () 5 () 5 () 8
Ramp Load Changes (For 5 Minutes)
1. 50% to MCR () 3 2
(+) 0.7
(-) 0.5
() 8 () 8 () 12
2. 50% to MCR () 5 3
(+) 1.0
(-) 0.5
() 10 ()10 () 12
Sliding Pressure Operation
1. 50% to MCR () 3 3
(+) 1.0
(-) 0.5
() 10 ()10 () 12
Step Load Changes
1. From 65% (+) 20 () 4
(+) 2.5
(-) 0.5
() 10 ()15 () 20
2. From 65% () 20 () 4
(+) 2.5
(-) 0.5
() 10 ()15 () 20
3. From 80% (+) 20 () 4
(+) 2.5
(-) 0.5
() 10 ()15 () 20
4.
From 100% to
15%
Fast Run
Back Rate
Upto Safety
Valve set
Pressure
(+) 3.0 () 10 () 15 () 60


2.03.00 TOTALSYSTEMAVAILABILITY

Bidder shall guarantee the total system availability of 99.7% by selecting suitable
components and by judicious incorporation of redundancies. The bidder shall
submit supporting documents on the system availability calculations of various
instruments items carried out by the vendors.

3.00.00 GENERALDESIGNREQUIREMENTS

3.00.01 Equipment and system shall be designed and constructed to perform accurately
and safely under the environmental and operating conditions described or implied
in this specification without undue heating, vibration, wear, corrosion.

3.00.02 Equipment and systems shall be supplied from latest model and proven product
range of reputed experienced manufacturer whose successful performance has

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 7 DCPL-11Z02

been established by a considerable record of satisfactory operation in 660MW
coal fired super critical thermal power stations. Bidder shall obtain Owners
approval for the selected manufacturers for critical items as will be identified
during execution of the Contract as Owners Hold items.

3.00.03 The equipment, systems and accessories furnished shall be designed and
constructed to meet the performance specification during the continuous service
life of the plant. Equipment or components that cannot meet this requirement
shall be identified in the offer and their expected failure rate be indicated.
Otherwise, it shall be deemed that the equipment or components are suitable for
the service life of the entire plant.

3.00.04 Bidder shall indicate the year in which the offered models of the instruments and
control system have been introduced and how long the commercial production of
the same is expected to continue. In any case, Bidder shall ensure supply of
spare parts for lifetime of the plant. In case if it is felt by Bidder that certain
equipment/components is likely to become obsolete, Bidder shall clearly bring it
to the notice of Owner and indicate step proposed to deal with such
obsolescence like maintaining bonded spares with the manufacturer/s.

3.00.05 Any part/module of the C&I system which are not listed under recommended
spares shall be deemed as having life expectancy not less than the expected life
of the plant i.e. 30 years.

3.00.06 Bidder shall supply proven latest version of hardware and software available at
the time of system designing. In case of future up-gradation of software, Bidder
shall remain committed to upgrade the supplied system at par with the new
version within the warranty period and ensure successful integration of the
system. Beyond the warranty period and during the remaining life of the plant,
any upgradation in hardware and software shall be brought to the notice of
Owner indicating whether it shall be possible to upgrade the system by partially
replacing, modifying and/or patching of hardware /software.

3.00.07 For the sake of completeness of the system and in order to ensure desired
performance & safety measures, any hardware or software item felt required,
shall be in the scope of Bidder irrespective of their explicit or implicit inclusion in
the accompanying document.

3.00.08 Technical details furnished in the accompanying documents are subject to
change in future within reasonable limits, which Bidder shall abide by.


4.00.00 GENERALTECHNICALREQUIREMENTS

4.00.01 Instrumentation and Control system design will aim at high availability, fuel
efficient performance, plant & personnel security and high level of automation
with minimum deployment of operational manpower.

4.00.02 Uniformity of make and type of instruments and control components shall be
followed throughout for rationalization of spares inventory, except for certain
proprietary items where this requirement can not be met


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 8 DCPL-11Z02

4.00.03 DDCMIS shall perform closed loop control, open loop & sequential control and
bulk data acquisition & archiving functions for the entire plant and auxiliaries in
hierarchical levels for integrated unit and station monitoring and control.

4.00.04 Suggestive Control System Architecture for the DDCMIS is schematically shown
in Drawing No.CPCPL-11Z02-DWG-I-221.

4.00.05 Transmitters and electro-pneumatic positioners shall be smart type (HART
Protocol). Each smart equipment shall communicate in the form of analog signal
4-20 mA DC with superimposed digital signal having HART Protocol to facilitate
configuration, zero adjustment, calibration and diagnostic from remote location.
4.00.06 Power supply for Transmitters, contact interrogation, interposing relay and
solenoid shall generally be ungrounded 24V D.C. Power supplies for
interrogation, relay and solenoid shall be provided from bulk power supply
modules separate from control rack power supplies. In all cases redundancy in
power modules shall be considered.
4.00.07 When more than one device utilizes the same signal, the signal source shall meet
such signal requirement and with proper isolation and without overloading. Short
circuiting or grounding of one device shall not have any perceptible influence on
any other consumer point nor shall change the transmitter calibration.
4.00.08 Final control device for regulating control shall have pneumatic actuator.
Actuators for isolating and inching duty dampers and valves shall be, in general,
electrical motor operated.
4.00.09 Electronics located outside control room areas shall be tropicalized and enclosed
in dust & weatherproof cabinets suitable for the environment.
4.00.10 Local instruments shall be provided in cases where these are required for
maintenance, commissioning and recommissioning of major equipment or for
calibration and setting of other instruments and for equipment safety. In general,
the plant operation shall not depend on local measurement or local manual
operation.
4.00.11 In general, instruments installed outdoors and in areas where these may be
exposed to splashing oil, water, steam etc. shall be mounted in closed type
enclosures. For other areas (indoor), open type racks may be used.
4.00.12 Drain from instrument rack/enclosure shall be routed to nearby plant drainage
system.
4.00.13 Temperature measurement shall have up scale / down scale drive to protect from
process upset in case of sensor failure. Both the elements of duplex temperature
sensors shall be terminated to junction boxes.
4.00.14 In general, for temperature measurements up to 300C, Platinum resistance
temperature detectors shall be used unless the area is prone to vibration. For
temperature measurement above 300C up to 1200C, Chromel-Alumel (K) type
thermocouple shall be used. For high temperature applications, noble-metal

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 9 DCPL-11Z02

thermocouple (TC) such as Pt Rh-Pt (R) type in inconel sheathed thermowell
shall be used.
4.00.15 Temperature elements shall be in sheath tube and in thermowells of suitable
material. Thermowell made of Tungsten carbide shall be used for highly abrasion
application.
4.00.16 In general, temperature transmitters shall not be used. Instead, temperature
elements shall be directly connected to their respective input modules. For non-
critical measurement applications (such as measurements for Boiler metal
temperature and Generator winding temperature) where the measurements are
not used for control / protection, sensors may be grouped and connected to
locally placed Remote IO units for onward transmittal to DDCMIS. However, for
the proprietary type of closed loop control system equipment vendor can follow
their standard.
4.00.17 In general, temperature switching function shall be configured by use of
temperature elements and software configured limit value monitors instead of
using conventional field mounted temperature switch.
4.00.18 The instruments and control equipment shall be logically grouped in electronic
cabinets in functional order for convenient fault location, troubleshooting and
maintenance.
4.00.19 Equipment and devices, which require maintenance, shall be suitably located to
ensure easy accessibility.
4.00.20 On-line automatic periodic testing, self-checking & diagnostic facility shall be
provided with fault indication for easy identification of the faulty module. The
system shall continuously check health of the component elements including the
stand-by ones and shall permit carrying out of the on-line checks while
maintaining safe condition of the plant without endangering the safety of
equipment and without influencing the process being controlled.
4.00.21 Failure of equipment used for alarm & trip purposes shall initiate alarm.
4.00.22 Automatic unadministered switchover to standby equipment (such as fan /blower
/pump) is foreseen in case of either running equipment is not adequate to
maintain the desired process condition or due to tripping of running equipment.
4.00.23 End positions of manually operated suction valves of critical pumps and all other
manual operated critical isolation valves shall be monitored & interlocked.
4.00.24 In case of HT motors, winding temperature for each stator winding and bearing
temperature of motors & driven equipment shall be monitored for abnormal rise.
4.00.25 Electrical drives rated at 30 KW or more or any critical drives of less than 30KW
shall be monitored for current, power and energy.
4.00.26 Drive shall have its local control station comprising of start and emergency stop
pushbutton and with a local & remote selection switch in SWGR/MCC (Refer
electrical volume of the specification). Local stop pushbutton shall always be

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 10 DCPL-11Z02

active. During the trial run of drives from local, safety permit and protection shall
be ensured.
4.00.27 Position transmitters shall be non contact type.
4.00.28 Process fluids shall not be piped directly in to Central Control Room (CCR) and
Control Equipment Room (CER) areas.
4.00.29 Ergonomically & aesthetically designed furniture viz. control desks & chairs shall
be provided for workstations, programming stations, PCs and various peripherals
at control room/computer room/equipment room. Furniture shall include
documentation racks, tables for laydown etc. The control room shall be
aesthetically designed and to be approved by owner.
4.00.30 KKS identification system shall be adopted consistent with the plant equipment
numbering system.

4.00.31 SteamGenerator(SG)IntegralControlandMonitoring

Steam Generator (SG) Integral Control shall be synthesized from the same family of
hardwareastheDDCMISandshallintegrateseamlessly.

Boiler protection system shall be based on triple-modular redundant
configuration(TUV Certified) in hardware & software meeting NFPA requirement.
Configuration shall be realized with three independent trip channels. Each
channel shall comprise of its own processor and input & output modules/relays.
Adequate self check and diagnostic with status report shall be available.

Secondary Air Damper (SADC), Soot Blower Control and other controls shall be
also synthesized from the same family of hardware as the DDCMIS.

4.00.32 TurboGenerator(TG)IntegralControlandMonitoring

TG control, interlock & monitoring shall be an independent control system and
shall be integrated with DDCMIS. This shall include controls and protective trips
functions like Electro Hydraulic Governor (EHG) control, Automatic Turbine Run
up System, Turbine Testing, Turbine Stress Evaluator, Turbine Protective Trip
System, Turbine supervisory Instruments, LP Bypass system and Other closed
loop & Open loop control of TG system and auxiliaries related to the integral
performance and safety. All trip and interlocking inputs shall be hardwired.

4.00.33 StationC&ISystem

This shall include the control & monitoring of all other balance non-integral
functions in SG area, TG area and other Balance of Plant equipment and
auxiliaries such as Boiler circulation water, ID fans, FD fans, PA fans, Air
preheater, Fuel oil pressurizing pumps, Boiler feed water pumps, Condensate
pumps, DM water cooling pumps, Condensate transfer pumps, Pressure reducing
& de-super heating system etc..

4.00.34 PlantAuxiliariesandOffsitePlantsControls


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In order to achieve optimum manning of the plant in terms of operating personnel,
all auxiliary and off-site units shall be monitored from the Central Control Room
with facility for limited remote operation, where recommended. Such monitoring
links are largely foreseen as Optical Fibre data hiways. Plants beyond the scope
of the package viz, water treatment plant, coal handling plant, effluent treatment
plant, shall also be linked similarly and Bidder shall create provision in DDCMIS
for such links as decided with Owner during detail engineering stage. Bidder shall
provide the required optical fiber cable, signal cable, trays and accessories as
required for the interface.

CW & ACW pumping system & Fuel oil system shall be controlled & operated
from DDCMIS unit operator workstation as well as from local operator
workstations. Remote processing units shall be provided at appropriate locations
for the purpose.

Control systems for other station auxiliaries like Condensate polishing unit and
Mill reject system shall be of PLC based with their local operator workstation and
local panel. MODBUS or Ethernet links shall be established with DDCMIS for
remote monitoring. However where limited remote operation is recommended,
hardwire signal exchange shall be established.

Instrument air and service air compressors shall have their own local proprietary
microprocessor based controls with HMI. Signal interface with the DDCMIS shall
be provided for remote monitoring and operation of compressors from central
control room. For limited remote operation like start/stop functions, hardwire
signal exchange shall be established
ESP controls shall have operator station in central control room (CCR) in addition
to their local operator station for operation & monitoring from the ESP building.

4.00.35 ElectricalDriveControlInterface

Electrical drives shall all be operated from DDCMIS. In order to segregate


different voltage levels, interposing relays shall be located at the respective Motor
Control Centers or Switch Gears.The interposing relays shall be provided driven
directly from DDCMIS. Relay contacts shall actuate the drive contactors.

4.00.36 ElectricalDistributionandManagementSystem

The purpose of the EDMS is to provide Control and Monitoring of the unit and
station in-plant Electrical Distribution System from the DDCMIS dedicated HMI
station for Electrical System.
Also the separate Energy management system is envisaged as detailed in
electrical section specification for the purpose of Energy accounting and Audit
(MEAA) as per latest CEA regulation. The Energy management system shall
collect electrical parameters data V, A, PF, MW, MWH, MVAR, F, harmonics from
all electrical meters in HT, LT switchgear and metering& relay panel. The energy
management system shall generate following reports.
Power generation report

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Power consumption report
PLF report
Single line diagram
Breaker status
Load flow
Reactive power flow.

The functionality covered in Energy management system need not be duplicated
in DDCMIS based EDMS system. EDMS shall control and monitor the electrical
distribution system. The Energy management system shall have Modbus
connectivity with DDCMIS for exchange of data as required.

The entire unit and station electrical distribution system within power house area
shall be implemented in DDCMIS system and need to be monitored and operated
from dedicted OWS of DDCMIS.

Plant Electrical Distribution system i.e. Unit Bus, Station Bus, Incoming &
Outgoing feeders, transformer feeders, bus-couplers etc. shall be operated and
monitored from DDCMIS. Trip and interlocking functions shall be hardwired at
equipment level.

The Bidder need to provide the components required for synchronization and live
bus closing with proper check relays for verification before synchronization.

MODBUS/OPC link with DDCMIS may be considered for display of data & status
from Switchyard SCADA, Numerical relays, smart switchgear, intelligent relays &
Energy metering system. Bidder shall provide the required optical fiber cable,
signal cable, trays and accessories as required for the interface.

4.00.37 InterfacewithOtherSystems

Coalbunker level measurement signals (4-20mA DC) provided by Coal Handling
Plant package supplier shall be interfaced with DDCMIS.

4.00.38 ErectionHardware

Standard engineering practice of international standard shall be adopted
throughout. All materials supplied shall be suitable for tropical, dust laden, humid
power plant environment and shall be from reputed manufacture.
Root valves shall be two for process pressure of 40 Kg/cm
2
and above and single
for process pressure less than 40 Kg/cm
2
.

4.00.39 LocalInstruments

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Required local instruments including gauge boards, level indicators etc. shall be
provided.

4.00.40 MachineConditionMonitoringSystem

Continuous monitoring and analysis of the mechanical health of rotating
equipment viz, Turbine, Generator & Exciter, BFP drive turbine & pump and all
HT motors & their driven equipment shall be performed by proven and latest
design On line Rotating Machine Condition Monitoring Systems.

Systems for Turbine Supervisory Instruments (TSI) and Vibration Monitoring
System (VMS) of HT motor & their driven equipment shall be separate.

4.00.41 CablingConcept

The instrument cable shall be of copper conductor, individual and overall
screened multi pairs cables for analog signals (4-20mA, RTD, T/C) and for digital
signals the pair cable shall be overall screened.

Binary and analog signals shall not run through the same cable. Signals of
different voltage levels shall not be routed through the same cable. The screen
shall be grounded at the control room end only.

Conductor cross section for single pair or triad signal cables shall not have
individual conductor cross section below 1.5 mm
2
and multi-pair or multi-triad
cables shall not have individual conductor cross section below 0.5 mm
2
. For
solenoid valves, depending on pick-up VA, individual conductor cross section
shall not be below 2.5 mm
2
. For interposing relay drive connection individual
conductor cross section shall not be below 1.5 mm
2
.

Bidders scope of supply of instrumentation and control cables shall include the
following:-

Bidder shall supply, lay, erect, terminate all the control, instrumentation,
interfacing (coaxial, fibre optic) etc cables when both end of equip. are in bidders
scope.

However bidder has to terminate all the cables at his equipment/panels,
irrespective of the scope of supply of cables.

a) All cables from sensors and contacts in field to the bidders local junction
boxes for field transmitters/sensors/switches etc.

b) All interconnecting cables and prefabs cables between bidders supplied
local J B, local instrument/transmitters, cabinets, panels and termination
cabinets and interconnecting cables between Bidders panels to equipment /
instruments/ Plant Control Room/MCC. All field J Bs / all field
instruments/Drives to/from DDCMIS cabinets in CER/ PLC cabinets/Relay
cabinets.

c) All cables interconnecting computers and peripherals.


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d) All co-axial cables/fibre optic cables and any other special cables for
interfacing with other packages via soft link (covering all packages
irrespective of scope).

e) T/C Extension cables and field instrumentation cables.

f) Interfacing cables (Coaxial, fibre optic etc) between owner supplied PLC
systems to DDCMIS.

g) Interfacing cables required for control, monitoring, DAS etc of the systems,
equipments.

h) All power cables required for UPS & 24 V DC system for battery,
ACDB/DCDB & consumer loads.

i) All Instrument signals cables shall be paired cables.

j) All others cables not included above however required for completeness,
commissioning and operation of plant.

The quantity of the above types of cables shall be estimated by the Bidder based
on his experience with similar capacity of plant.

Any shortfall in cable quantity during actual laying at site shall be compensated
by the Bidder at no extra cost to the owner

Preferred types of cables for different applications have been specified in this
section. Bidder shall supply the specified type of cable on as required basis for
different cabling and interconnection work, provided the same meet the
requirements of Bidders I&C application. Bidder shall clearly bring out the
shortcomings of the particular type of cable specified and shall quote for superior
type of cable.

Cable quantities included shall be specified in the offer, class wise and pair-wise.
Any shortfall in cable quantity observed during detailed engineering or actual
laying shall be compensated by the Contractor by suitable additional cable
quantity at no extra cost.

All spare contacts/terminals on relays, control switches, limit switches or similar
devices , dupex RTDs & Duplex T/Cs shall be wired to accessible terminal blocks
for Owner's future connections. All wiring leaving a junction box or enclosure
shall leave from terminal blocks and not from devices in the enclosure.

The required quantities of cable accessories shall be similarly estimated on the
basis of number of terminations and proposed routing of the cables and shall be
included in the offer allowing a positive allowance of at least 30% for each
accessory. The exact quantity of different accessories shall be specified in the
offer. Any shortfall in the quantity of accessories observed during actual laying
shall be compensated at no extra cost.




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5.00.00 PROVENPRODUCT

5.00.01 The offered model of DDCMIS must have been successfully supplied, erected,
tested and commissioned as complete station Control & Instrumentation system
for at least two units of capacity not less than 600 MW Supercritical Thermal
Power Station(s) with reheat type pulverized coal fired boiler. Further, these units
should be in successful operation for a minimum period of two (2) years.
5.00.02 Similarly, all other C&I equipment / systems / sub-systems / instruments and
accessories in the power cycle shall also be of make and model whose
guaranteed and trouble-free performance has been proven at least for two (2)
years in not less than two (2) different reheat type pulverized coal fired units of
unit size not less than 500 MW.
5.00.03 Bidder shall furnish required information to fully satisfy Owner regarding
successful operation and high reliability of products / systems furnished.


6.00.00 CODESANDSTANDARDS

6.00.01 Items such as thermowells, control valves, flow elements and other in line
devices in high and medium pressure steam, feed water and similar services,
which fall under the purview of Indian Boiler Regulation Act shall be either
certified by IBR or shall be certified by authorities acceptable to IBR. It shall be
responsibility of Bidder to obtain the necessary approval of the concerned
Authority / Chief Inspector of Boilers for the design and design calculations,
manufacturing and erection procedure as called for under the IBR Act for all items
requiring such certification.

6.00.02 Generally, the following latest edition of codes and standards such as ASTM,
ANSI, ASME, IEEE, NEMA, NFPA/EC etc prevailing at the time of award of
contract shall be applicable. Bidder to follow rlevent codes and to the approval of
the owner.

1) TemperatureMeasurement

a) Instrument and apparatus for temperature measurement - ASME PTC
19.3 (1974).
b) Temperature Measurement - Thermocouples - ANSI - MC 96.1 - 1982.
c) Temperature Measurement by electrical resistance thermometers - IS:
2806
d) Thermometer-element-Platinum resistance - IS: 2848 / DIN 43760.

2) PressureMeasurement

a) Instrument and apparatus for pressure measurement - ASME PTC
19.2 (1964).
b) Bourdon tube pressure and vacuum gauges - IS: 3624/1996.

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3) FlowMeasurement

a) Instruments and apparatus for flow measurement - ASME PTC 19.5
(1972) Interim supplement, Part-II
b) Measurements of fluid flow in closed conduit - BS 1042.

4) ElectronicMeasuringInstrumentsandControlHardware

a) Automatic null balancing electrical measuring instruments -ANSI C
39.4 (Rev. 1973), IS 9319
b) Safety requirements for electrical and electronic measuring and
controlling instrumentation - ANSI C 39.5 / 1974.
c) Compatibility of analog signals for electronic industrial process
instruments - ISA-S 50.1: ANSI MC 12.1 / 1975.
d) Dynamic response testing of process control instrumentation - ANSI
MC 4.1 (1975) - ISA -S26 (1968).
e) Surge withstand capability (SWC) tests - ANSI C 37.90A (1989), IEC-
255.4.
f) Printed circuit boards - IPC TM-650, IEC 326C.
g) General requirements and tests for printed wiring boards - IS-7405
(Part-I)/1973.
h) Edge socket connectors - IEC 130-11.
i) Requirements and methods of testing of wire wrap terminations--DIN
41611 Part-2.
j) Dimensions of attachment plugs and receptacles- ANSI C73-
1973.(Supplement ANSI C73a 1980)

5) InstrumentSwitchesandContacts

a) Contact Rating - AC services NEMA ICS Part-2 125, A-600
b) Contact Rating - DC services NEMA ICS Part-2 125, N-600

6) Enclosures

a) Enclosures for Industrial Controls and SystemsNEMA ICS-6-110.15
through 110.22

b) Racks, panels and associated equipment -EIA: RS-310-B-1983 (ANSI
C83.9 - 1972).

7) Apparatus,EnclosuresandInstallationPracticesinHazardousArea

a) Classification of hazardous area - NEMA Article 500, Volume-6, 1978.

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b) Electrical Instruments in hazardous dust locations - ISA-RP 12.11.
c) Intrinsically safe apparatus - NFPA Article 493 Volume-4 1978.
d) Purged and pressurized enclosure for electrical equipment in
hazardous location - NFPA Article 496 Volume-4, 1978.

8) SamplingSystem

a) Stainless Steel material of tubing and valves, for sampling system -
ASTM A 269-79 GRTO-316.
b) Submerged helical coil heat exchangers for sample coolers -- ASTM
D11-98.

9) Annunciators

a) Specifications and guides for the use of general-purpose annunciators
- ISA RP 18.1.
b) Surge withstand capability tests -ANSI C37.90 a -1971 and IEEE
Standard 472-1974.


10) Interlocks,Protections

a) Relays and relay system associated with electric power apparatus -
IEEE Standards 3.13.
b) Surge withstand capability tests - ANSI C37.90 a - 1971 and IEEE
Standard 472-1974.
c) General requirements and tests for switching devices for control and
auxiliary circuits including contactor relays - IS-6875 (Part-I)/1973.
d) Turbine water damage prevention - ASME-TDP-1-1980.
e) Boiler safety interlocks - NFPA Section 85B, 85D, 85E, 85F, 85G.

11) UPSSystem

a) Practice and requirements for semi-conductor power rectifiers - ANSI
C34.2.
b) Relays and relay systems associated with electrical power apparatus
IEEE Standard - 3.13.
c) Surge withstand capability tests - ANSI C 70.90 A/1971, IEC-255.4.
d) Recommended practice for sizing large lead storage batteries for
generating stations and sub-stations - -IEEE-485.

12) ControlValves

a) Control valve sizing (Incompressible fluids) - ISA-S39.2 / 1972.

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b) Control valve sizing (Compressible fluids) - ISA-S39.4 / 1972.
c) Control Valve seat leakage ANSI / FCI 70.2
d) Face to face dimensions of Control Valves - ANSI B16.10
e) Control Valve Capacity Test Procedure ISA S75.02

13) InstrumentTubing

The material code for instrument tubingshall be as relevant as in latest
industrial norms.

a) Seamless Carbon Steel Pipe - ASTM-A-106.
b) Forged carbon steel fittings - ASTM-A-105.
c) Dimensions of fittings - ANSI-B16.11.
d) Code for pressure piping, welding, hydrostatic testing - ANSI-B 31.1.
e) Nomenclature for instrument tube fittings - ISA-RP 42.1 / 1982.
f) Seamless Stainless Steel Tube ASTM A-213 TP 316 / ASTM A-269
TP 316
g) Seamless Alloy Steel Pipe ASTM A 335 P22
h) Seamless Stainless Steel Pipe ASTM A-312 TP 316

14) Cables

a) Thermocouple extension wires / cables - ANSI MC96.1.
b) Insulated Wire and Cable for the Transmission and Distribution of
Electrical Energy-IPCEA S-61-402
c) Guide for design and installation of cable system in power generating
station (insulation, jacket materials) -IEEE Standard 422.
d) Requirements of vertical tray flame test - IEEE 383
e) Standard specification for tinned soft or annealed copper wire for
electrical purpose - ASTM B33.

15) ElectronicCards,SubassembliesandComponents

a) Unpackaged
i) Vibration : IEC-68.2.6
ii) Shock : IEC-68.2.27
iii) Drop & Topple : IEC-68.2.31


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b) Packaged

Vibration, Drop & Static Compression - NSTA.

c) ElectromagneticCompatibility

i) Electrical Fast Transient : IEC-801.4
ii) Surge Withstand : IEC-255.4
iii) Radiated Electromagnetic Field : IEC-801.3
iv) Electrostatic Discharge : IEC-801.2
v) Electromagnetic Emissions : VDE 0871, Class-B

16) CableTrays,Conduits

a) Guide for the design and installation of cable system in power
generating station (cable trays, support systems, conduits)- IEEE
Standard 422, NEMA VE-1, NEC-1981. Test Standards NEMA VE-1-
1979.

b) Galvanizing of carbon steel cable trays - ASTM A-386.


17) Optical Fibre Cable

a) Mono Mode Fibre ITU-T G.652

b) OFC Cable IEEE 1138-94 / IEC 1089 / TIA / EIA-455-B.


7.00.00 DESIGNCRITERIA

This section lays down the general design criteria to be adapted in designing the
instrumentation and control system of the plant.

7.01.00 GENERALREQUIREMENTS

7.01.01 Instrumentation, control and automation devices and accessories shall be
designed with the following considerations:
a) Stable in spite of temperature fluctuations.
b) Able to withstand high humidity.
c) Weather proof.
d) Dust proof.
e) Corrosion resistant.
f) Erosion resistant.

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g) Able to withstand high vibration.
h) Easily accessible for operation & maintenance.

7.01.02 Parts subject to high pressure, temperature or other severe duty shall be of
materials and construction suitable for the service conditions and long operating
life.

7.01.03 Components of instruments, control devices, accessories, piping etc. which
contact steam, condensate or boiler feed water shall be manufactured from
copper-free materials.


7.02.00 INSTRUMENTACCURACY,STANDARDSCALESANDRANGES

7.02.01 InstrumentAccuracy

Instruments shall meet the following general requirements.

a) Pressure measurement shall be linear with respect to the measured
pressure.

b) Flow meter shall meet the specified accuracy criteria when operating
between 25 and 100 % of full-scale flow. The accuracy shall include the
effect of errors in the differential head measuring device, square root
converter and signal generator.

c) Level measurement shall be linear with respect to the measured level based
on a water specific gravity of 1.00.

d) Wherever the measured parameter is influenced by process pressure &
temperature, required compressibility correction shall be introduced.
Following compensation ranges shall generally be applied.





SL.
NO.
MEASUREMENT
TEMPERATURE
RANGEDEG.C
PRESSURERANGE
KG/CM
2

1. Feed Water Flow 100 to 300 50 to 300


2. Secondary Air Flow 0 to 400
3. Individual Coal Mill
Primary Air Flow
0 to 200

4. Main Steam Flow 200 to 600 50 to 300


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e) Temperature compensation shall produce corrections over a flow range from
10 percent to 100 percent of maximum flow subject to a plus or minus
tolerance of one-half of one percent of the maximum flow.


7.02.02 InstrumentScaleDisplays

a) All displays shall be in engineering units. Instrument scales displayed on
screen will have graduations with scale divisions based on multiples of 10.
The smallest division shall preferably be a whole number approximately 1%
of the scale range if not otherwise impracticable.

b) Pressure instrument shall have the unit suffixed with a or g to indicate
absolute or gauge pressure, respectively.

c) Scales and charts of all instruments shall have linear graduations

7.02.03 InstrumentRanges

Instrument range shall be selected to have the normal reading, preferably
between 50% and 70% of full scale for linear parameters and 70% to 80% for
flow measurements. Deviation indicators shall have the null position at mid scale.
The normal operating parameter shall be identified with a clear green mark.


7.03.00 OPERABILITY&MAINTAINABILITY

7.03.01 The system shall be designed such that any single-failure should not lead to loss
of availability of the plant, alteration in operating routine or degradation of
performance. This shall be achieved by judicious introduction of redundancy at all
critical levels. The plant operator remains totally transparent to single-failures.

7.03.02 Bidder shall ensure proper operability and also take into account protections to
minimize accidental maloperations.

7.03.03 The choice of hardware shall take into account sound maintainability principles
and techniques and shall not be limited to the following:

a) Standardization of parts.
b) Minimum use for special tools.
c) Modular and hot replacement.
d) Logical grouping of functions.
e) Separate and non-interactive adjustability.
f) Malfunction identification facility through self-diagnostics.
g) Easy removal, replacement and repair.
h) Easy assembly and disassembly.

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i) Fool-proof design to preclude improper mounting and installation.
j) Redundancy of critical parts.
k) Unique process equipment vis a vis hardware identifiability by assigning
sub-racks / sub-rack sections to specific plant areas.

7.03.04 Intercommunications in between sub-racks and system termination cabinets and
in between sub racks and other panels shall be made by prefabricated
connectors and cables with mechanical latch.

7.03.05 Adequate test facility shall be incorporated in the design.

7.03.06 The removal and replacement of various modules like I/O modules in DDCMIS
and PLC system shall be feasible on line for maintanence.

7.04.00 ESTABLISHEDRELIABILITY&AVAILABILITY

7.04.01 The target reliability of each component/module shall be established by taking
into consideration its Mean time between failure (MTBF) and Mean time to repair
(MTTR), so that availability of the complete system is assured for 99.7%.

7.04.02 In order to establish the target reliability Bidder shall perform necessary
availability tests and burn-in tests for major systems. Surge protection for solid
state systems, selection of proper materials, manufacturing processes, quality
controlled components and parts, adequate derating of electronic components
and parts shall be ensured to meet the reliability and life expectancy goals.

7.04.03 Continuous self-checking features shall be incorporated in system design with
automatic transfer to healthy/redundant circuits to enhance the reliability of the
complete system.

7.05.00 SECURITYANDFAILUREPHILOSOPHY
7.05.01 General

It is essential that interlock, protection, supervision and automatic control systems
shall have high integrity. Control & instrumentation system shall meet the
following requirements:
a) No single failure shall cause failure of the control.
b) No single fault shall cause the protection system to operate spuriously or
cause the protection system to become inoperative.
c) Grouping of the control functions into system blocks shall be such that
failure of any one block will only partly degrade the overall system.
d) Control system shall be structured with redundancy so that no single failure
within the control system can cause the failure of plant on duty and at the
same time cause the standby plant to be unavailable.
e) Due to control system failure if a final control element or plant item does not
respond then the control element shall go into a fail safe status.

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f) Field wiring for contact interrogation or device control shall be protected
such that a fault on the cable does not cause loss of more than a minimum
tolerable functionality of the system.

7.05.02 Measurement&ChannelRedundancy

To meet the failure and self checking criteria for the control system, measurement
redundancy shall be provided for all the critical parameters. Throughout the
control system, the security and validity of signals are to be ensured based on the
following design principles.
a) Where a plant measurement is to be duplicated or triplicated such signals
shall be separately fed to the different input modules.
b) Signals, after due security and validity checking by means of voting,
averaging, median, difference monitoring or similar technique shall be used
for control functions.
c) Where duplicated measurements are used, provision shall be there for
selecting any one as the duty signal. Continuous monitoring of difference
between the signals shall be made.
d) For protection purposes, multi channel measurement shall be provided
incorporating either 2 out of 3, 2 out of 2 with fail safe design or 1 out of 2
trip action.
e) Signals shall be verifed against cable failure.

7.05.03 Redundancyininput/outputmodules

1. a) Redundancy in input / output modules for close loop control systems,
open loop control system, protection, interlocking and sequential control
shall be provided as follows:

i) Wherever redundant sensors are employed in CLCS each sensor
shall be wired to a separate input module so that even if one input
module fails, the parameter will be available from the other input
module.

ii) If only one sensor is provided for CLCS control then redundant
input cards shall be provided and wired accordingly.

iii) Redundant output card shall be provided for the signals from
CLCS going to final drive control elements.

b) As regards redundancy for drive control functions the following
philosophy may be adopted.

i) For open loop control system iniput/output I/O modules for
realizing drive control functions redundancy in input / output and
processing modules shall be envisaged for HT drives and critical

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LT drives (approx. 20 nos.) For FSSS and Turbine Trip system
Refer relevant section elsewhere.

In addition to above, 20% wired input/output spare channel should be
provided for each I/O modules.

2. Bidder to note that All I/O cards shall be sourced from their original Principals
works.

3. The system shall be provided with extensive diagnostic features so that a
system failure can be diagnosed down to the module level giving location and
nature of fault. Ease of maintenance and trouble shooting shall be a primary
consideration in equipment selection.

4. The system shall provide inherently safe operation under all plant
disturbances and component failures so that under no circumstances safety
of the plant personnel nor equipment is jeopardised. The DDCMIS hardware
shall be suitably sized to ensure that the implemented scheme meets the
desired requirements. The Bidder through detailed calculations shall establish
the adequacy of the system selected and demonstrate the same during shop
testing and site testing.

7.05.04 DatahighwayRedundancy

There shall be Redundancy in the system for high reliability of communication. The
redundant buses shall work continuously. All communication modules, bus couplers,
bus interfaces etc. shall also be hot redundant.

Communication between the operator station and the functional groups of control
microprocessors shall be by means of hot redundant data highways. Redundancy
failure shall also be indicated in operating station.

7.05.05 RedundancyforPowersupplyunit

All power supply feeders from UPS (in parallel mode having 50% load sharing) or 24 V
DC system (in parallel mode having 50% load sharing) shall be redundant with auto
changeover in each ACDB/DCDB panel.

7.06.00 DESIGNOFENCLOSURES

7.06.01 Design of outdoor enclosures shall be weather proof, dust-tight, drip-proof and
shall take into account the environmental conditions.
7.06.02 Enclosures shall be adequately sized so that the maximum permissible
temperature rise above 50
O
C ambient is 10
O
C (maximum).
7.06.03 Enclosures design shall also take into account greatest possible personnel
safety.

7.07.00 ELECTRICALNOISECONTROL

7.07.01 Equipment furnished by Bidder shall incorporate necessary techniques to
eliminate problems caused by electrical noise interferences and power line borne

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surges encountered in power plant environment. Equipment, which are
vulnerable to electrical noise interference or surge shall be suitably immunized to
eliminate possible problems.

7.07.02 Bidder shall be responsible for implementation of the shielding, input balancing,
ripple filtration and grounding for field inputs to achieve installation with minimum
noise coupling.

7.07.03 Radiated immunity test shall be in accordance to IEC 801.3.

7.08.00 SURGEPROTECTIONFORSOLIDSTATEEQUIPMENT

7.08.01 All solid-state equipment shall be able to withstand the surges inherent in a
powerhouse environment. Equipment shall be designed to successfully withstand
surges without damage to components and/or wiring on application of surge
wave whose shape and characteristics are defined in ANSI publication C37.90-a
(IEEE-472-1974) entitled "Guide for Surge Withstand Capability (SWC) Tests".

7.08.02 To immunize the system against surge, coupling free wheeling diodes, surge
suppressors, opto / galvanic isolators shall be used as required.

7.09.00 BURNINANDELEVATEDTEMPERATURETEST

Solid-state equipment / system shall be certified to be tested for a minimum
period of 168 hours continuously under power.Solid-state logic systems shall be
subject to the elevated temperature test and burn-in test as complete assemblies.

7.09.01 ElevatedTemperatureTest

a) During the first 48 hours the ambient temperature shall be maintained at 50
O
C and the equipment shall be made to repeatedly perform operations it will
be expected to perform in service with loads on various components being
equal to those which will be experienced in actual service.

b) The 48 hours test period shall be continuous but shall be divided into four
12-hour segments. The power supply voltage during each 12 hours segment
shall be nominal voltage for 11 hours; followed by 110 percent of nominal
voltage for 30 minutes; followed by 90 percent of nominal voltage for 30
minutes.

c) During the elevated temperature test the cubicle doors shall be kept closed
and inside temperature in the zone of highest heat dissipating component
/module shall be monitored. Temperature rise inside the cubicle should not
exceed 10 Deg.C above the ambient temperature of 50 Deg.C.

7.09.02 Burn in Test

The 48 hours elevated temperature test shall be followed by 120 hours of burn in
test at normal operating temperature. This test shall also be conducted as per
above procedure.



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VOL-II-E-SEC-I - 26 DCPL-11Z02

7.10.00 PANELS,CUBICLESANDENCLOSURES

7.10.01 General

a) All panels, cubicles and enclosures shall be furnished complete with integral
piping, internal wiring, convenience outlets, internal lighting, grounding,
ventilation, space heating, vibration isolating pads and other accessories.
b) Unless otherwise specified cable entry for panels / desks / cabinets shall be
through bottom via glanding plate. Fireproof seal shall be used to seal the
bottom to prevent entry of dust.
c) Panels and cabinets shall be constructed from steel sheet reinforced as
required to provide true surface and adequate support for devices mounted
thereon. Thickness of the steel plate shall conform to the requirements of UL
50 or equivalent standard. Panels and cabinets shall be of adequate
strength to support mounted components during shipment and to support a
concentrated load of 100 Kilograms on their top after erection.
d) Panel /cabinet shall have eyebolt on top for lifting.

7.10.02 SurfacePreparationandPainting

Sheet metal exterior steel surfaces shall be sand blasted, ground smooth and
painted as specified below:

a) Suitable filler shall be applied to all pits, blemishes and voids in the surface.
The filler shall be sanded so that surfaces are level and flat; corners are
smooth and even. Exposed raw metal edges shall be ground burr-free. The
entire surface shall be blast clean to remove rust and scale. Oil, grease and
salts etc. shall be removed from by one or more solvent cleaning methods
prior to blasting.

b) Two spray coats of epoxy primer surfacer shall be applied to all exterior and
interior surfaces, each coat of primer surfacer shall be of dry film thickness
of 1.5 mil. A minimum of two spray coats of final finish color (Catalyzed
epoxy or polyurethane) shall be applied to all surface of dry film thickness
2.0 Mil. The finish colors for exterior and interior surfaces shall conform to
the following shades:
i) Exterior RAL 7032.
ii) Interior - Brilliant White.

c) Paint films, which show sags, cheeks, blisters, teardrops, fat edges or other
painting imperfections shall not be acceptable.

7.10.03 Wiring

Wiring within the panels shall conform to NEC standards and shall be factory
installed and tested at the works. All interior wiring shall be installed neatly.
Features shall not be limited to the following :


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 27 DCPL-11Z02

a) All spare contacts of relays, switches and push buttons shall be wired up to
the terminal blocks.

b) Each wire shall be identified at both ends with wire designation as per
approved wiring diagram. Heat shrinkable type ferrules with indelible
computerized print shall be used with cross- identification.

c) Wire termination shall be made with insulated sleeve and crimping type lugs.
All external connections shall be made with one wire per terminal. Wire shall
not be spliced or tapped between terminals. Open-ended terminal lugs shall
not be used.

d) Internal wiring should be terminated uniformly on one side of the terminal
block leaving the other side available for termination of outgoing cables.

e) Thermocouple lead wires, analyzer measuring lead wires, or any other lead
wires carrying measuring signal of the order of low milli volt or micro volt
shall be electrically and physically isolated from other AC and DC wiring.

f) All low-level signal cables shall be separately bundled from control cable.

g) Wires shall be dressed and run in troughs with clamp-on type covers.
Wirings shall be neatly bunched in groups by non-metallic cleats or bands.
Each group shall be adequately supported along its run to prevent sagging
or strain on termination.

h) Shield wires shall be terminated on separately.

i) Common connections shall be limited to two wires per terminal.

j) Wiring to door mounted devices shall be provided with multi-strand wires of
(49 strands minimum) adequate loop lengths of hinge-wire so that multiple
door openings will not cause fatigue to the conductor.

k) Wiring shall be arranged to enable instruments or devices to be removed
and/or serviced without disturbing the wiring. No wire shall be routed across
the face or rear of any device in a manner, which will impede the opening of
covers or obstruct access to leads, terminals or devices.

l) Panel internal wiring shall follow distinct color-coding to segregate different
voltage levels viz. 24V DC, 48V, 110V AC, 240V AC, 220V DC etc.

m) Panels /cabinets /desks shall be provided with removable gasketted cable
gland plates and cable glands. Split type grommets shall be used for prefab
cables.

n) Wire shall be multistranded annealed flexible high purity copper conductor
with heat resistant FRLS PVC insulation and shall pass vertical flame test
per IPCEAS-1981.

o) Wire sizes used for internal wiring shall not be lower than the followings :

i) Control wiring : 1.5 Sq.mm
(switches, pushbuttons etc.)

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VOL-II-E-SEC-I - 28 DCPL-11Z02


ii) Power supply/receptacle : 2.5 sq. mm or higher as per load.
/illumination wiring

iii) 4-20mA DC current : 0.5 Sq. mm
and low voltage signal
upto 48V DC

p) Identification of conductors shall be done by insulation color-coding
identified on drawings or by printed wiring lists.

7.10.04 Grounding

a) System cabinet AC and DC ground shall be electrically isolated from each
other and also electrically isolated from the Instrumentation signal ground.
All the above ground shall be individually connected to the single point on
the ground pit. Dedicated redundant earth pit shall be provided which shall
be away from the HV equipment. This earth pit shall not be shared with
other electrical equipment ground and shall also be insulated from other
electrical system ground to ensure single point grounding of the system.
Grounding resistance shall be better than 1.0 ohm. IEEE guideline shall be
followed while designing the grounding system.

b) Panels and cabinets shall be provided with a continuous tinned copper
ground bus bar of minimum 25 mm x 6 mm cross section, extending along
the entire length of the panel / desk / cabinet assembly. The ground bus
shall be bolted to the panel structure and effectively ground the entire
structure.

c) The panel /desk /enclosure /J B ground shall have two (2) bolt drilling with GI
bolts and nuts at each end to connect to GI/ copper flat ground riser by
means of insulated copper ground cable of required cross section with lug.

d) Circuits requiring grounding shall be individually and directly connected to
the panel ground bus.

e) For electronic system cabinets, the electronic system ground bus shall be
similar but insulated from the cabinet and shall be separately connected to
the system ground. Signal cable shields shall be grounded at the panel end
only and shall not be left open. The ground in between panels of a shipping
section shall be firmly looped.

f) Electrical meters, relays, transmitters and switching devices, operating at a
voltage less than 50V may be grounded through the steel structure.

7.10.05 Panel/Cabinet/Desk/EnclosuresEnvironmentalProtections

a) Panels, cabinets, desks, distribution boxes, junction boxes, terminal boxes
and all other field mounted equipment / enclosures shall suit the
environmental condition of the area and shall not be inferior than the
requirement indicated in the following table.


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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 29 DCPL-11Z02

SL.
NO.
LOCATION ENCLOSURETYPE
1.
Indoor type non- ventilated
enclosure in non-hazardous area
IP-54
2.
Indoor type ventilated enclosure in
non-hazardous area
IP -42
3. Enclosure in Air conditioned area
IP-22 with suitable canopy at
top to prevent ingress of
dripping water.
4.
Outdoor type in non-hazardous
areas
IP-55
6. Outdoor in hazardous areas
As per requirements of the
NEC Code for the location

b) The construction of electrical enclosures located in areas subject to
conditions classified in the National Electrical Code (NEC) as hazardous
shall be of a type designated suitable for the environment in which they are
located.

7.10.06 TerminalBlocks

a) Terminals shall be chromated galvanized DIN rail mounted screwless cage
clamp type. Terminals shall have screwed connection for conductor cross-
section above 2.5 mm
2
. Terminal blocks shall conform to IEC 947-7-1.

b) The characteristics of the terminal blocks shall be as follows.
i) High contact force, independent of conductor cross-section and large
contact surface area.
ii) Self-loosening protection.
iii) Resistant to thermal aging and vibration.
iv) Low and constant voltage drop

c) Tension spring shall be made of high quality, non-rusting, acid-resistant
steel. The current bar shall be of tin-lead plated copper or brass.

d) Terminals shall be of non flammable suitable thermoplastic material such as
polyamide.

e) Terminal blocks shall be mounted vertically in panels and cubicles with
clearance for at least 100 mm between two sets and between wall and
terminal block.

f) Terminal blocks shall be provided with white marking strips / self-adhesive
marker cards. Power terminals shall have protection covers.


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 30 DCPL-11Z02

g) At least 10 percent spare unwired terminals shall be provided for all panels
/cabinets /desks /junction box etc.. This shall be in addition to 20% spare
wired terminals of spare IO channels and 10% wired spare modules.

h) Bottom of the terminal block shall be at least 200 mm above the cable gland
plate for bottom entry type panels.

i) For extending 24 V DC supply to panels, the size of the terminals shall be
decided based on voltage drop and not based on current.

j) Other requirements of the terminal blocks are as follows:

i) The last block in a rail-mounted assembly shall be closed with an end
plate and end bracket.
ii) For visual and electrical separation of terminal groups, partition plates
shall be provided, which can be push fitted after forming an assembly.
iii) Design shall permit testing of incoming and outgoing signals by using
suitable test plug and socket without disconnecting the cable
connections.
iv) It shall be possible to use jumper plugs through the test plug socket to
connect adjacent terminals.
v) Where more than one connection to a terminal block is required, two
tier terminals shall be used.
vi) Terminal blocks shall be of different colors depending on voltage levels.


7.10.07 NameplatesandLabels

a) Each item shall have permanently attached to it, in a prominent position, a
rating plate of non-corrosive material upon which is to be engraved the
manufacturer's name, equipment, type / model number, range, serial
number, together with details of the loading conditions under which the item
of plant in question has been designed to operate.
b) Such nameplates or labels are to be of white non-hygroscopic material with
engraved black lettering, or alternatively of transparent plastic material with
suitably colored lettering engraved on the back.
c) The nameplates shall be held by self-tapping screws. The size of nameplate
shall be approximately 20 mm x 75 mm for equipment and 40 mm x 150 mm
for the panels.
d) Items of plant such as valves, which are subject to handling, are to be
provided with an engraved chromium plated nameplate or label with
engraving filled with enamel, suitably mounted or affixed with strong
rustproof chain.
e) All such nameplates, instruction plates, lubrication charts etc. shall be with
English inscriptions.


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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 31 DCPL-11Z02


8.00.00 METERINGBASESANDCHARTUNITS

The following system of units shall be followed for various displays and scales
unless otherwise mentioned:

i) Pressure : Kg/cm
2

ii) Differential Pressure : mm of H
2
O column / Kg/cm
2

iii) Draught : mm of H
2
O column
iv) Vacuum : Kg/cm
2
(abs)/mm of Hg column
v) Temperature : Degree Celsius (
O
C)
vi) Flow (Steam, Water) : Tonnes / hr, M
3
/Hr
vii) Flow (Oil) : M
3
/ Hr, Litter/Hr
viii) Flow Air : Tonnes / hr / M
3
/ Hr.
ix) Density : gms / c.c.
x) Level : Mm /%
xi) Conductivity : Siemens / cm
xii) Gas Analyzer : Percentage by weight or as
specified in respective case.
xiii) Dissolved Oxygen /
Silica / Sodium
: ppm /ppb


9.00.00 PROCESSCONNECTION&INSTRUMENTHOOKUP

9.00.01 Instrument connection to the process system (piping, vessel etc.) shall be
according to the process & piping specification upto and including the root valves.
Root valves shall be installed as close as possible to the piping or vessel.

9.00.02 Each instrument shall have its own independent connection to the process except
for instruments located on standpipe. Each instrument shall be connected
independently to the standpipe through isolation valve.

9.00.03 Isolation and blowdown drain valves adequate for duty and capable of
withstanding continuous design condition of main process shall be provided.
Instrument blow down valve near to the instrument shall be of gradual opening
type. For process pressure equal or above 40 kg/ sq.cm double blowdown valves
shall be used connecting to blowdown header. Instrument manifold / gauge valve
shall be installed close to the instrument.

9.00.04 The nominal size of the takeoff connections on line shall not be less than NPS
for source conditions not in excess of either 900 psi or 425
O
C and NPS (for
adequate physical strength) for design conditions exceed either of these limits.

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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 32 DCPL-11Z02

Where the size of the main is smaller than the limits given above, the takeoff
connections shall not be less than the size of the main line.

9.00.05 Process connection for instruments lines and vessels shall be in accordance to
standards such as ASME or other recognized international standards. Table
below indicates the type of connection generally to be used.

INSTRUMENTS EQUIPMENT/PIPESIDE INSTRUMENTSIDE
Level Instruments
Internal Displacer 4 - Flanged 4 - Flanged
External Displacer 2 - Flanged 2 - Flanged
Level gauge -Flanged - Flanged
DP Type
(min.)-welded
1 welded for vessel like HP
heaters, LP heaters, De-
aerator etc. application
- NPT
External cage Level
switch
1- welded 1- welded
Flow Instruments
DP Type
- welded in general
1 welded for high pressure /
temperature main steam,
feed water, PRDS etc.
application
- NPT
Pressure Instruments
Conventional
(min.)-welded
1- welded for high pressure/
temperature main steam,
feed water, PRDS etc.
application
- NPT
Diaphragm type-HFO
application
NPT NPT

Temperature Instruments
Thermowell
Generally - M 33 X2 (M)

1 Flanged- For air/FG path
application
NPT


Analyzer
Liquid analyzer
- 1 - welded




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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 33 DCPL-11Z02

9.00.06 Size of impulse pipe for pressure measurement in air and flue gas duct path of
boiler shall not be less than NB.

9.00.07 Separate stubs and take-off points with thermo well / root vlves shall be provided
for performance guarantee test.

9.00.08 Impulse pipes shall be clamped at suitable interval not exceeding 1.5 meter.
Process pipe shall not be used for supporting the impulse pipe.

9.00.09 Fittings shall conform to ANSI B 16.11. Threads of piping component shall be of
tapered construction.

9.00.10 Instrument blowdown header shall in no case be lower than the material grade
ASTM A 106 Gr. C.

9.00.11 Impulse pipe shall be laid at least with slope of gradient 1:10 to avoid any air
pocket or water accumulation.

9.00.12 Expansion loop shall be provided at least at every 2.5 meter interval without
affecting the gradient of slope in long run impulse pipe to avoid stress on the
piping.

9.00.13 Siphon shall be provided in the impulse pipe or tube to protect the instruments
where fluid temperature is 100
O
C or more.

9.00.14 Orientation of tappings shall be as follows :

a) For liquid service within 45
O
at lower half of the pipe horizontal plane.
b) For gas service within 90
O
at upper half of the pipe horizontal plane.
c) For steam service within 45
O
at upper half of the pipe horizontal plane.
As a rule tap orientation of high and low pressure side should be parallel and
symmetrical.
9.00.15 Pressure & Differential pressure instruments in steam and liquid services shall be
located below the taps and the piping shall be sloped to avoid formation of air
pocket.

9.00.16 Pressure & Differential pressure instruments in air and flue gas service shall be
located above the taps and the piping shall be sloped back to process to avoid
formation of any liquid.

9.00.17 Impulse pipe including taps for furnace, flue gas and coal mill application shall be
provided with air purge connection. Differential instruments for such application
shall have continuous and as well as intermittent purging. Whereas, pressure
measurement shall have only intermittent purging.

9.00.18 Material of impulse pipe for the instruments mounted on rack and enclosure shall
be same as that of main process pipe except stainless steel tube of Gr. 316H or
better shall be provided for connection in between impulse pipe (from tee
connection on impulse pipe) and instrument manifold valve & instruments.

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 34 DCPL-11Z02

Impulse pipe, tubes, fittings and accessories shall have the same design
pressure and temperature applicable for the related main pipe.


10.00.00 POWERSUPPLYSYSTEMS

10.00.01 Instrumentation power supply system shall include all conditioning equipment
required to accommodate normal variations in the electrical supply. All panels
and cabinets shall accept redundant power feeds from two different sources.

10.00.02 The power supply systems envisaged for the various C&I system ,DDCMIS, HMI
shall be from 240 AC redundant UPS system as detailed in Vol II E, Section X

UPS system shall be used for Man Machine Interface, Peripherals and Interface
Stations of DDCMIS and other I&C systems such as panel instruments, field
instruments requiring 240V AC, SWAS, Microprocessor based control (Viz.
gravimetric feeder and air compressor), Chimney emission monitoring
instruments, CCTV and other microprocessor based instruments etc. The UPS
shall comprise of 2 set of static type converters, Auto/Monual changeover and
inverters each capable of supplying 100% load connected in parallel. The battery
bank for the system should be 100% capacity batteries. The battery sizing shall
be such that each battery shall supply the load of one hour in case of mains or
charger failure. UPS should be designed to sustain 100% more than full load for
more than one minute.

The other voltage level and DC power supply required for DDCMIS system
cabinets for DDCMIS controllers (OLCS/CLCS/DAS), Boiler protection, Turbine
EHG control and Turbine protection including Turbine Supervisory Instruments
and other controllers under BTG shall be provided by the bidder and the power
supplies are to be fed from UPS system..

11.00.00 ENVIRONMENTALCONSIDERATIONS

11.01.00 I&C components should operate properly with no degradation in expected lifetime
or in operation parameter in the normal power plant environment. C&I system
shall be designed considering all the operating conditions which may be
encountered during installation and operation.

11.02.00 TEMPERATURE
11.02.01 Where the environmental extreme exceeds the capabilities of the selected
system, Bidder should take appropriate steps to control the environment.

11.03.00 HUMIDITY

I&C system shall be designed to withstand the humidity limits specified for the
project. Condensation shall not be allowed to form in the cabinets nor should
water be allowed to be admitted through conduit entering the cabinets from top or
sides.

11.04.00 ATMOSPHERICCONTAMINATION

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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-I - 35 DCPL-11Z02


Particulate contamination from fly ash and coal dust and gaseous contaminants
such as SO
2
and other flue gas constituents in the coal fired plant are foreseen.
This hazard shall be taken into design considerations.

11.05.00 VIBRATION

Design of the systems shall include features such as locking devices, anti
vibration pads etc, to withstand vibration. In general, I&C equipment shall be
installed away from the vibration zone.

11.06.00 LIGHTNING

Protection against lightning shall be considered by providing proper grounding,
metal oxide varistors, spark gap lightning arrestor, optical isolator and isolation
transformer.


12.00.00 SECURITY

12.00.01 Door lock shall be provided in all Panels, Cabinets and Enclosures.

12.00.02 System mode key switch or password to prevent tampering of system program.

12.00.03 Redundant elements of the system shall not be exposed to the common hazards.
For example routing of the redundant network cable through separate cable
raceway, using separate cabinet / separate rack for redundant controller and
redundant IO modules.





VOLUME : II-E

SECTION-II

SCOPE OF WORK


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
CONTENT DCPL-11Z02





CONTENT



CLAUSE NO. DESCRIPTION PAGE NO.


1.00.00 SCOPE V.IIE-S-II : 1

2.00.00 SCOPE OF SERVICES V.IIE-S-II : 8





CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-II - 1 DCPL-11Z02


VOLUME : II-E

SECTIONII

SCOPE OF WORK



1.00.00 SCOPE

1.00.01 This section describes Control & Instrumentation equipment, material and
services to be provided for 2 x 660 MW coal fired supercritical boilers &
auxiliaries, steam turbine - generating units & auxiliaries and plant auxiliaries of
the CPCPL 2x660MW STTP Main Plant package.

1.00.02 Bidder shall provide material, equipment & services specified or otherwise
required within the scope boundary to fulfill the intent of specification and to
integrate into a fully functional Instrumentation and Control system ensuring
operability, maintainability and reliability described in this specification.

1.01.00 SCOPE OF SUPPLY

The scope of supply shall include but shall not be limited to the following within
the scope boundary:

1.01.01 Field instruments and sensors for remote measurement viz. smart transmitters,
thermocouple, RTD, process switches, converters, analyzers etc. with all
accessories.

1.01.02 Primary flow elements along with branch pipes, root valves, nipples, flanges,
nuts, bolts, gaskets and accessories.

1.01.03 Pneumatic,motorized and hydraulically operated valves and dampers along with
actuators, smart positioners, limit & torque switches, handwheels, solenoid
valves, position transmitters and accessories.

1.01.04 Thermocouple extension cables, Instrumentation pair, triad & core cable,
instrumentation power cable, optical fiber cable, special cable as required.

1.01.05 Control panel, panel instruments, accessories and furniture, as required.


1.01.06 Boiler integral instrumentation related to Master fuel trip (MFT), BMS, SADC,
Soot blower control system, Flame Scanner Cabinets, Coal feeder control,
Electromatic safety valve, Acoustic furnace Temperature Measurement system,
Furnace temperature probe, Automatic steam leak Detection System, Boiler
Flame Monitoring System (FMS) T.V.

1.01.07 Turbine Generator integral control & instruments including Turbine Supervisory
Instruments (TSI) with decision support system.

1.01.08 Integrated Distributed Digital Control & Management Information System
(DDCMIS) for closed loop control, open loop control, sequence control and bulk

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-II - 2 DCPL-11Z02

data acquisition system for steam generator & its auxiliaries, turbine generator &
its auxiliaries, station C&I, electrical distribution system and other auxiliary
systems, complete with operators work stations, historical storage units, alarm &
sequence of event recording, advanced control system, servers & gateways,
management information system, intelligent field device maintenance terminals,
engineering & diagnostic terminal, required highway & interconnecting cables and
devices, interposing relays for signal exchange with electrical system, peripherals
including printers etc. and links for interface with third party systems with all
associated software.

Proposed DDCMIS control system architecture is illustrated in drawing no.:
11Z02-DWG-I-0010.

1.01.09 Isolation, conversion and distribution of UPS, DC and non-UPS Power supply to
all instruments, panels, consoles, etc.

1.01.10 Complete Steam and Water Analysis System (SWAS).

1.01.11 24V DC battery & battery charger and Uninterruptible Power Supply (UPS)
Systems for powering DDCMIS and PLC based Plant auxiliaries controls. Other
power supply systems at voltage levels, as required. Refer section X for detail
specification.

1.01.12 a) Local Panels, Gauge Boards and Transmitter Racks, stanchions, brackets
etc.
b) Local instruments e.g.- pressure gauges, temperature gauges, level
switches, flow gauges, flow switches, level gauges etc. with all accessories.
c) Bearing temperature sensors for pumps, motors or other equipment driven
by H.T. motors and drive turbines and as necessary.
d) All HT motors winding temperature monitoring sensor duplex RTDs
(PT-100).
e) Conductivity type Level Switches for steam line (such as CRH line) drain
pots based on TDP guidelines for automatic operation of drains.
f) External chamber guided radar type or smart displacer type level
transmitters cum switches for vessels in vacuum, open channels and oil
tanks.
g) Temperature elements at up stream & down stream of Heat Exchanger and
Coolers. DP gauge & switch to check fouling condition of Heat exchangers
and strainers.
h) Remote I/O multiplexers for bulk data acquisition of superheaters, reheater,
evaporator (cage), air heater and separator metal temperatures, Generator
stator winding & bearing temperature & exciter bearing temperature.
i) Closed Circuit Television system for monitoring and surveillance.

1.01.13 Process connection and piping materials including impulse pipes of different
grades & stainless steel tubes, stub, bosses, root valves, isolation & drain valves,

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-II - 3 DCPL-11Z02

valve manifolds, gauge valves, condensate pot, fittings, stands, brackets etc. as
applicable, for satisfactory installation of all field instruments and analyzers.

1.01.14 Pneumatic tubing along with fittings and isolating cocks for air consumers.

1.01.15 a) Erection hardware including junction boxes, canopies, structural steel
items viz steel angles, channels, flats.
b) Complete cable accessories viz, flexible conduits, sub-trays/perforated
trays, pull boxes, inspection covers, bends, elbows, mounting brackets,
clamps, nuts and bolts, glands, lugs, ferrules, connectors, markers, tray
supports, rigid conduits, tie wraps etc.
c) Complete optical fiber cable /special cables with accessories like optical
fiber distribution box, patch cord / pigtail, converter, terminators, taps,
heavy duty conduits etc. to make the system complete in all respect.
d) Rating plates, Nameplates and Labels.

1.01.16 Optical Time Domain Reflectometer and splicing kit for optical fiber cable testing
& maintenance.

1.01.17 Maintenance, calibration, commissioning, site testing and troubleshooting
equipment.


1.01.18 02 (Two) nos. of each type of hand held configurators for Smart Transmitters per
unit.

1.01.19 Supply of all start-up, commissioning and recommended spares in addition to the
mandatory spares.

1.01.20 Complete flue gas analyzers including Continuous Emission Monitoring System
instruments.

1.01.21 Minimum of four (04) Large Video Screens terminals of about 67 size per unit

1.01.22 GPS based Master Clock system with slave clocks and free ports for
synchronization of off-site equipment.

1.01.23 Plant view & Management Information System server and terminals as soft client
for MIS function.

1.01.24 Fiber optic cable and accessories including tray /conduit for system data network
and for data collection from BOP package suppliers such as Coal Handling Plant,
Mill Reject System, AHP, Demineralization Plant, fuel oil unloadind plant, ETP
and Pre Treatment Plant through MODBUS,Ethernet or OPC connectivity.

1.01.25 Machine condition monitoring system for all HT drives & their driven equipment
and TDBFP & Turbine including all monitors, servers with on line decision support
system and required cabinets, cable including optic fiber /special cable &
accessories for each unit.

1.01.26 Plant performance analysis, diagnostic & optimization system through advanced
control algorithm including fuzzy logic (PADO).

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1.01.27 Arranging all performance test instruments and equipment.

1.01.28 Supply of complete control and monitoring systems for plant auxiliaries including
PLC system, micro controller and field instruments with DDCMIS connectivity.

1.01.29 Instrument control panels including back up panel and Electrical control panel.

1.01.30 Furnance Flame Monitor T.V

1.01.31 HART Manegement System.

1.01.32 Performing tests on the equipment as per Quality Plan prior to shipment.

1.01.33 Complete set of laboratory instruments as detailed out in section IX


1.02.00 SOFTWARE

Bidder shall be responsible for software licensing, design, development,
debugging, system engineering, customizing, installation, site modification,
tuning, adjustments, commissioning and furnishing manuals, documentation etc.

1.03.00 DRAWINGS AND DOCUMENTS

1.03.01 Bidder shall furnish system description, operational write-up, bill of materials,
drawings, data, information, technical catalogues, test certificates and other
details to establish the provenness, capability and performance of the equipment
and systems offered.

1.03.02 Document to be submitted with the Bid shall not be limited to the following :

a) DDCMIS architecture with write up explaining SG control, TG control,
Station C&I, Electrical distribution & management system and in-plant
auxiliary controls.
b) GPS system write up with configuration / scheme
c) Technical features / write up of critical items including critical valves
indicating make, model.
d) Proposed General Arrangement of Control panels and Desks.
e) Brief description of Type and Routine tests proposed to be carried out at
shop and at site and write-up on the in-house quality assurance practice.
f) List of reference of similar system in service with performance record.
g) Details of training of Owners personnel specifying duration of each course,
number and category of personnel proposed to be trained in each course,
location etc.
h) Data/information as per Bid Proposal Sheets (Technical Part).
i) Details of post-commissioning services.
j) Organizational structure of the company and proposed site organization.
k) Write up and scheme for UPS system.

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l) Write-up on acoustic furnace temperature measurement and acoustic
steam leak detection system.
m) Write up on Plant performance calculation analysis and optimization
system including advanced control features proposed.
n) Write up on computerized maintenance & inventory management system.
o) Write up on LAN Network
p) Write-up on CCTV system including architecture.
q) Furnalce Flame Monitor T.V.
r) Write-up and specification of machine condition monitoring system.

s) Write-up on Management Information System & plant-wide Network.

t) Write up on Steam water analysis system.

u) Deviation list, if any.

v) All other schemes, data, drawing, document required to establish product
quality and completeness of supply.

1.03.03 Submission of Drawings and Documents by Contractor

On award of Contract, successful Bidder shall submit progressively, drawings and
documents in multiple copies for approval of Owner at different stages of the
Contract. Contractor shall obtain Owners approval in writing and manufacture the
equipment as per these approved drawings and documents. Contractor shall
revise the drawings in line with Owners comments and resubmit till approval is
accorded. After award of the Contract, Owner in association with Contractor will
draw up a list of drawings, document/ deliverables with corresponding submission
schedule and will assign review status of either A (for approval) or I (for
information) to each deliverable. The drawing and document should be submitted
in Laser print in white paper (No Ammonia print acceptable). The drawing should
be only in good English Language. The documents in soft form also to be
submitted. The drawings & documents shall not be limited to the following.

1.





Write up on various schemes viz. acoustic steam leak
detection, furnace temperature measurement,
FSS/BMS Flame T.V., soot blower system, EHG, SG &
TG Protection, ERV,

:





I





2.
.

Write up on Overall plant start up/shutdown sequence
of different process areas, HP&LP Bypass, Co-ordinate
Master Control etc.

:


I

3.
Write up and DBR for various BTG and other system
scheme for Steam/FW/A&F and schedule of instruments : I
4. Write up on Plant performance calculation. : I

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5. General arrangement drawings of desk, panels, various
equipment, components/ sub-assemblies.
: A
6. DDCMIS & PLC system architecture drawings with
write up.
: A
7. Controller partitioning diagram /document. : A
8. Scheme drawing of SWAS : A
9. Layout drawings viz. control rooms, equipment room,
SWAS room, auxiliary plants etc.
: A
10. Schedule of instruments : I
11. Specification & Data sheet for Instruments & devices. : Spec.- A
Data sheet- I
12. Drive control philosophy & interface diagram with write
up
: A
13. Analog & Binary Drive list : I
14. Cable block schematic diagram. : A
15. Specification and Data sheet of cables : Spec.- A
Data sheet- I
16. Specification and Data sheet of junction box : Spec.- A
Data sheet- I
17. Specification, Sizing calculation of control valve & data
sheet
: Spec.- A
Data sheet- I
18. Sizing calculation of flow element & data sheet : I
19. Specification and Data sheet of Temperature element &
gauges with sizing calculation of thermo well.
: Spec.- A
Data sheet- I
20. Closed loop control schemes & write up : I
21. Open loop control schemes & write up : I
21. Sensor grouping in racks : I
22. Instrument hook up drawings : A
23. Analog & Binary IO list : I
24. Schedule of alarms : I
25. Sequence of events (SOE) schedule : I
26. Schedule of logs and display : I

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VOL-II-E-SEC-II - 7 DCPL-11Z02

27. Plant schematic display : I
28. Cable schedules : Reference
29. Wiring & Interconnection diagram. : I
30. Product catalogues : Reference
31. General arrangement drawing of Instrument racks with
data sheet
: I
32. CCTV scheme drawing, specification & data sheet : Schm. &
Spec.- A
Data sheet- I
33. Data sheet for HART Management Scheme : A
34. Data sheet for GPS master clock : A
35. Data sheet for LVS : A
36. Scheme & data sheet for TSI & VMS : A
37. MIS scheme including plant wide network. : A
38. Layout drawing of unit control room showing
arrangement of LVS, Panels, Control desk etc.
: A
39. Grounding schemes : A
40. Performance calculation, diagnostic analysis &
optimization
I
41. I&C Power distribution schemes : A


1.03.04 Final Drawings

a) Contractor shall secure approval on the design drawings from Owner for
the drawings identified as category A, in writing. Any manufacture done
prior to approval of the drawings shall be rectified in accordance with the
approved drawings by Contractor at his own cost and the equipment shall
be supplied within the stipulated period.

b) Contractor shall furnish final drawings and documents in multiple hard and
soft copies. Contractor shall furnish instruction manuals containing various
components, sub-assemblies, method of installation, check-ups and tests
to be carried out during erection and commissioning of the equipment. The
manual shall also include instruction for step checking, trouble shooting
and fault rectification for different components and sub-assemblies.

c) Contractor shall incorporate all modifications in the drawings carried out at
site during trial run, start-up performance and guarantee tests till hand over

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VOL-II-E-SEC-II - 8 DCPL-11Z02

of the units to Owner and submit these final as-built drawings both in hard
and soft copy.

d) Final documents shall be submitted in proper bounded form. All catalogs
and literature (including sub-suppliers catalogs), datasheets, Instrument
list, input output list, function control diagram, loop diagrams, configuration
diagram etc. shall be bounded together in indexed volumes. All O&M
manuals shall be in handy size and neatly bound for carrying it to the work
place.


2.00.00 SCOPE OF SERVICES

2.01.00 ENGINEERING AND OTHER SERVICES

Bidder shall refer Lead Specification and Conditions of Contract for scope of
services, in general.

2.01.01 Supply of spare parts for at least 30 years after commissioning of the plant shall be
provided by Bidder.

2.01.02 Participation of Bidder's personnel and experts as well as experts from their
collaborator in discussion with Owner/ Consultant and other equipment Vendors
during various stages of contract implementation as required by Owner to achieve
desired C&I system configuration and performance.

2.02.00 ERECTION

2.02.01 Scope of Erection

In general all items supplied by Bidder shall be erected by Bidder. Sound
engineering practice of international standard shall be adopted throughout. Scope
of works shall not be limited to the following:

a) Installation of equipment, system, control room panels, desks, cabinets,
junction boxes, instruments, gadgets and other accessories supplied as per
this specification.
b) Cable interconnection amongst different panels/cubicle/field instruments etc.
c) Installation of field mounted instruments and devices including primary
elements along with impulse pipe laying and wiring etc. Installation of
thermowells at the stubs provided at the tapping points.
d) Installation of all transmitter racks & enclosure, cubicles, brackets, laying of
impulse pipes and cable termination etc.
e) Hook up of pneumatic tubes and interconnection between air supply point
and all accessories of final control element as required.
f) Laying of all cables including erection of sub-trays, G.I. conduits along with
accessories, termination and ferruling at both ends of all cables laid.
g) Termination & testing / checking of cable.

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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-II - 9 DCPL-11Z02

h) Supply of the erection hardware, consumables, tools and tackle, test
instruments and deployment of experienced personnel needed for
completing the erection.
i) Painting of site mounted structures and impulse lines after completion of
erection.
j) Providing a tentative programme of manufacture, erection, testing and
commissioning.
k) Erection activities shall comply with stipulated project schedule.

2.03.00 SCOPE OF TESTING, CALIBRATION & COMMISSIONING

Scope of works shall not be limited to the following:

2.03.01 Testing /calibration /configuring /software development, loading, commissioning
of instruments and systems supplied by Bidder as per the guidelines laid down in
the specification.

2.03.02 Setting up of site instrument laboratory equipped with testing equipment for running
and maintenance of the plant and instruments needed to carryout the testing,
calibration and commissioning.

2.03.03 Site modifications shall be documented and issued to Owner as design change
notification and shall be signed by Owner. Subsequently, all such approved and
agreed changes shall be incorporated in relevant design documents to elevate all
documents to As Built status


2.04.00 COMMERCIAL OPERATION, PERFORMANCE LIABILITIES, GUARANTEES

Major services to be rendered by Bidder on this account shall not be limited to the
following:
2.04.01 Trial operation, performing performance guarantee test, control system
performance and system availability test, interfacing and co-ordination with other
agencies, as indicated in relevant clauses of specification.
2.04.02 Satisfactory operation of the entire instrumentation and control system at varying
loads within the capacity of the unit after commissioning for one month without
disturbing any setting or adjustments whatsoever during the period. During this
period, maintenance and supervision shall be in the scope of Bidder. Any defect or
deficiency noted during this period shall be rectified by Bidder at no extra cost.






VOLUME : II-E

SECTION-III

CONTROL AND INSTRUMENTATION
FOR
STEAM GENERATING UNIT & AUXILIARIES



CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
CONTENT DCPL-11Z02





CONTENT



CLAUSE NO. DESCRIPTION PAGE NO.


1.00.00 INTENT OF SPECIFICATION V.II-E/S-III : 1

2.00.00 GENERAL REQUIREMENTS V.II-E/S-III : 1

3.00.00 BURNER MANAGEMENT SYSTEM V.II-E/S-III : 5

4.00.00 SOOT BLOWING CONTROL SYSTEM V.II-E/S-III : 6

5.00.00 SECONDARY AIR DAMPER CONTROL V.II-E/S-III : 7

6.00.00 BOILER EQUIPMENT V.II-E/S-III : 7

7.00.00 CONTROLS V.II-E/S-III : 10

8.00.00 CHEMICAL FEED SYSTEM V.II-E/S-III : 11

9.00.00 FLUE GAS ANALYZERS V.II-E/S-III : 11



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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-III - 1 DCPL-11Z02

VOLUME : II-E

SECTION-III

CONTROL AND INSTRUMENTATION
FOR
STEAM GENERATING UNIT & AUXILIARIES



1.00.00 INTENT OF SPECIFICATION

This section is intended to broadly describe the requirements of Control &
Instrumentations related to Steam Generator and its auxiliaries such as Burner
Management System including Master Fuel Trip, Flame Scanners, Secondary Air
Damper control, Overfire air damper control, Scanner air fans, Pulverizers, Seal
air fans, Soot Blowing System, Draft Plant, Air preheaters & steam coil air
preheaters, Primary Air Fans, Boiler circulation water pumps etc. and other
integral auxiliaries.


2.00.00 GENERAL REQUIREMENTS

2.00.01 The Control & Instrumentations related to the steam generator being specific to the
design of the steam generator, the subsequent clauses in this section shall be
deemed as typical and qualitative requirement only. However any deviation from
these clauses to be brought out in the proposal.

2.00.02 Dual and Triple redundant measurements shall be provided and shall not be limited
to the following. In general all control inputs shall be redundant:

Parameter Measurement Redundancy

SH Spray Water Flow (each) 1 out of 2 (on each Left & Right)

RH Spray water Flow 1 out of 2 (on each Left & Right)

Secondary Air Flow 2 out of 3 (on each air path)

Oxygen in Flue Gas 2 out of 3 (after economizer)

Furnace Pressure 2 out of 3

P.A. Header Pressure 2 out of 3

PA Flow to each Mill 1 out of 2


Parameter Measurement Redundancy

Mill outlet Temperature 1 out of 2 (for each mill)


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VOL-II-E-SEC-III - 2 DCPL-11Z02

Final Superheater outlet Temperature 2 out of 3 (on each Left & Right)

SH Desuperheater outlet temperature 2 out of 3 (each on each Left & Right)

Reheater Steam outlet Temperature 2 out of 3 (on each Left & Right)

RH Desuperheater outlet temperature 2 out of 3 (on each Left & Right)

Auxiliary Steam Pressure 2 out of 3

Auxiliary Steam flow 1 out of 2

Auxiliary Steam Temperature 1 out of 2

Windbox to Furnace DP 2 out of 3

H.F.O pressure control 2 out of 3

H.F.O Temp Control 1 out of 2

L.D.O Pressure Control 1 out of 2

Burner atomizing steam pressure 1 out of 2

APH outlet temperature 2 out of 3

Main steam pressure 2 out of 3

CRH steam pressure 2 out of 3

Separator level 1 out of 2

HP Bypass flow 2 out of 3

Additional measurements :-

Furnace draft Wide range

2.00.03 Bidder shall offer 1 out of 2 or 2 out of 3 measurements for other critical
measurement areas.

2.00.04 For measurement of metal temperature of evaporator, super-heater and re-heater
Bidder shall provide duplex type mineral insulated thermocouples terminated in
junction boxes at boiler platforms with MgO filled metal sheathed extension wires.

2.00.05 Necessary primary elements for measurement of secondary airflow to the furnace
and primary airflow to pulverizers shall be provided.Primary and secondary airflow
shall be measured by aerofoil or venturi or by on line measurements technique with
high accuracy (better than 2%) as per proven standard and practice. Generally,
Flow nozzle shall be used for measurement of Feed water flow, SH & RH
attemperation flow, Auxiliary steam flow and for lines equal to or above 4
diameter.

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-III - 3 DCPL-11Z02


2.00.06 Adequate sensors for monitoring, alarm, interlocking, automatic changeover to
standby equipment shall be provided with lube oil pressure, flow, temperature etc.
of equipment like Mills, ID Fans, PA and FD Fans etc.

2.00.07 a) Coal feeder shall be gravimetric type based on variable voltage & frequency
drive with proven microprocessor based controller having soft DIL start facility.
Coal flow measuring system shall have a linear output of 4-20 mA DC.
Weighing system shall be based on load cell and shall have the high
resolution by proper selection of cell range.

b) Feeder shall be controlled by 4-20 mA DC signal from station DDCMIS fuel
controllers. Required signal like feeder run, feeder stop, coal flow rate,
totalizer, clean out conveyer run & stop, coal chute plugged etc. shall be
available. Bidder shall provide acoustic type no coal flow detector.

c) Features of coal feeder controller shall not be limited to the following :

i) Alphanumeric display of feed rate; density; motor speed; total weight,
automatic and manual calibration of the weighing system and
adjustment of system drift, non volatile memory to store information
and program data, alarm generation automatic transfer from
gravimetric to volumetric in case of failure of load cell, status LED,
keyboard for configuration.

ii) Required interface terminals for control and monitoring of coal feeder
from station DDCMIS including feeder diagnostics shall be provided.

2.00.08 Measurement and totalization of both heavy and light oil flow shall be provided with
Coriolis mass flow instruments with 4-20 mA DC output for indication, control and
totalization giving actual oil consumption. The Mass flow meter shall have the
facility for configuration to indicate Mass and Volumetric Flow rate. Heat tracing
shall be considered for heavy fuel oil application.

2.00.09 Temperature, pressure and differential pressure measuring devices shall be
installed at various zones in the flue gas path for monitoring.

2.00.10 Bidder shall provide electrically operated retractable type furnace temperature
probes at both sides of furnace complete with actuating mechanism, temperature
element, position transmitter, limit switches etc. for measuring flue gas
temperature.

2.00.11 Acoustic pyrometer type flue gas temperature measurement shall be provided to
determine the average and complete temperature profile at different sections of
furnace such as economizer, furnace exit zone etc.. System shall be complete
with required transmitters & receivers located in different zones, air purging
system, monitoring terminal with required hardware, software & colour 24 LCD
monitor and colour laser printer etc. The system shall be able to eliminate the
effect of varying noise to obtain a high accuracy of measurement. Range shall be
adequate to cover boiler operation during all regimes. Accuracy of measurement
shall be better than 2%.


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-III - 4 DCPL-11Z02

2.00.12 For measurement of pulverizer outlet temperature and flue gas / air temperature,
suitable abrasion resistant thermowells of material such as Tungsten carbide or
Inconel, respectively, shall be provided.

2.00.13 Automatic steam leak detection system shall be provided for detecting tube
leakages at different zones of boiler. Isolated 4-20mA DC signals shall be
provided for monitoring the acoustic level in DDCMIS. Bidder shall provide
necessary acoustic signal generator, signal receiver, air purging system, signal
processor & controller, operators station, cabinet, junction boxes, connecting
cables and interface to DDCMIS. The system shall be able to eliminate the effect
of surrounding noise to obtain a high accuracy of leak detection.

2.00.14 Isolated 4-20mA DC from Ultrasonic type coal level measuring system at
coalbunkers shall be provided for display of bunker level at the central control
room.

2.00.15 3 (three) switches operating at same setting shall be used for all critical trip
interlocks such as furnace pressure high, furnace pressure low, fuel oil pressure
low, atomizing steam pressure low etc.

2.00.16 Initiating devices for auxiliaries viz. ID fan, FD fan, PA fan & Pulverizer lube oil
system etc. shall be provided for starting, stopping, interlock, protection, automatic
change over and annunciation.

2.00.17 Necessary pressure controller for electromatic safety valve/s complete with all
accessories like special cables, pressure sensing devices, solenoid valves, impulse
piping etc shall be provided for superheater and reheater safety. System shall be
operated from DDCMIS.

2.00.18 Local instruments shall be mounted on gauge boards / racks located at convenient
places.

2.00.19 Air preheater shall be monitored for fire by means of strategically located
temperature sensors both at cold and hot ends. Protection of airpreheater shall
incorporate the fire protection logic as well. Air preheaters shall also be monitored
for differential pressure across air and flue paths.

2.00.20 Dirty condition alarm of various strainers in the fuel oil line and lube oil line shall be
monitored in DDCMIS.

2.00.21 Instruments for performance and guarantee test measurements including tapping
points with root valves for pressure measurement and temperature stubs with
thermowells are to be provided.

2.00.22 Continuous air purge connections shall be provided for pressure, differential
pressure and flow instruments on flue gas, flue gas/air and coal/air lines to avoid
clogging.

2.00.23 Wherever hand wheel or local inching operation is foreseen, the controlled
parameter shall be prominently displayed close to the point of operation.



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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-III - 5 DCPL-11Z02

3.00.00 BURNER MANAGEMENT SYSTEM (BMS)

3.00.01 Burner Management System (BMS) sequence control shall include Master fuel trip
(MFT) relay; purge of the boiler, flame scanners, oil burner controls, Milling plant
sequence control; Seal air fans and scanner cooling fans.

3.00.02 Burner Management system shall be implemented in the DDCMIS with adequate
safety, diagnostic and redundancy with fault tolerant hardware and software.
Related hardware shall be segregated in identifiable cabinet/s with hardwired
signal exchange with other cabinets as required and with no sharing of I/Os with
any other system. BMS shall conform to NFPA 85 requirements in all respects for
(i) the prevention of furnace explosions/ implosions in multiple burner boilers and
(ii) for pulverized fuel system.

3.00.03 Boiler protection shall be based on triple-modular redundant configuration(TUV
Certification) in hardware & software meeting NFPA requirement. Configuration
shall be realized with three independent trip channels. Each channel shall comprise
of its own processor and input & output modules/relays. Adequate self check and
diagnostic with status report shall be available.

Dual redundant hardware and software has been envisaged for all other controls.

3.00.04 BMS shall perform the following functions :

a) Master Fuel Relay.

b) Individual controls for oil and coal burners including sequential start-up and
shut-down of individual mill system.

3.00.05 BMS will be adequate for prelightup checking, purging of the boiler, sequential start
/ stop operation of burners, milling system, scanner air fans, seal air fans,
emergency and administrative shutdown of the boiler and/or any of the auxiliaries
and safety protection of furnace as a whole.

3.00.06 BMS shall have password protected forcing facility for over-riding auto logic circuit
so that start-up and normal running of boiler is not affected unduly as a result of
malfunction of any part of the auto circuits or field device.

3.00.07 Complete BMS logic configuration, loading and documentation shall be permissible
from common DDCMIS engineering station.

3.00.08 Local burner control cubicles shall be provided for maintenance of burners.

3.00.09 Initiating devices for safety & interlocks viz, pressure switches, level switches, flow
switches, transmitters, temperature elements etc. shall be provided.

3.01.00 Flame Monitoring System

3.01.01 Flame Monitoring system shall be provided for the following :

- enhance the furnace safety


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-III - 6 DCPL-11Z02

- avoid spurious and unwanted trips

- increase operational reliability, availability and efficiency of the steam generator

Flame Monitoring System (FMS) shall include flame detectors of proven type
conforming to NFPA recommendation with solid-state logic circuits. FMS shall be
capable of discriminating between oil and coal flames and to monitor fireball. The
flame monitoring amplifiers shall generate 4-20 mA DC signals corresponding to
flame intensity, which shall be monitored in DDCMIS.


FMS shall have the features not limited to following: -

a) 100% self-checking for electronics and flagging of failures.

b) Flame condition display by means of bar graph indicator on amplifier.

c) Early warning of flame instability, flame-out condition and diagnosis of Burner
Malfunction.

d) Pre-selectable "Flame Off" response time.

e) Potential free contact for interface with BMS.

f) Automatic shutter closure / retraction on high temperature.

g) Detection not influenced by deposits on sighting head

h) Immunity from picking up of signal from adjacent burners or other sources.

i) Flame detector testing kit.

3.01.02 Cooling air system for the flame scanners shall be provided from the scanner
cooling air fans to constantly purge and cool the flame sighting head. Availability of
cooling air from DC emergency scanner air fan shall be ensured during black out
condition to protect the scanner from undue heating.

3.01.03 Flame Monitoring System (FMS) shall be provided with one(1) set of flame TV
consisting of one(1) monitor with two (2 ) cameras.


4.00.00 SOOT BLOWING CONTROL SYSTEM (SBC)

4.00.01 Soot blowing control system shall be part of DDCMIS. When set on automatic
mode the sequencing system shall perform soot blowing at predetermined intervals
at all specified locations including the main furnace as well as the air preheater
areas. The control system shall maintain the required steam pressure and
temperature conditions. SBC system shall be implemented with adequate safety,
diagnostic and redundancy. Related hardware shall be segregated in identifiable
cabinet/s. Smart soot blowing system is preferred.

Functional requirements shall not be limited to the following:

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-III - 7 DCPL-11Z02


a) Automatic sequential starting.

b) Selection facility for individual soot blower for automatic sequential operation.

c) Manual over-riding of automatic operation.

d) Cancellation of operation of any soot blower, if required.

e) Indication of the soot blower in operation.

f) Monitoring all essential parameters of the soot blowing system.

g) Indication of malfunctioning of soot blower.

h) Steam pressure and drain temperature control

i) Local operation of blowers and Local/Remote selection facility.

4.00.02 Local control box shall be provided for local operation.


5.00.00 SECONDARY AIR DAMPER CONTROL (SADC)

Control of Secondary Air Damper will apportion the total secondary air between
various elevations depending upon the type of fuel is being burnt, number of
elevation is in service and the firing rate in each elevation. SADC system shall be
implemented in the DDCMIS with adequate safety, diagnostic and redundancy.
System shall be complete with windbox to furnace differential pressure
transmitters, switches, actuators with non contact position transmitters etc.


6.00.00 BOILER EQUIPMENT

Controls for the following equipment including their auxiliaries shall be
implemented with redundancy, safety and diagnostic. Features of the
system/equipment shall not be limited to the follwing.

6.01.00 ID FAN

6.01.01 Induced draft fan control shall be either axial flow type with inlet vane control or of
variable voltage & variable frequency type additionally with damper control. The
drive electronics shall be 2 X100% redundant with manual /automatic fall back on
diagnostic failure and monitoring features for speed and current. The speed turn
down of the system shall be matched with the system requirement within the
allowable limits. The response time of the system shall be fast enough to comply
with the requirement of the Boiler control system.

6.01.02 Monitoring, alarm and safety devices shall be provided for the ID fan and lube oil
system and shall not be limited to the followings:

a) Fan speed & current

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-III - 8 DCPL-11Z02


b) Tank oil level

c) Lube oil pumps discharge pressure

d) Lube oil flow

e) DP across lube oil strainer

f) Fan & motor winding and bearing temperature.

6.01.03 Required local instruments such as level, pressure & temperature gauges, flow
sight glass, temperature gauges etc. shall be provided.

6.02.00 FD FAN

6.02.01 Forced Draft fans shall be provided with Inlet pitch control vanes complete with
actuator, converter and position transmitter for control of secondary air flow.

6.02.02 Monitoring, alarm and safety devices shall be provided for the fan and its lube oil /
control oil system and shall not be limited to the followings :

a) Oil pumps discharge pressure

b) DP across lube oil strainer

c) Fan & motor winding and bearing temperature.

d) Lube oil tank level

e) Oil flow

6.02.03 Required local instruments like level, pressure & temperature gauges, flow sight
glass, temperature gauges etc. shall be provided.

6.03.00 PA FAN

6.03.01 Primary air fans shall be provided with Inlet pitch control vanes complete with
actuator, converter and position transmitter for control of air flow through mills.

6.03.02 Monitoring, alarm and safety devices shall be provided for the fan lube oil /
control oil system and shall not be limited to the followings :

a) Oil pumps discharge pressure

b) DP across lube oil strainer

c) Fan & motor winding and bearing temperature.

d) Lube oil tank level

e) Oil flow

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6.03.03 Required local instruments like level, pressure & temperature gauges, flow sight
glass, temperature gauges etc. shall be provided.

6.04.00 AIR PRE-HEATER

Following measurements shall be provided

6.04.01 O
2
in FG path at each air pre heater outlet shall be measured as a measure of air
leakage through seals. In addition, O
2
shall be measured by triple redundant
sensors (03 nos.) after economiser.Following measurements shall be provided.

6.04.02 Differential pressure transmitter across air preheater.

6.04.03 Pressure transmitters and Temperature elements at I/L & O/L on Flue gas path
and Air path.

6.04.04 No rotation switch to monitor the status of AHP.

6.04.05 Thermocouples for Air pre heater fire sensing and bearing oil temperature
elements at cold and hot ends, pressure & temperature gauges, lube oil flow
switch etc. for guide & support bearing.

6.04.06 There shall be provision for turning the airheaters in case of AC failure by air
motor or DC drive.

6.05.00 COAL MILL

Following measurements shall be provided

6.05.01 DP across lube oil strainer alarm

6.05.02 Temperature element for lube oil temperature, pressure transmitter for lube oil
pressure and flow switches for low lube oil flow.

6.05.03 Coal mill DP

6.05.04 Mill outlet coal-air mixture temperature.

6.06.00 BOILER CIRCULATING WATER PUMPS

6.06.01 Pump control and instrumentation shall not be limited to the followings :

a) Double Temperature elements for Motor cavity temperature adequate start
permit, high alarm and monitoring.

b) Triple Temperature elements (2/3 configuration) for Motor cavity temperature
very high trip.

c) Temperature elements at Pump casing and Suction manifold for monitoring of
temperature differential.


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d) Flow switch with local indication for Coolant water flow to pump motor cooler
low alarm.

e) Purge filter DP high alarm.

f) Differential pressure transmitters for measuring differential pressure across
the pump.

g) Adequate local gauges for Purge filter DP monitoring, pressure gauges at
pump suction and discharge etc.

h) Limit switches for pump discharge valve stem position monitoring and safety
start permit.


7.00.00 CONTROLS

7.01.00 Closed loop controls shall not be limited to the following :

a) Coordinated Master Control.

b) Boiler Master control
c) Fuel flow control
d) Air flow control
e) Furnace Draft Control.
f) Steam Separator Level control.
g) SH Steam Temperature control
h) RH Steam Temperature control
i) Fuel oil pressure control.
j) Steam coil air-preheater temperature control.
k) Auxiliary Steam Header Pressure & Temperature Control.
l) Mill outlet Temperature control
m) Primary air header pressure control
n) Atomizing steam pressure control
o) Separator level control
p) Drain and Flush tank level control.

q) Any other control required to complete the system.

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8.00.00 CHEMICAL FEED SYSTEM

The boiler water treatment system shall comprise of AVT (All Volatile treatment)
and optionally, OWT (Oxygenated Water treatment).

Control & Instrumentation of the dozing system shall not be limited to the following.


a) Each dosing pump shall be provided with diaphragm seal, snubber, glycerin
filled type pressure gauge of proper range on discharge piping with isolation
valves, fittings etc. Each solution tank shall be provided with stainless tube
magnetic type level gauge with colour changing ball or flapper and graduated
scale. Level switch shall be provided for low-level alarm and interlock. The
chemical feed system shall be operated and adjusted from the local panel and
also from the station DDCMIS in unit Control Room.

b) Start/Stop operation of the Agitator motors and Dozing Pumps from the
DDCMIS.

c) Dosing rate control shall be adjusted from both local and remote automatic &
manual from central control room DDCMIS. Required local controller, drive
unit as required shall be provided for this purpose. Use of resistance type
feedback mechanism for position indication shall be avoided.


9.00.00 FLUE GAS ANALYZERS

Bidder shall familiarize with the permit requirement of the units and supply a
Continuous Emission Monitoring System complete in all respects to meet the
environmental monitoring requirements. Bidder shall provide following gas
analyzers with all accessories including purge and calibration facilities, sampling
sumps, coarse and find filters, refrigeration type dryer, manifolds, standard gas
bottles etc for each unit, as required :

a) One (1) extractive type analyzer on the stack for monitoring SOx, NOx, CO
& CO
2
and O
2
(Combined analyzer).
b) One (1) in-situ type Flue Gas Velocity measurement at stack.
c) One (1) Smoke density analyzer to be installed on stack.
d) Opacity monitor at each ESP oulet.
e) One in-situ type CO analyzer at economizer outlet.
f) Three numbers in-situ zirconium type oxygen analyzers after economizer
and one number at each air preheater outlet shall be provided for
measurement of oxygen in flue gas.


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To estimate the emission quantities gravimetrically, Bidder shall provide a flow
measuring system in the stack. Either thermal or ultrasonic mass flowmeter shall
be preferred.

Continuous stack emission monitoring instruments shall be provided with a Data
acquisition station for configuration, monitoring and data logging. The system
shall compute the pollutants both volumetrically (ppm) and gravimetrically
(mg/m3) generate reports conforming to EPA standard and store & transmit the
data to DDCMIS via OFC link. In addition, isolated 4-20mA DC output shall be
provided for monitoring in DDCMIS.

Bidder may include an air-conditioned analyzer shelter for each unit to
accommodate all above analyzers and accessories & the Data acquisition station
with an UPS. The optical fibre cables to the control room shall be included.

Bidder shall note that stack emission monitoring instruments shall be installed on
the chimney provided by the Owner. Bidder shall perform necessary coordination
and furnish the required input drawings & documents to Owner to keep provision
on chimney.


Note :

1. The successful bidder should submit the brief system write up covering
Interlock, Ptection and Operatin of different equipments in the system along
with each scheme.

2. The write up on CLC and OLC need to be submitted by successful bidder.


VOLUME : II-E

SECTION-IV

CONTROL AND INSTRUMENTATION
FOR
TURBINE GENERATOR, AUXILIARIES AND
FEED CYCLE EQUIPMENT


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
CONTENT DCPL-11Z02




CONTENT



CLAUSE NO. DESCRIPTION PAGE NO.

1.00.00 INTENT OF THE SPECIFICATION V.II-E/S-IV : 1

2.00.00 GENERAL REQUIREMENT V.II-E/S-IV : 1

3.00.00 FUNCTIONAL REQUIREMENT FOR TURBINE
AND ITS AUXILIARIES V.II-E/S-IV : 3

4.00.00 GENERAL REQUIREMENT OF GENERATOR
AUXILIARIES AND FEED CYCLE SYSTEM V.II-E/S-IV : 17

5.00.00 BOILER FEED PUMPS V.II-E/S-IV : 20

6.00.00 CONDENSER AND AIR EXTRACTION
EQUIPMENT V.II-E/S-IV : 22

7.00.00 FEED WATER HEATERS AND DEAERATOR V.II-E/S-IV : 23

8.00.00 HP-LP BYPASS SYSTEM V.II-E/S-IV : 24

9.00.00 REDUNDANCY IN MEASUREMENTS V.II-E/S-IV : 24

10.00.00 MAJ OR CONTROLS V.II-E/S-IV : 25




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VOLUME : II-E

SECTION-IV

C&I FOR TURBINE GENERATOR, AUXILIARIES AND
FEED CYCLE EQUIPMENT



1.00.00 INTENT OF THE SPECIFICATION

This section is intended to broadly describe the requirements of Control &
Instrumentations related to Turbine Generator (TG) and its auxiliaries such as
Electro hydraulic governing (EHG) system, Turbine protection (TP),
Automatic turbine run up system (ATRS), Turbine stress evaluator (TSE),
Automatic turbine tester (ATT), Turbine supervisory instruments (TSI), Gland
seal steam system, Condenser air evacuation system, Generator mechanical
protection, Generator seal oil system, Generator gas system, Generator
stator cooling water system, Excitation control, HP/LP bypass system and
other auxiliaries and Regenerative cycle control & instruments.

1.00.01 It is envisaged that the entire operation of the Turbine generator shall be
performed from the unit control room for all regimes of operation including
black start, hot restart, load rejection, run down, turbine trip, emergency trips
of auxiliaries etc. All necessary valves including drain & vent valves, isolating
and regulating valves etc. that are to be regulated under the above
conditions, therefore, shall all have facilities for operation from unit control
room.

1.00.02 The entire system shall be designed, supplied and commissioned to enable
the plant to be operated in a safe, efficient and reliable manner, without
invoking plant or system operational limits and to provide the quality of control
to support the overall performance guarantees detailed in other sections.

1.00.03 The principal design objective for the C&I System shall be for optimization of
fuel consumption with high degree of automation to relieve station operation
and maintenance personnel from routine functions.


2.00.00 GENERAL REQUIREMENT

The Control & Instrumentation related to the Turbo generator being specific to
the design of the Turbo generator, the subsequent clauses in this section shall
be deemed as typical and qualitative requirement only.

2.00.01 Controls shall include automatic start up & speed control, synchronization, load
control, load rejection, frequency control, overspeed runback and valve testing.
Protection shall include monitoring & safety interlock related to turbine critical
parameters, over speed tripping and test for trip channels. The above shall be



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integrated into the plant automation system so that similar hardware & software
components, operators stations, communication network, operation &

reporting mechanism can be utilized and common coordinated boiler & turbine
control can be realized. Supervisory systems such as rotor stress calculation,
automatic start up program and performance calculation shall also access the
turbine control system over the communication network.

Control system shall be designed meeting the criteria of high reliability and
maintainability by incorporating fault tolerant hardware and software. Duplex
control configuration is envisaged for Turbine protection, Turbine EHG control
and Generator mechanical protection. Duplex control configuration shall
include redundant EHG valves position control modules for EHG. Two
channels shall be installed in separate cabinets to avoid common failure.

Balance controls of TG system such as ATRS, Bypass, Gland steam pressure,
TG integral pumps, Turning gear, Condenser evacuation system, Generator
auxiliaries etc. shall be configured in DDCMIS with dual redundant controller.

Controls in regenerative cycle such as steam system, feed water system,
condensate system, drain & vent system, heater drain system, cooling water
system, pressure reducing & de-superheating system etc. including their
protection & control shall be configured in DDCMIS with dual redundant
controller.

2.00.02 The controls shall be adequate for the check-out, initial start-up, commissioning
and maintenance / trouble shooting, normal operation of the set including
starting, run-up, synchronizing, loading, run-back, run-down, normal &
emergency shut-down etc. A single command operation for automatic start up
and shutdown of Turbine shall be established.

2.00.03 Provision shall be kept for manual output forcing by over-riding auto logic
circuit so that start-up and normal running is not affected as a result of mal-
function of a part of the circuit or a field device. However all such overrides
shall be registered and stored.

2.00.04 Bidder shall provide hydraulic type actuators for the control valves such as
turbine governing and stop valves and HP/LP Bypass valves where speed of
response is important. For other regulating duty applications where response
type may not be such a critical factor, pneumatic type actuator shall be
considered.

2.00.05 Generator synchronization shall be performed both in automatic and manual
mode. In automatic mode, synchronization shall be performed by EHG controls
and auto-synchronizer. Manual synchronization shall be performed from
Electrical control panel with conventional control hardware.


2.00.06 Steam Turbine shall be equipped with instruments not limited to the followings :


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a) Pressure transmitters for pressure measurement downstream of main
stop valve, after 1
st
.stage, before reheat stop valve, extraction pressure to

b) water heaters, turbine exhaust pressure, bearing oil pressure and control
oil pressure.
c) Thermoelements for measuring main steam, reheat steam, turbine casing
wall and rotor, LP exhaust, extraction steam to water heaters, oil at oil
cooler outlet, bearing oil and bearing metal temperature.
d) Level transmitter and Level gauge for measuring oil level in main oil tank
and control oil tank.
e) Protective & interlock initiating devices including devices for automatic
operation of standby equipment and auxiliaries viz. Turbine AC/DC lube
oil pumps, control oil pumps, jacking oil pumps and seal oil pumps shall
also be furnished.

2.00.07 Generally Flow nozzle shall be used for feed water flow, Auxiliary steam flow
etc. and for lines equal to or above 4 diameter. For lines of lower sizes
suitable orifices will have to be provided.

2.00.08 Major equipment such as MDBFP and TDBFP including their sub systems
shall be adequately monitored for Oil pressure of various oil systems such as
lube oil /working oil /control oil, Oil level in various tanks, Oil temperature,
Bearing temperature, Motor winding temperature and other parameters
such as suction & discharge pressure of the pumps, flow through pumps etc,.
Initiating devices for automatic switching over to standby equipment and
auxiliaries shall be furnished.

2.00.09 Critical strainers such as Turbine oil strainers, BFP suction strainers and CEP
suction strainers shall be continuously monitored in control room with DP
transmitters.

2.00.10 Important tank levels such as turbine lube oil tank, control oil tank, seal oil
tanks, BFP lube oil tank etc. shall be monitored.

2.00.11 Performance test instrument for carrying out performance test shall be
furnished.

2.00.12 External chamber co-axial guided wave radar type level transmitters shall be
provided for the level measurement of Main Turbine oil tank, Control oil tank,
BFP oil tanks, Condenser hotwell and LP heater under vacuum.


3.00.00 FUNCTIONAL REQUIREMENT FOR TURBINE AND ITS AUXILIARIES

3.00.01 The entire system shall be designed, supplied and commissioned to enable
the unit to be operated from the control room under all operating conditions
including foreseeable emergencies in a safe, efficient and reliable manner,
without invoking plant or system operational limits.

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3.00.02 The C&I System shall be configured to perform the following basic functions:



a) Automatic sequencing of the start-up and shutdown of major equipment
and auxiliaries including group level start-up to minimize operators
intervention under normal operating conditions.
b) Regulating function for various valves to achieve guaranteed
performance.
c) Open loop, sequential and closed loop control for all associated drives.
d) Protection of plant equipment and monitoring of equipment life.
e) Acquisition, display and archiving of plant data and generation of reports.
f) Coordinated machine control.

3.00.03 In the event of loss of a major plant equipment, controls shall be coordinated
to ensure that the plant is automatically brought to a safe holding condition
consistent with maintaining maximum safe generation permissible under
reduced plant availability.

3.00.04 Major control, monitoring and supervisory subsystems typically shall be as
follows.

a) Electro-hydraulic Governor control
b) Automatic Turbine Testing System.
c) Turbine Protection System.
d) Turbine Stress Evaluator
e) Automatic Turbine Run-up System.
f) Turbine auxiliaries control system.
g) Turbine Supervisory Instrumentation System.
h) Condenser evacuation system
i) LP Bypass control system

3.00.05 Following measurements shall be considered for remote monitoring in control
room:

a) Main oil tank level and Control oil tank level.
b) Auxiliary /Emergency oil pump discharge pressure.


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c) J acking oil pump discharge pressure.
d) Trip oil pressure.
e) DP across critical strainers such as lube oil and control oil strainers
f) On/Off status indication of Turbine oil purification system.


3.01.00 Emergency Protection

3.01.01 Emergency Over-speed Protection

A quick acting emergency over-speed protection system (including
emergency governor) shall be provided to close instantly the emergency stop
valves, control valves, reheat interceptor stop valves and also the non-return
valves in the extraction lines at about 111% of the rated speed in case the
speed governor fails to limit over-speed. It shall be capable of being reset
when the speed is reduced to approximately normal level. The emergency
over-speed governor shall be provided with means for testing its operation
even when the machine is on load, without exceeding rated speed of the unit.
A back-up governing system shall be provided so that the emergency valve
remains active during the test. Three (03) speed sensors for over speed
protection shall be considered.

3.01.02 Turbine Trip

Turbine trip should occur typically under the following conditions: -

Electrical over-speed operated, turbine protection system failure, EHG
system failure, lube oil pressure low, condenser/s vacuum low, axial shift high
or thrust bearing wear, steam generator tripped, steam inlet pressure low, HP
exhaust steam temperature very high, control oil pressure low, inlet steam
temperature very high & low, generator protection operated, presence of
liquid in generator terminal bushing, generator cold gas temperature high,
generator hot air temperature high, seal oil temperature high etc.

3.01.03 Emergency Stop

Emergency stop should occur under the following conditions: -

Local manual trip device, Local manual electrical emergency stop, Remote
manual electrical emergency stop.

3.01.04 Alarm Devices

Alarms for steam turbine not limited to the following shall occur: -

a) Wear of thrust bearing pads

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-IV - 6 DCPL-11Z02

b) High exhaust temperature of LP cylinders

c) High bearing temperature
d) Excessive vibration
e) Pre trip alarms for all trip conditions of turbine

3.02.00 Speed regulation

The turbine shall be provided with remotely operable speed changer (Speed
governor) to control its speed or power output within limits. Speed governor
shall have the following characteristics or better:

(i) The speed changer provided shall be capable of adjusting (manual/auto)
the speed of the turbo set to any value in the range 94% to 106% of
rated speed, to facilitate synchronizing and loading of generator.
(ii) Governor shall be capable of varying the load on the machine from no
load to full load.
(iii) Dead band of the governor shall be 0.06% or better.

3.02.01 Load Limiting Device

Turbine shall be equipped with a remotely operated load-limiting device. A
signal shall be provided for indication of the setting of the load limiter.

3.03.00 Turbine Supervisory Instrumentation

Turbine Supervisory Instruments shall incorporate monitoring of the following
parameters as a minimum:

Turbine rotor eccentricity, key phasor, casing expansion, axial shift, casing
/rotor differential expansion, shaft vibration, bearing pedestal vibration, steam
and metal temperature of turbine to determine the thermal stresses, turbine
speed and valve position meter. All the vibrations shall be measured in X,Y
directions.

3.04.00 Displays and Logs

Displays and logs related to the turbine-generator system are indicated as
below:

a) Real Time Parameter / Status Display (default screen).
b) Real Time Trend / Historical Trend graph display, print out (on demand).
c) Alarm summary display / print out (on demand)
d) Alarm limit display / print out (on demand).

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
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e) Turbine Start-up log / print out (even actuated).

f) Shift Log / Daily Log / print out (on demand).
g) Generator trip log / print out (even actuated).
h) Turbine trip log / print out (even actuated).
i) Operator Control Screens.
j) Group Display screen (at least 8 loops).
k) Individual display screen (single parameter).
l) Flow chart / logic screens.
m) Operators guidance message screen.
n) Process Subsystem Display Screens.
o) Machine running hour.

3.05.00 Functional Requirements Of Various Sub-Systems

3.05.01 Turbine Run-Up System

An automatic run up system shall, under operators initiation, shall run up the
turbine to synchronous speed conforming to all permissive and safety
conditions from cold, warm or hot standstill or barring stage, synchronize the
machine and load it to initial block load without manual intervention.

a) Run-up system shall perform the task of acquisition, analysis and
collection of information pertaining to various parameters like oil
pressure, condenser vacuum, metal and steam temperature at various
depths, speed etc.. The operation of the Turbine Run-up System shall
be performed during normal operation, initial start-up, commissioning,
shutdown, trial operation and maintenance checkouts.
b) The system shall utilize a operator friendly programming language
based on functional instruction set.
c) The following displays shall be provided.

i) Plant schematic displays

ii) Alarm displays

iii) Missing criteria displays

d) The Turbine Run-up System shall divide the control area into clearly
defined Functional Groups. Each functional group shall be

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
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hierarchically arranged in Sub-group, Sub-Loop and drive Interface
level.
e) All such control areas shall be distributed as clearly segregated hardwire
units.
f) Sub-group control shall execute commands to bring the related
equipment to a pre-defined status in a pre-defined sequence. Number of
criteria shall be set as preconditions before the Sub-group control can
execute its sequence, failing which, the system would automatically act
in such a manner to ensure the safety of the equipment.
g) For each step there shall be a waiting time and a monitoring time.
h) Waiting Time shall imply that the subsequent step will not be executed
unless the specified time elapses.
i) Monitoring Time shall be the time required for executing the command of
any step as well as the time required for appearance of criteria for the
next step. Under healthy conditions it should happen within the specified
time, otherwise an alarm shall be initiated.
j) Turbine Run-up automation shall be switched on at any stage even after
completing certain steps manually, if so desired. In such cases, the
program shall scan through the steps and shall start executing from the
previously executed stage onwards.
k) There shall be a selection for auto or manual mode. In manual mode,
operations can be performed at the control interface level to bring-up
various equipment to their desired status.
l) In auto-mode, a single operators command shall be issued for starting
the sequence. Clear and legible display shall indicate when the desired
and defined status is achieved, that the program is running towards the
desired status, that a fault has appeared, the step in which the program
is in at a given moment, that the program is stuck or which criterion has
not been fulfilled.
m) The signals identified as protection channel shall have the highest
priority and shall be executed even without manual initiation.
n) A Sub-Loop control, when activated, will actuate the related equipment
and shall bring it to the desired status as demanded by the process.
o) Sub-Loop controls shall be switched on either manually or through its
Sub-group control.
p) In addition to the automatic mode of operation of the sub-group, the
following two modes shall also be available under authorization:
(i) Step-by-step-mode: In this mode, criteria for a step are simulated or
forced and the command is issued automatically.


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(ii) Operator guide mode: In this mode, the output commands are
blocked. The commands have to be issued manually.


3.05.02 Turbine Stress Evaluator

a) The turbine shall be equipped with a Stress Evaluator, to assist in
attaining optimized start up, operation and shutdown without impairing
the operating life of the internals of the machine due to thermal stresses.
The thermal stress shall be continuously compared with the permissible
stress to monitor overstressing. The Stress Evaluator shall maintain
track of the number of cold, warm and hot starts and compare with the
permissible numbers specified by the turbine manufacturer to arrive at
residual life computation of the machine.
b) The actual thermal stress acting on any component shall be computed
from the difference of temperature at the surface coming in contact of
steam and the mean wall temperature of the component. The
temperature difference shall be compared with the permissible
temperature differences derived from the mean wall temperature to
arrive at the available temperature margins to avoid material fatigue. The
permissible thermal stresses, dependent on factors like, expected load
cycle of turbine, thermal fatigue strength of material, the geometry of the
components etc. shall be derived from the mean wall temperature. The
difference between the permissible stress value and the actual stress
value shall be computed and displayed as positive or negative
temperature margins before synchronization and as positive or negative
load margins after synchronization. A margin (both temperature and
load) shall provide the amount of step increase / decrease of steam
admission / load, which will not impair turbine life.
c) Thermoelements, at suitable locations, shall be used to measure the
metal and the steam temperature after the turbine 1
st
. stage and in the
reheat inlet chamber to evaluate the thermal stresses on the turbine
casing wall and rotor surface to determine the safe speed rate and load
changing rate.
d) For the stop valve and the control valve of the HP turbine, designated as
Admission area and the turbine casing & shaft designated as Turbine
area, temperature margins shall be independently computed.
e) The TSE system shall receive speed, temperature, load signals and
generate temperature and load margin signals and develop graphic
displays. The displays shall be ergonomically designed for effective
information to the operator. Following form of display is proposed.
Temperature margins for all the channels shall be displayed in bar graph
form. In addition, the values of temperature margins (both upper and
lower) in each channel shall be displayed in digital form. The digital
display of actual speed and load shall also be displayed.
3.05.03 Automatic Turbine Tester

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a) An Automatic Turbine Tester shall be used to check/test, at a regular
interval, the function of the Safety Devices of the turbine and Stop and
Control Valves, in operation, without causing turbine trip.
b) The Automatic Turbine Tester shall be divided into sub-groups. Each
sub-group shall further be sub-divided into sub-tests for each individual
device covered under the sub-group. The selection of the sub-group for
test shall be manual. Operation of only one subgroup shall be possible
at a time.
c) The momentary status of the test program shall be indicated by means
of text display.
d) If a fault is detected during a test, the test shall be discontinued and the
reset program shall be started automatically. The testing cannot be
switched off before the program selected has been completed.
e) Automatic Turbine Tester for the Safety Devices shall not be limited to
the following sub-tests : -
i) Remote Trip
ii) Over-speed Trip
iii) Low Vacuum Trip
iv) Thrust Bearing Trip
v) Control oil Trip
vi) Lube oil Trip
vii) Axial shift Trip
f) To ensure complete protection of the turbine, appearance of emergency
trip conditions during the test shall cause the solenoid valves to be de-
energized, resulting in turbine trip.
g) An alternative trip oil circuit shall be established during the testing of the
Safety Devices to isolate the trip oil circuit from the Safety Devices
and supply with control oil via the Test Trip Solenoid Valves.

3.05.04 Turbine Supervisory Instrumentation
a) Vital mechanical parameters shall be continuously supervised in order to
provide information related to the operational conditions of the turbine
during various regimes of operation like startup, loading, load changes
and shut down.



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b) Specification shall be guided by the on line Rotating Machine Condition
Monitoring system described in section-VI of this volume.
c) The measurement system shall include all necessary adapters /bosses
/mounting pads, sensors, flexible leads for connection to junction boxes,
monitors, redundant power supply modules, trip relays etc. to generate
information about the following parameters:
i) Bearing pedestal vibration (X-Y direction)
ii) Shaft vibration (X-Y direction)
iii) Absolute shaft vibrations (X-Y direction) [computed]
iv) Axial shaft position of the rotor
v) Differential expansion
vi) Absolute expansion
vii) Valve position.
viii) Ecentricity
ix) Key phasor
x) Speed
d) For all vibration measurements indicated above viz. bearing vibration
and shaft vibrations, computer based analysis system with decision
support shall be provided to achieve the following functions:
i) On-line spectrum / harmonic analysis
ii) Identification of exact nature of failure resulting in increase in
bearing vibration and direct message on the monitor indicating the
exact nature of fault e.g. misalignment, crack, bearing looseness,
rotor rub, vector changes etc.
iii) Storage and comparative analysis of vibrations with decision
support.
iv) Generation / analysis of Bode plot / orbit plot and time waveform/
Nyquist plot, waterfall, transient data (during start up and shut
down).
v) Storage and comparative analysis of vibrations.

The computer based analysis system is common for both units T.G and all
the H.T motors and their driven equipments (pumps, fans)



CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-IV - 12 DCPL-11Z02

Turbine supervisory parameters shall be fed to DDCMIS. Software link shall
be established with DDCMIS for receiving of data from DDCMIS for analysis.

e) The system shall be adequate for providing necessary information for
balancing various sections of the turbine-generator and shall be from the
latest proven range of reputed manufacturer with proven experience in
similar application.
f) Bearing Vibrations
i) Measurement of shaft vibration in X-Y direction shall be carried out
in a contact less manner according to the eddy current method.
ii) Seismic type pickup shall be mounted on bearing pedestal in X-Y
direction.
iii) The measurement system shall be designed to operate
satisfactorily over the frequency range and shall measure the
amplitude of displacement. Failure of sensor and field cable shall be
annunciated.
iv) Measurement of absolute shaft vibration shall be done by
measuring the relative shaft vibration with respect to the bearing
pedestal and by adding the bearing vibration to it.
v) Key phasor shall be used for analysis purpose

g) Axial Shaft Position

i) Measurement shall continuously monitor the relative axial position
of the thrust collar with respect to thrust bearing and shall generate
alarm and interlock contacts when axial shift reaches beyond
permissible limits to avoid any mechanical interference and surface
rubbing.
ii) The measuring principle shall be carried out in a contactless
manner based on eddy current principle. Redundant measurement
with three sensors shall be provided.

h) Differential Expansion

Relative axial expansion of HP, IP & LP turbines shall be monitored by
contact less measurement for relative axial displacement between the
rotors and casings of the turbine due to their different thermal inertia
particularly during start up/shutdown and in case of major load changes.

i) Absolute Expansion

ii) Measurement is used to measure the relative axial displacement of
the bearing pedestal with respect to the turbine foundation. This
measurement shall be carried out at the front pedestal as well as the
middle-bearing pedestal.


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-IV - 13 DCPL-11Z02


iii) The displacement sensor shall be mounted on the foundation and
connected to the casing. Sensor shall be non contact type.

j) Valve Position

Measurement for valve position shall be carried out for all main steam and
reheat steam governing control valves with the help of non contact type
displacement sensors. Steam stop valves such as reheat stop valves

shall be monitored for full open and full close position.

i. Eccentricity

Eccentricity measurement shall be non contact type measurement and
shall assist to monitor condition of the turbine during start up.

ii. Keyphasor

Keyphasor shall be non contact type measurement which will assist for
vibration analysis.

iii. Speed

Speed sensor shall be provided for monitoring and analysis.

iv. Calibration kits for proximity type sensor shall be offered as common for
TSS and VMS.

v. It shall include PC with DVD writer,160 GB mirroring type hard disc and
21 LCD monitor with 1 GB RAM.

3.05.05 Electro-Hydraulic Turbine Control

a) The electro-hydraulic governing system shall limit the over speed of the
turbo set below the trip points or safe limits on loss of full load.

b) The controls shall operate satisfactorily without causing the turbine to
hunt under any conditions of steam supply and variation in load
regardless of whether the turbine is operating synchronously or
asynchronously.

c) The speed-sensing element shall respond sensitively to speed variations
so as to maintain dead band within 0.06% of nominal speed. Speed
shall be adjustable within 0 to 106% and Frequency compensation
adjustment shall be within 2 to 8%.

d) The electro-hydraulic controller (EHC) shall have the following features:
i) Capable for run up, run down, synchronization, loading, load
rejection and house load operation with good dynamic response and
high operational reliability and dependability.

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-IV - 14 DCPL-11Z02

ii) The turbine governing controls shall position the control valves and
adjust load. Turbine Stress Evaluator (TSE) signal shall be used for
safe operation of the turbine.
iii) Hydraulic control for quick, smooth and continuous delivery of large
actuation forces.
iv) Precise maintenance of the rated frequency of the power grid by
means of an exact frequency-load-characteristic with sensitive
response and facilities for fine tuning of the characteristics.
v) Reliable operation of isolated power grid by automatic switch-over of
the load reference value with the aid of the Turbine Stress Evaluator
(TSE).
vi) Support of the pressure control system of the steam generator via
adaptation of the turbine load.
vii) Free governor operation in interconnected grid.

e) The electrical part of the EHC shall contain,
i) The devices for acquisition of the measured data from various
transducers & sensors.
ii) The electrical controller consisting of the power supplies and
Controllers for valve position, rotational speed, load & throttle steam
pressure.

f) Following devices are foreseen.
i) Measuring devices for the rotational speed of the turbo set.
ii) Power measuring devices for active electrical power delivered.
iii) Throttle pressure measuring transmitters.
iv) Electro-hydraulic positioner to position the control and stop valves.
v) Sensors to determine the position of the electro-hydraulic transducer.
vi) Control valve position transducer.
vii) Stop valve position switches


g) Controls within EHC shall include:
i) Speed control to control the steam admission in the range for speed
control upto synchronization.




CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-IV - 15 DCPL-11Z02

ii) Load control to control the steam admission in the load control range
after synchronization.
iii) Pressure control to control the turbine load with respect to the steam
pressure.
iv) Automatic tracking Device.
v) Device to form the frequency dependent characteristic (droop
characteristic).

h) Measument of the Rotational Speed
i) Three channel measurements for the rotational speed shall be
adopted. If one of the probe /channel fails, the control shall continue
to operate without interruption.
ii) In addition, at least one probe shall be provided for monitoring and
one shall be kept as spare.

i) Power Measurement

The power delivered by the generator shall be measured with three-
channel containing three independent measuring systems.

j) The Electro-Hydraulic Transducer

Electro hydraulic transducer (servo valve) shall accept electrical signal
from the EHG controller and convert it into hydraulic signal to operate
hydraulic actuator of control valve. Servo valve shall be of at least two
coil design and position feed back signal of servo valve shall be
available to the control system.

k) Steam Control Valve Position Control Loop

i) The Control Loops for speed, load and steam pressure shall be
superimposed in the steam valve position control loop.
ii) Position control loop shall be designed for the high sensitivity.
iii) Each channel of Turbine EHG control shall have its independent
valve position controller.
iv) Controller shall be able to detect for any open and short circuit
condition of servo valve coil and stuck valve condition.
v) Controller can perform calibration of Servo valve and valve
testing.

l) Speed Control Loop




CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-IV - 16 DCPL-11Z02


i) The time dependent speed reference shall rise during start-up
until the final speed reference value has been reached. The
gradient of the signal shall be modified according to the available
margins computed by the TSE in every instant to allow a rise of
the turbine speed at the highest permissible rate.

ii) The speed controller shall be used
For start-up and shutdown of the turbine.
For synchronization of the generator with the power grid.
To provide a minimum load operation and to operate the turbo-
set in the complete power range.
iii) When the load or pressure controller controls the turbine gain
control, the speed controller shall remain in a standby mode.
iv) In cases of load shedding with subsequent operation of the turbo-
set in idling mode or supplying station load only, the speed
controller shall assume control of the turbo-set.
v) The speed controller shall temporarily control the set during rapid,
large frequency fluctuations.

m) Load Control Loop

i) The load reference value shall be adjusted manually or from
coordinated master control.
ii) The time dependent load reference shall have a time constant set
based on loading curve. TSE signal will continuously influence the
rate of integration.
iii) To protect the turbo-set against overload or to limit the power
delivered by the turbo-set, the turbine controller shall limit the
power output. Frequency deviation shall not cause the turbo-set to
exceed the preset power level.
iv) The load limit shall be allowed to vary only at a defined rate.
v) The coordinated master controller signal shall be limited by an
upper and a lower loading set value. Within the limits the
coordinated master controller shall be permitted to vary the load
freely.
vi) In case of faults in the coordinated master controller, the load
reference value assumes control of the turbo-set.
vii) If the unit becomes isolated, the controller shall automatically
switch to speed control for supplying station load.


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-IV - 17 DCPL-11Z02


n) Steam Pressure Control
i) The pressure controller shall control the turbine load with respect
to the steam pressure deviations and shall prevent pressure drop
during a quick load increase.
ii) Two operational modes Initial pressure control and Limit
pressure control shall be permitted.
iii) In Initial Pressure Control mode, the press controller reduces a
pressure difference between the reference pressure value and the
actual pressure value to zero.
iv) In Limit Pressure Control mode, the pressure controller
influences the control valve to support steam generator pressure
control, if a preset main steam pressure deviation is exceeded.
v) Three transmitters shall be employed for throttle steam pressure
control

o) Transfer of Control
i) During operation of the turbo-set one of the controllers shall be
active. The other controllers, on standby duty, shall match with the
active controller to allow quick transition from one type of control
to the next without bumps.
ii) The speed and the load controller shall be tied to each other by
means of a maximum selection circuit.
iii) The combined speed and load dependent valve lift signals shall
be tied to the output signal of the pressure controller by means of
a minimum selection circuit.

p) Load rejection anticipation
In case of sudden opening of main generator breaker the protection
partition will send command to close the control valve rapidly and reduce
the load reference setting to house load.

Note : As the Electo Hydraulic Govening System is proprietary and varies with
the different vendors, the successful bidder shall make the Audio /
Visual presentation on the EHG and Turbine Control System after
submission of documents before review.


4.00.00 GENERAL REQUIREMENT OF GENERATOR AUXILIARIES AND
FEED CYCLE SYSTEM

4.01.00 Generator Auxiliary Control


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-IV - 18 DCPL-11Z02


4.01.01 Operation of generator & its auxiliaries shall normally be performed from
DDCMIS. Controls shall be adequate to operate the complete system including
excitation adjustment, automatic synchronization, generator circuit breaker
operation, seal oil system, hydrogen cooling system including hydrogen dryer
operation, generator cooling system, stator cooling water system, load control
etc. with required indication & metering including generator winding
temperature, active power, reactive power, power factor, energy meter and
annunciation.

4.01.02 Manual synchronization panel shall be equipped with operating devices for
speed control, excitation control, voltmeters, frequency meters, control
switches, lamps, semaphore indicators and LED driven mimic.

4.02.00 Generator Gas System

Control & monitoring instruments for Generator Gas System shall not be limited
to the following:

a) Cubicle for gas system shall include instruments and regulating valves
required to fill and empty the generator casing and to monitor the normal
operation of the gas system. A suitable regulator shall be provided within
the cubicle to maintain the casing gas pressure at the required value and
to take care of any leakage within the hydrogen gas system. Instruments
including analyzers to check purity for hydrogen /carbon dioxide, H
2
and
CO
2
manifold pressure, moisture content meter, casing gas pressure
etc. Necessary signals shall be provided in DDCMIS for monitoring.
b) Moisture measurement in Hydrogen shall be of sampling type.
c) Triple temperature sensors shall be provided for generator hot gas outlet
temperature high protection.
d) Generator gas drying system shall be operated from central control room
in addition to its local operation.


4.03.00 Generator Seal Oil System

Generator seal oil system shall include the required instruments not limited to
the following:


a) Dial type temperature indicator for measuring the temperature of cooling
water, seal oil.
b) Detectors for monitoring the temperature of seal oil.

c) Pressure gauges at the outlet of each pump, cooling water pressure at
inlet to oil coolers, hydrogen side and airside seal oil pressure at inlet to
seals.

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-IV - 19 DCPL-11Z02

d) Differential pressure indicators and differential pressure switches across
the strainers.
e) Flow indicators to measure seal oil flow through seals and cooling water
flow through oil coolers.
f) Adequate number of liquid detectors at the bottom of the generator tank
to detect any liquid leakage.
g) A water detector with sight glass & drain valves shall be mounted
adjacent to the gas manifolds at the end of a pipe connected to the
bottom of the generator casing.
h) Oil level indicator shall be provided in the different tanks for visual
checking of oil level and level switches shall be provided for tank level
low, high alarm.
i) A local H
2
and seal oil signaling panel with indicators, indication lamps,
together with window annunciation system shall be furnished for local
operation & checks and re commissioning in addition to facilities for
remote operation. The panel shall be provided with suitably rated
indirect strip heaters. The instruments mounted on the front of the panel
shall not be limited to the indicators for H
2
manifold pressure, Generator
casing gas pressure, CO
2
manifold pressure, Generator casing gas
purity, Gas temperature leaving the generator gas coolers, Seal oil
pressure and Hydrogen seal oil differential pressure. Panel layout &
scheme drawings, instrument details and alarm list shall be furnished
during detailed engineering for owners approval.
j) In addition, following shall be considered for remote monitoring:
i) Pump discharge pressure transmitters.
ii) Temperature of seal oil across cooler.
iii) Level transmitters at Seal oil storage tank and seal oil tank.
iv) Hydrogen to seal oil difference pressure

4.04.00 Generator Stator Cooling System


4.04.01 The system shall include sensors, pressure & temperature gauges,
temperature elements and control valve for generator gas temperature
control. Signals shall interface with DDCMIS.

4.04.02 RTD for monitoring water temperature at generator hydrogen and exciter
cooler inlet and outlet.






CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-IV - 20 DCPL-11Z02

4.04.03 Stator cooling water system shall be equipped with flow transmitters, pressure
switches, water conductivity meter, level transmitters & switches, gauges etc.
not limited to the following.

a) Three Flow transmitters for measurement and protection against low flow.
b) Pressure switches at pump discharge.
c) Two conductivity meters for monitoring and protection.
d) Level transmitters and switches at expansion tank.
e) Temperature elements at inlet and outlet of generator.


5.00.00 BOILER FEED PUMPS

5.00.01 Control logic & protection for motor driven and steam driven Boiler Feed
Pumps shall be configured in DDCMIS and pumps shall be operated from the
central control room.

5.00.02 Redundant sensors shall be provided for protection and control such as lube oil
pressure low, speed probes for TDBFP, axial shift etc..

5.00.03 Motor driven pump shall have hydraulic coupling actuator with 4-20 mA DC
signal interface and transmitter for scoop tube position.


5.00.04 BFP shall have instruments, not limited to the following, for safe, reliable and
efficient operation:
a) Bearing pedestal vibration sensors in X-Y direction for pump & motor
bearings, key phasor and speed.
b) Pump & motor bearing temperature sensors & gauges
c) Zero speed sensor, speed sensor.
d) Pressure gauges, temperature gauges, Level switches, level gauges, flow
switches, transmitters, temperature elements and switches for the sub
systems such as lube oil, working oil, cooling and other systems
/equipment.
e) Local gauge board for each BFP with local instruments not limited to the
following :
i) Supply oil pressure and drain oil temperature gauge at each
bearing.
ii) Gauges for differential pressure across feed water suction strainers,
discharge pressure of main and booster pump, suction pressure of
the booster pump, balancing leak-off pressure.

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-IV - 21 DCPL-11Z02

iii) Gauges for lube oil temperature and cooling water temperature at
inlet and outlet of coolers.
iv) Gauges for seal water temperature and cooling water temperature
at inlet and outlet of coolers.
v) Suction & discharge temperature gauges of main & booster pump.
vi) Pressure switches for main & booster pump suction and discharge,
balance leak-off, lube oil, aux. oil pump.
f) RTDs for measurement of motor winding, pump suction, pump discharge,
bearing drain oil, seal water outlet temperature etc.
g) Open limit switch of feed water pump suction valve
h) In addition, following instruments shall be provided for remote indication.
i) Pump re-circulation flow
ii) Balance leak off pressure.
iii) BFP discharge pressure
iv) BFP suction flow
v) Lube oil pressure
vi) Lube oil tank level
vii) DP across strainers
viii) Differential temperature across pump suction & discharge.
ix) Oil temperature at inlet & outlet of coolers.
x) Steam pressure at inlet to turbine
xi) Steam pressure & temperature at turbine exhaust
xii) Top and bottom barrel temp.
i) Feed pump re-circulation valves of suitable size and capacity and having
j) proven background for BFP re-circulation flow service for similar operating
condition with pneumatic actuators.
k) Signal cables exposed to high temperature area shall be Teflon coated.

5.00.05 BFP Turbine Electro hydraulic Governing System
a) The drive turbine speed shall be controlled by electro hydraulic governor
with stable and satisfactory speed control over full speed range from 0%
to 100% with control accuracy 0.1% or better.

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-IV - 22 DCPL-11Z02

b) In auto mode, it will receive speed demand signal from CLCS. The actual
speed of the turbine shall be measured by three independent speed
sensors and three independent speed measuring channels.
c) Transfer between different steam sources should be bumpless.
d) The electrohydraulic control system shall be of proven design.


5.00.06 BFP Turbine Supervisory Instruments

Turbine supervisory instruments for Turbine & Boiler Feed Pumps shall not
be limited to the following.
a) Shaft eccentricity
b) Vibration (X-Y)
c) Key phasor
d) Axial shift (Three pick ups)
e) Differential & overall expansion
f) Speed (three pick ups)
g) Governing valve % position indication
h) Stop valve end position indication
i) Bearing metal temperature for all bearings
j) Stop valve metal temperature


6.00.00 CONDENSER AND AIR EXTRACTION EQUIPMENT

6.00.01 Sequence control logic & protection for the vacuum pumps shall be configured
in DDCMIS and shall be operated from central control room.


Following instruments shall be provided as minimum. Level instruments shall
be mounted on stand pipes equipped with isolation and drain/vent valves: -

a) Magnetic type Direct Level Gauge (Flip Type) for hotwell level indication.
b) Three co-axial Guided wave radar type level transmitters in 2 out of 3
configuration for hotwell level.
c) Direct reading manometer for local indication of condenser vacuum.
d) Level switches shall be provided in hotwell for safety interlock in 2 out of 3
configuration.

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-IV - 23 DCPL-11Z02

e) Three Pressure transmitters for condenser pressure.
f) Specific conductivity measurement at each compartment of the hotwell.
Conductivity probes shall be of Insertion type with isolating valve.
g) Temperature gauge and element for condensate at CEP suction.
h) CEP minimum Recirulation control valve
i) Each CEP discharge pressure transmitter
j) CEP discharge header flow and pressure transmitters with 1 of 2 voting.
k) Direct magnetic level gauge, level switch, pressure & temperature gauge
for gland steam condenser.
l) CEP- pump & motor winding and bearing temperature.
m) Vibration sensors (X-Y) for pump & motor bearings with key phasor.
n) Condensate Make-up & Dump water flow and totalizer for monitoring
make up water consumption.
o) DP transmitter and gauge across CEP suction strainer.
p) Open & Close indication of CEP suction valves
q) Ejector steam pressure control station with pressure transmitters.


7.00.00 FEED WATER HEATERS AND DEAERATOR

Interlock, protection and controls for the system shall be configured in DDCMIS
and system shall be operated from central control room.

Following instruments shall be provided as a minimum. Level instruments shall
be mounted on stand pipes equipped with isolation and drain/vent valves: -

a) Field instruments viz. pressure gauge, temperature gauge, direct level
gauge shall be provided on Deaerator.
b) Temperature gauge and elements at the inlet and outlet of all heaters for
steam and condensate/feed water.
c) Pressure & level transmitters and temperature elements shall be provided
for remote monitoring and control of Deaerator parameters in DDCMIS.
Three wide range level transmitters shall be provided at Deaerator for
control. For level switching function, three separate level transmitters shall
be provided.
d) Magnetic type level gauge (Flip Type) shall generally be provided for LP
Water Heaters. Level gauge for HP feed water heaters and deaerator can
be of Reflex type.

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-IV - 24 DCPL-11Z02

e) Three transmitters in 2 out of 3 configuration shall be provided for drain
level of HP & LP heaters.
f) Three co axial Guided wave radar type level transmitters shall be provided
at LP heaters where the shell pressure can reach vacuum.
g) Shell temperature measurements for HP & LP heaters.

8.00.00 HP-LP BYPASS SYSTEM

8.00.01 HP-LP Bypass System shall consist of pressure reducing and desuperheating
stations (PRDS) stations.

a) HP Bypass station (HPBP) shall comprise of electro hydraulic control
valves along with integral type desuperheaters supplied with spray water
from Boiler Feed Pump. Pressure and temperature measurements for
control of HPBP shall be in 2/3 configuration.
b) LP Bypass station (LPBP) shall also comprise of electro hydraulic control
valves along with non-integral desuperheaters getting spray water from
Condensate Extraction Pump discharge. Pressure and temperature
measurements for control of LPBP shall be in 2/3 configuration.

8.00.02 Closed loop controls, interlock and protection for the system shall be
configured in DDCMIS and shall be operated from central control room.

8.00.03 System shall be supplied with control oil unit, pressure gauges, temperature
elements, transmitters as required for completeness of the system. The control
oil unit control and interlocks shall be configured in DDCMIS

8.00.04 Following parameters of the oil unit shall be monitored in DDCMIS.
a) Oil level in tanks indication & alarm.
b) Oil pump discharge pressure indication.
c) Oil temperature indication & alarm.
d) Group fault alarm.

9.00.00 REDUNDANCY IN MEASUREMENTS

Bidder shall comply with the following minimum redundancy requirement:


a) Main steam pressure : 2 out of 3
b) Turbine inlet pressure : 2 out of 3
c) Feed water flow to economizer : 2 out of 3
d) Feed Water Temperature : 1 out of 2
e) Turbine 1
st
. stage pressure : 2 out of 3

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-IV - 25 DCPL-11Z02

(Turbine steam flow)
f) Main Steam Temperature : 2 out of 3
g) Bypass steam flow : 2 out of 3
h) BFP Discharge Header Pressure : 1 out of 2
i) Hotwell Level Control : 2 out of 3
j) Deaerator Level Control : 2 out of 3
k) Gland Seal Steam Pressure Control : 1 out of 2
l) DP across feed control station : 1 out of 2
m) CEP discharge flow : 1 out of 2
n) CEP discharge pressure : 1 out of 2
o) BFP Suction Flow : 1 out of 2 (for each BFP)
p) BFP Suction temperature : 2 out of 3
q) BFP discharge temperature : 2 out of 3
r) HPBP Pressure & temperature : 2 out of 3
s) LPBP Pressure & temperature : 2 out of 3
t) LP & HP heater level control : 2 out of 3
v) Frequency transducers for correction : 2 out of 3
w) Load control (MW transducers) : 2 out of 3


10.00.00 MAJ OR CONTROLS

Following major controls in DDCMIS are foreseen for the regenerative area.

10.00.01 Closed Loop Controls

a) Feed water flow control
b) BFP speed control
c) BFP minimum recirculation flow control
d) Drain and Flush tank level control
e) HP heater level control
f) Condenser hotwell level control

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-IV - 26 DCPL-11Z02

g) LP heater level control
h) CEP Minimum recirculation flow control
i) Deaerator level & pressure control
j) Ejector steam pressure control (if steam ejector is proposed)

10.00.02 Open Loop & Sequence Controls
a) Boiler feed pump sequence control
b) Condensate extraction pump & condenser evacuation sequence control
c) Non sequential drives control

Note :

1. The successful bidder should submit the brief system write up covering Interlock,
Protection and Operatin of different equipments in the system along with each
scheme.

2. The write up on CLC and OLC need to be submitted by successful bidder.

VOLUME:IIE

SECTIONV

CONTROL&INSRUMENTATION
FOR
PLANTAUXILIARIESANDOFFSITEPLANTS


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
CONTENT DCPL-11Z02

CONTENT



CLAUSE NO DESCRIPTION CLAUSE NO.

1.00.00 GENERAL V.II-E/S-V : 1

2.00.00 SPECIFIC TECHNICAL REQUIREMENTS V.II-E/S-V : 6

3.00.00 TECHNICAL SPECIFICATION
CONTROL SYSTEM V.II-E/S-V : 8

4.00.00 OPTICAL FIBRE CABLE V.II-E/S-V : 13



CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-V - 1 DCPL-11Z02

VOLUMEIIE

SECTIONV

CONTROL&INSTRUMENTATION
FOR
PLANTAUXILLIARIESANDOFFSITEPLANTS



1.00.00 GENERAL

1.00.01 Specification herein describes the controls and interfaces for various off site
plants, which will be a part of BOP package, beyond the scope of this
specification but with limited interface with plant DDCMIS & plant auxiliaries which
are part of this package. Type of control vis-a vis the plant area are delineated
below.

A. PlantAuxiliariesSystemunderBTGpackage:

(i) DM Cooling Water System & process Heat exchangers for Turbine
and Boiler
(ii) Condenser on line tube cleaning system.
(iii) Auxiliary Cooling Water System (ACW system) with self-cleaning
strainers.
(iv) Condensate Transfer (CT) pump.
(v) Mill Reject Handling System.
(vi) Fuel Oil Pressurizing & Heating System.
(vii) Condensate On-line Polishing Unit.
(viii) Chemical Feed system.

(ix) CCTV


B. InterfacewithOtherOffsitePlantsunderBOPPackage

Data acquisition / indication of selected parameters from the following off
site plants to DDCMIS are foreseen through MODBUS/OPC protocol:The off
site plant is covered in another package(BOP package)

(i) CW sytem, CT blowdown cum reject water tank Transfer pump sytem,
CW pretreatment system.

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-V - 2 DCPL-11Z02

(ii) RO Demineralization Plant and DM water transfer system
(iii) Desalinationt Plant .
(iv) Coal Handling plant
(v) Fuel Oil Unloading& Storage
(vi) Turbine Oil Purification system
(vii) Central oil purification system
(viii) ETP Plant
(ix) Hydrogen Generation Plant
(x) Ash Handling Plant
(xi) Compressed air ( Instrument and service air) system

(xii) Electro Chlorination Plant.

(xiii) Fire Detection and Protection System.

(xiv) Heating, Ventilation & Air Conditioning

(xv) DG set

(xvi) Switchyard .


1.00.02 Off Site Plants shall be operated from their local control stations located in the
respective plant local control rooms. Some of the Plants shall have limited
operational facility from central control room as well.
All PLC based based control systems for plant auxiliaries of BTG and other offsite
plants shall be powered from separate redundant UPS. Local control panels for
such systems shall be kept in air condition environment.

Control system configuration, whether unit wise or common, shall be guided by
the respective equipment configurations indicated elsewhere in the specification
and as per approved system design philosophy.




Common station systems shall be operable from both units.





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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-V - 3 DCPL-11Z02



The following table briefs the type and mode of control for various plant auxiliary system.

SL.
NO.
AUX.SYSTEM /
PLANT
CONTROL SYSTEM CONTROL LOCATION DDCMIS INTERFACE
A. Plant Auxiliaries System (Covered in BTG Package)
i. DM Cooling
Water System-
Turbine (Closed
Cycle DMCW
System)
DDCMIS DDCMIS Monitors in
central control room
(OWS)
Integral part of
DDCMIS
ii. DM Cooling
Water System-
Boiler (Closed
Cycle DMCW
System)
DDCMIS DDCMIS Monitors in
central control room
(OWS)
Integral part of
DDCMIS
iii. ACW system DDCMIS. DDCMIS Monitors in
central control room
(OWS).
Integral of DDCMIS
iv. Condenser
online tube
cleaning system
Redundant PLC 1. Local control panel
with MIMIC.

2. DDCMIS Monitors in
central control room
Redundant OPC /
MODBUS Soft link
with DDCMIS for
monitoring.

Hardwired connectivity
to DDCMIS for critical
alarm signals.
v. Mill Reject
Handling System
Redundant PLC 1. Operator stations in
local control room.

2. DDCMIS monitors in
central control room
Redundant OPC /
MODBUS Soft link
with DDCMIS for
monitoring.

Hardwired connectivity
to DDCMIS for critical
alarm signals.
vi. Fuel oil
Pressurizing &
Heating system
Remote DDCMIS
input & output with
redundant
processor.
1. DDCMIS Monitors in
central control room.

2. DDCMIS Operator
stations at FO pump
house local control
room .
Extended node of
main plant DDCMIS
network.
vii. Condensate
Transfer pumping
system
DDCMIS DDCMIS Monitors in
central control room
Integral
viii. Condensate
Polishing unit
Redundant PLC Operator stations at
CPU control room
Redundant OPC /
MODBUS Soft link
with DDCMIS for
monitoring
ix. Chemical Dozing
System
Microprocessor
based control
Local Control Panel with
front panel PB and
indication lamps.
Hard wired interface to
DDCMIS for control &
On/Off operation &
status indication.
x. Auxiliary Boiler (if Redundant PLC Operator stations at Redundant MODBUS

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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-V - 4 DCPL-11Z02

SL.
NO.
AUX.SYSTEM /
PLANT
CONTROL SYSTEM CONTROL LOCATION DDCMIS INTERFACE
supplied in BTG
package)
Local Control Room Soft link with DDCMIS
for monitoring
xi. ESP Microprocessor
based control
(Vendor
proprietory control)
Operator Station in ESP
Local Control room.
Redundant OPC /
MODBUS Soft Link
with DDCMIS for
monitoring
xii.
CCTV
Microprocessor
Based Control
(Vendor
Proprietory
System)
-
Redundant OPC /
MODBUS Soft Link
with DDCMIS.
B.
Off Site Plant (Covered in other package (BOP))
i. CW system, CT
Blowdown cum
Reject water tank
transfer pumps
system & CW
treatment.
Redundant PLC 1. Operator stations at
CW pump house
local control room.

2. Control & Monitor
from DDCMIS.
Redundant MODBUS
Soft link with DDCMIS
for monitoring.
ii. Sea Water
Pretreatment,
RO-Desalination
Plant, Reject
water System
Miscelleneous
Pumps in
desalination plant
Redundant PLC Operator Staion in
Desalination Plant
Control Room.
Redundant MODBUS
Soft link with
DDCMIS for
monitoring
iii. RO-DM Plant &
DM Transfer
System.
Redundant PLC Operator station in DM
plant control room.
Redundant MODBUS
Soft link with
DDCMIS for
monitoring.
iv. Fuel oil unloading
& Storage
system
Redundant PLC LCP with front panel PB
and indication lamps.
Redundant MODBUS
Soft link with DDCMIS
for monitoring.
v. Turbine Oil
Purification
system
PLC / Relay based Local Control Panel Hard wired interface to
DDCMIS for
monitoring motor
current & On/Off
status indication.
vi. Coal Handling
Plant
Redundant PLC 1) Operator station at
CHP Control Room &
Hardwired Backup
panel with MIMIC.

2) DDCMIS monitor in
Central control room.
Redundant MODBUS
Soft link with DDCMIS
for monitoring
vii. ETP Plant Relay Based ETP control room None
viii. Hydrogen
Generation Plant
Redundant PLC HGP control room None
ix. Ash Handling
Plant
Redundant PLC 1) Operator stations at
AHP control room.

2) DDCMIS monitor in
central control room.
Redundant MODBUS
Soft link with DDCMIS
for monitoring

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VOL-II-E-SEC-V - 5 DCPL-11Z02

SL.
NO.
AUX.SYSTEM /
PLANT
CONTROL SYSTEM CONTROL LOCATION DDCMIS INTERFACE
x. Centralized
Turbine Oil
Purification
system
PLC / Relay based Local Control Panel Hard wired interface to
DDCMIS for
monitoring motor
current & On/Off
status indication.
xi. Instrument Air &
Service Air
Compressors &
air drying plant
Vendor
Proprietary PLC
for compressor
control &
Redundant PLC
for other items not
covered in
compressor
vendor proprietary
PLC.
1. Local compressor
panel

2. DDCMIS Monitors in
central control
room
Hardwired & soft link
connectivity with
DDCMIS for remote
start/stop, alarm and
monitoring.
xii.
Electrochlorinatio
n Plant(Common
for Desalination
SW Inlet Pre-
Treatment & SW
Intake pump)
Redundant PLC Operator Station at
Local Control Room.
Redundant MODBUS
Soft link with
DDCMIS for
monitoring
xiii.
Heating,
Ventilation & Air
Conditioning
Redundant PLC Operator Station in
Local Control Room
Redundant OPC /
MODBUS Soft Link
with DDCMIS.
xiv.
Fire sensing and
protection system
Microprocessor
based control
(Vendor
proprietary
system)
Local Control Panel Redundant OPC /
MODBUS Soft Link
with DDCMIS.
xv. DG Set
Vendor
proprietary control
system
Local Panel.
Redundant OPC /
MODBUS Soft Link
with DDCMIS.

Hardwired connectivity
to DDCMIS for critical
signals.
xvi.
220kV / 400kV
switch yard.
SAS(SACDA)
Operator Station in
Local Control Room
Redundant OPC /
MODBUS Soft Link
with DDCMIS.
C. Offsite Area (Separate Package)
i.
Sea Water Intake
& Chlorination
PLC based
Operator Station in
Local Control Room
Redundant OPC /
MODBUS Soft Link
with DDCMIS.
ii.
Unloading coal
J etty
PLC based.
Operator Station in
Local Control Room
Redundant OPC /
MODBUS Soft Link
with DDCMIS.

1.00.03 Considering the high ambient noise and electromagnetic interference prevailing in
power plant, it is recommended that communication links between off-site controls
and plant DDCMIS shall be based on dual Optical Fiber Communication (OFC)
medium. Redundant cable shall be laid separately. Necessary ports / converters
shall be provided.

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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-V - 6 DCPL-11Z02


1.01.00 GENERALDESIGNPHILOSOPHY

1.01.01 General design philosophy outlined in the specification shall apply to plant
auxiliaries as well..

1.01.02 PLC systems shall be time synchronized with the GPS Master Clock. Bidder shall
arrange for the necessary ports ans cable for the purpose as wel.

2.00.00 SPECIFICTECHNICALREQUIREMENTS

2.01.00 FUELOILPRESSURISING&HEATINGSYSTEM

2.1.01 ControlPhilosophy

a) Control system shall be responsible for withdrawl from storage and
transportation of fuel oil from the storage tank up to the furnace.

c) Pressurizing pumps shall be operated from local station as well as from
control room. Start of standby pump in case of running pump trip or pump
developing low pressure shall be automatic by selection. Required pressure
switches shall be furnished.

d) HFO temperature at outlet of heaters shall be adjusted by regulating steam
flow to heater. Adjustment shall be possible from both local station as well
as from control room.

e) Fuel oil pump discharge header pressure control shall be automatic.
Adjustment shall be possible from both local station as well as from remote.
Control valve with accessories and pressure transmitters shall be provided.

f) Drain oil pumps in boiler area shall be operated from CCR. Drain tank shall
be provided with high and low level switch for alarm & protection.

g) Non contact radar type level transmitters, mechanical type level gauges,
level switches, temperature elements & gauges etc. shall be provided on
fuel oil day tanks for control & monitoring.

j) Strainers shall be monitored for fouling with local indication.


2.02.00 CIRCULATINGWATER(CW)&AUX.COOLINGWATER(ACW)SYSTEMANDCONDENSEROLTC:

2.02.01 CW SYSTEM: The CW system control, logic, interlocks and monitoring shall be
by dedicated PLC system to be covered in BOP package. The CW system shall
be controlled and monitored from HMI station of the PLC panel to be located at
CWPH control room.

The PLC System shall have redundant Fibre optic connectivity to DDCMIS for the
control and monitoring of CW system from DDCMIS HMIs also.


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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-V - 7 DCPL-11Z02

2.02.02 Control shall be realized in DDCMIS & ACW pumps shall normally be operated
from central control room
2.02.03 Pump and motor bearings of ACW pumps shall be provided with vibration pick
ups (both in X-Y direction) and key phasor for on line monitoring and analysis.
2.02.04 HT motors winding temperature and bearing temperature of equipment and motor
shall be monitored in DDCMIS..
2.02.05 Motor current & energy consumption shall be monitored in DDCMIS.
2.02.06 Inlet & outlet temperature of heat exchangers shall be monitored. DP transmitters
& gauges for monitoring fouling condition of heat exchangers.
2.02.07 Tube cleaning system and automatic self-cleaning filter, where envisaged, shall
be furnished with its own PLC based local control with limited hardwired interface
with DDCMIS.

2.03 CLOSEDCYCLEDMCOOLINGWATERSYSTEMFORBOILERANDTURBINE

Field instruments shall not be limited to the following:

a) Level instruments viz, transmitter, gauge and switches on the damper tank.
b) pH at outlet of heat exchangers.
c) Inlet & outlet temperature (both for cooling medium & coolant) of heat
exchangers. DP transmitters & gauges for monitoring fouling condition of
heat exchangers.
d) Pressure transmitters, pressure gauges, pressure switches and flowmeter,
standpipe etc. shall be furnished.
e) DMCW discharge header pressure control valve.

2.04 CONDENSATETRANSFERPUMPS&DMSERVICEWATERPUMPS

Field instruments shall not be limited to the following :

a) Guided wave radar type level transmitters and level switches at condensate
storage tank shall be provided for interlock & monitoring.
b) Strainers shall be monitored & alarmed for fouling condition by providing DP
gauge and DP switch.
c) Flow measurements for monitoring actual consumption of makeup water.
d) Pressure transmitters, pressure gauges, pressure switches and flowmeter,
standpipes etc. as required shall be furnished.




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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-V - 8 DCPL-11Z02


3.00.00 TECHNICALSPECIFICATIONCONTROLSYSTEM

3.00.01 Brief technical specification of the PLC based control systems are delineated
below.

3.00.02 Programmable Logic Controller (PLC) based control system shall have 1:1 hot
redundant configuration. Central Processing Units (CPUs) shall have word length
of 32 bits minimum.

3.00.03 Following components shall be redundant as well : communication processors,
memory modules, rack power supply units, bulk IO power supply units, IO
communication modules, data highway and high speed (100Mbps) data network
connecting the operator stations.

3.00.04 Two CPUs shall operate on fault tolerant mode with continuous self and cross-
monitoring. Failure of the active CPU shall not affect the operation of the plant. In
the event of failure of active CPU, tasks shall be transferred to the standby CPU
within fastest possible transfer time (<5m sec.) without causing any relays to
drop out during the transfer.

3.00.05 CPUs shall not be loaded to over 60% of their capacity even under worst data
loading conditions. It shall be possible to make a manual transfer from the active
to the back-up CPU from engineering station and as well as from the front panel
of CPU module.

3.00.06 Modules shall have adequate status and diagnostic indication on the front panel.

3.00.07 System shall be of modular construction and expandable by adding hardware
modules. Bidder shall provide at least 20% or a minimum of one off, spare
channels as hot-on-rail spares in each configured cards / modules. In addition to
this, 10% or minimum of one off, extra assigned complete spare modules
mounted on rails in racks for each type of I/O modules shall also to be provided.
The spare channel and cards shall be fully wired and terminated.

3.00.08 Memory unit of the CPU shall be field expandable at least by 25%. Operating
system / application program / sequence logic etc. shall be stored in nonvolatile
memory for automatic re-booting. Dynamic memories shall be provided with
battery back up at least for 360 hours.


3.00.09 Number of input / output points per card shall not exceed 16 (sixteen) for digital
and 8 (eight) for analog / thermocouple / RTD signals. Individual input and Output
channels shall have galvanic / optical isolation. Merely fusing of individual or a
group of channels is not acceptable.

3.00.10 Data communication system of the PLC shall not be limited to the following:

2.04.01.1 Internal bus and external data network loading shall in no case be
more than 60% of its capacity.


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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-V - 9 DCPL-11Z02

2.04.01.2 Disrupted message shall be automatically retransmitted when the
system is restored.

2.04.01.3 Failure or physical removal of any module connected on the system
bus shall not lead to any loss of communication.

2.04.01.4 Diagnostics message shall be issued on fault detection.

2.04.01.5 Bus change over from active bus to stand by bus, during failure of
active bus, shall be performed automatically and bumplessly. Such event
shall be suitably logged or alarmed.

2.04.01.6 Noise immunized and reliable highspeed dual fault tolerant optic fiber
cable communication with standard communication protocol shall be
provided between PLC s and remote or extended I/O modules.

2.04.01.7 Main data network shall comply with the International Standard IEEE-
802.3 (Ethernet) for data exchange and communication.

3.00.11 Operator workstation shall be complete with latest user friendly operating system,
24 colour LCD monitor, membrane KB, mouse, colour laser printer and dot
matrix printer. In addition, a laptop unit loaded with engineering software shall be
furnished.

3.00.12 The functions performed from the HMIs shall not be limited to the following:

a) Selection of auto/Manual, open/close, sequence auto, start/stop operation.
b) Dynamic Mimic display depicting the process.
c) Alarm monitoring, report & log generation, printing of trends etc.
d) On line / historical trending, historical storage and retrieval of data.


3.00.13 Software

a) Necessary software for implementation of the control logics, operational
displays & logs, data storage, retrieval and other functional requirements,
shall be provided.

b) Licensed version of required software including operating system,
configuration and HMI software shall be provided.

c) Detail documentation on the programming softwares as part of the O&M
manual.

3.00.14 PowerSupply

a) Power supply to the PLC system shall be provided from solid-state 240V AC
1% packaged UPS (Uninterruptible Power Supply) units to be placed local
to the control systems. UPS system shall be complete Ni-Cd type battery &

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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-V - 10 DCPL-11Z02

battery chargers. UPS shall have adequate capacity to cater 100% load
without overloading. UPS system shall be adequate to provide back up
power for not less than 60 minutes.

b) UPS shall be complete with AC Distribution board. Two feeders shall be
extended from ACDB to PLC.

c) Bulk power supply units for interrogation, relay and solenoid voltage shall be
separate from system power supply units and shall be redundant.

3.00.15 System shall have MTBF better than 99.7% and shall be hot maintainable.
System hardware shall be designed to be `fault avoidant' by selecting high-grade
components of proven quality and properly thermally de-rated design. The
network shall have extensive fault monitoring, self-surveillance & on-line self-
diagnostic capability so that failure is immediately detected.

3.00.16 System shall automatically check & correct gain & drift for ADDCMIS on-line.

3.00.17 Data exchange in a bus shall be fully monitored and checked for validity.

3.00.18 Response time consisting of IO scan time, data communication time, processing
time etc. shall be equal to or less than the following :

a) OLCS & sequence control inputs : 100 ms.
b) CLCS inputs : 250 ms.
c) Monitoring analog parameters : 500 ms.
d) Monitoring digital parameters : 100 ms.

3.00.19 Following operations will be performed on I/Os, as required:

a) Square root extraction
b) Pressure & temperature compensation
c) Reasonability check of all inputs, validation and quality tagging like good,
bad, suspect etc.
d) Channel wise engineering unit conversion
e) Contact bounce filtering with adjustable time constant.

3.00.20 The controllers shall be time synchronized to GPS master clock via IRIG-B or
Ethernet port. Software capability shall be provided to implement closed loop
control functions as follows:

a) PID control and their variations.
b) On-off control
c) Cascade control
d) Ratio and bias control

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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-V - 11 DCPL-11Z02


3.00.21 Features for Open Loop Control shall not be limited to following:

a) Logic functions like AND/OR/NOT gates, timers (on-delay, off-delay), shift
registers, counters, latches, flip-flops, mono-shots etc.
b) Automatic sequence control for start up and shutdown of auxiliaries /
equipment in functional groups initiated by command from operators
console. A sequence shall be made of steps executed in predetermined
order according to logic criteria. For each step there shall be a provision for
`waiting time' and `monitoring time'. System shall have the capability to
bypass a step, if desired, from the operators station. Such action however
shall be registered as an exception.
c) Inputs for protection system shall be of high priority. In the event of either
loss of control power or control signal input to the drive, the drive shall
remain in its last position unless specifically required otherwise. The system
shall be designed such that no upset occurs either to process or to the drive
when the power is restored.


3.00.22 Interface of the system with M.C.C/ Switch gears shall be in the form of potential
free contacts via interposing relay modules mounted in the respective switchgear
or MCC unit. Other interfacing relays shall be mounted in a cabinet separate from
the system cabinet. 10% wired additional interposing relay modules shall be
provided as installed spare. Freewheeling diodes shall be provided across the
coil of DC solenoid and contactors / relays. For AC solenoids and contactors
directly driven from output cards, arc suppressors shall be provided across the
coil.

Each IO rack shall have 10% spare rack space for future upgradation.

3.00.23 Single programming instruction / command shall be sufficient to delete a program
rung from memory. Similarly, any rung can be inserted into the existing program.
The active and the stand-by CPU programs shall equalize automatically, once the
new program is permitted to RUN.

3.00.24 Updating time and reaction time shall be as follows:

a) Calling up a mimic : 2 sec or better
b) Updating status signal in mimic : 1 sec or better
c) Updating variables in a mimic : 1 sec. or better
d) Issuance of command to output : 1 sec. or better
(without considering process lag)

3.00.25 Displays shall be classified into overview display, group display, point display and
trend display.


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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-V - 12 DCPL-11Z02

3.00.26 Printing of logs shall be initiated automatically at prescribed time intervals, or
initiated on demand by the occurrence of predefined events.

System shall permit the operator to specify minimum of 5 summary logs each
with minimum of 25 points to be printed on demand.

3.00.27 Salient features of the PLC system for I/O handling shall be as follows.

a) Input filters to attenuate noise.
b) Isolation of 1500V AC for the input & output module.
c) Comm. Mode Noise rejection for analog inputs of 120 db at 50 Hz.
d) Normal mode noise rejection for analog inputs of 60 db at 50 Hz.
e) LED indicators on each card to show status of input.
f) All the outputs shall be with individual fuse.
g) J /K type thermocouple mV input where applicable.
h) Pt-100 three / four wire resistance thermometer input where applicable.
i) 24 V DC power supply to field mounted two wires transmitters.

3.00.28 Salient hardware/ software features of the CPUs shall be as follows:

a) Watch dog timer : Periodical reset. Alarm and interruption, if not
reset within stipulated time.

b) Max. scan time for inputs : 1 sec. max.

c) Maximum Scan Rate : 1 ms (Per K Word) or better

d) Memory capacity : 25% spare capacity after full utilization.
Expandable in multiples of 16 K.

e) Comm. processor : Separate

f) Battery back up for RAM : 360 hrs continuous operations.

g) Diagnostic feature : Periodic, automatic self- diagnostic.

3.00.29 Salient features of the Input / Output modules are as follows.

a) Allmodules
1. Surge withstand capability : IEC-255.4

b) DigitalGeneral
1. No. of channels / module : 16
2. Interrogation voltage : 24V DC or 48 V DC

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VOL-II-E-SEC-V - 13 DCPL-11Z02

3. Status indicator : LED type.
4. Isolation : Optical

c) DigitalInputModule
1. Contact bounce filtering : Adjustable time constant of 15 m.
sec.
2. Diagnostic : Module fault


d) DigitalOutputModule
1. Output protection : Short ckt. Proof & Individual fuse
2. Diagnostic : Module fault

e) AnalogGeneral
1. No. of channels / module : 8
2. Isolation : Galvanic/Optical

f) HilevelAnalogInputModule
1. Type of input : 4-20 mA DC / 1-5V DC
2. A/D Converter : 11 bits +Sign (or better)
3. Accuracy : 0.1% or better
4. Diagnostic : Module fault
5 Powering of transmitter : 24 V DC 2 W type

g) LowLevelAnalogInputModule
1. Type of input : PT-100; T/C(As required)
2. C-J -C : On Module
3. Accuracy : 0.1% or better
4. A/D converter : 15 bits +Sign (or better)
5. Diagnostic : Module fault

h) AnalogOutputModule
1. Type of output : 4-20 mA DC
2. Accuracy : +0.1% or better
4. A/D Converter : 11 bits +Sign (or better)
5. Load : 600 OHM
6. Diagnostic : Module fault

3.00.30 Bidder shall provide control furniture etc. as required.


4.00.00 OPTICALFIBRECABLE

4.00.01 This specification defines the minimum general requirements for the Design,
manufacture, supply, inspection, installation, testing & commissioning of optical
fiber cables and accessories, such as fiber distribution (patch) panels, adapters,
connectors, joint boxes, pigtails and other components, as required to complete
the system. Bidder shall consider all related activities, such as cable stripping,
cable entry in boxes and panels, cable fiber splicing/fusion, cable performance
testing and other services, to achieve a properly documented and operational
cable network.

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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-V - 14 DCPL-11Z02


4.00.02 Fiber Optic Cables shall be installed on cable tray, duct bank, cable trench, as
necessary. For outdoor applications the cable shall be armoured with Poly
Ethylene sheathing. Cable shall be routed through suitable grade permanently
lubricated HDPE protection pipe as per IS 4984, IS 12235 & TEC.G/CDS-08
/01of suitable size @ 53% fill factor.

4.00.03 The Optical Fiber core shall be of ultra pure fused silica glass coated with UV-
cured acrylate suitable to withstand temperature of about 80C (continuous).

4.00.04 Fiber optic cable shall be of loose tube design. Typically, fibers shall be housed
in-groups of 6 (minimum) within gel-filled buffer tubes to protect against ingress of
moisture and vibration. The tubes shall be manufactured with industry standard
material like Poly-Butelene Terathylate (PBT). They shall be colored for easy
identification. Buffer tubes shall be approachable with industry standard tools and
practices. The buffer tubes shall be stranded around the Central Strength
Member utilizing Reverse Oscillating Lay (ROL). Blank fillers shall be used as
necessary to maintain circular cable structure. Cable shall withstand water
penetration when tested with a one meter static head or equivalent continuous
pressure applied at one end of a one meter length of filled cable for one hour. No
water shall leak through the open cable end.

4.00.05 The central strength member of the cable shall be Fiberglass Reinforced Plastic
(FRP) or other material with equivalent mechanical strength to provide both
tensile and anti buckling strength to the cable.

4.00.06 In addition to central strength member, additional strengthening substance like
aramid yarns shall be helically applied over the cable core to provide additional
tensile strength to the cable.

4.00.07 The cable shall be of dual jacket & armoured. Inner sheath consists of a medium
density polyethylene (MDPE) jacket extruded over the cable core. Two highly
visible ripcords are placed under the jacket to aid in sheath removal. A co-
polymer coated steel tape is corrugated and wrapped around the inner jacket to
provide additional cable compression strength and rodent protection. The armor
is covered with an outer black FRLS MDPE jacket. A ripcord is also placed
underneath the armor for easy outer jacket removal.

4.00.08 Minimum bending radius shall be equal or more to 15 D. A continuous strength
member shall be provided for the entire length of the cables. Every tube and fiber
shall be colour coded to provide easy identification. The outer sheath shall be
marked to show fiber type and cable classification at suitable intervals.


4.00.09 Entire length of the cable shall be marked with the following at regular intervals:

Manufacturers Name
Month and year of manufacturer
Coded description of the cable based on Telcordias (Bellcore) SR-2014
Suggested Optical Cable Code (SOCC).
Sheath Identification Number

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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-V - 15 DCPL-11Z02

Sequential Length Marking in meter
A Telephone Handset symbol to distinguish communication from power
cable as per NESC section 35 G.

4.00.10 Fiber optic cable shall provide a long life expectancy of minimum 25 years and
shall meet the industrial standard of continuous operation at temperature of 55
O

C and humidity to 100% without degradation to optical or mechanical
performance.

4.01.00 Optical fiber used in the plant shall generally conform to the following
specification.



SPECIFICATIONFORG.652MONOMODEFIBER

ATTRIBUTES VALUE
1. Cladding Diameter 125 m 1.0 m
2. Cladding non-circularity 1.0%
3. Attenuation Coefficient at
(a) 1290 nm to 1340 nm
(b) 1525 nm to 1575 nm

< 0.36 dB/km
< 0.25 dB/km
4. Chromatic Dispersion Coefficient
at
(a) 1310 nm
(b) 1550 nm

< 3.5 ps/nm.km
< 18 ps/nm
5. Polarization Mode Dispersion
(PMD)
0.5 ps/ km
6. Mode Field Diameter at
(a) 1310 nm
(b) 1550 nm

9.2 0.4 m
10.50 1.0 m
7. Mode Field Concentricity Error 0.5 m
8. Proof Test 1%
9. Fiber Curl (ROC) 4.0 m
10. Macro-bend Test on Fiber at
1550 nm
0.1 dB



4.02.00 CABLEASSEMBLY

4.02.01 OpticalFiberEnvironmentalSpliceEnclosure

Optical fiber environmental splice joint enclosures shall be re-enterable and rack /
wall mountable. The interior splice case shall be equipped to mechanically
accommodate single-mode optical fibers connected by the fusion method. Splice
case shall be equipped to organize the splice trays and the required service loops
of buffered incoming optical fibers and outgoing 'pigtails' in such a way that allows
each completed splice and associated optical fiber to be maintained in an
unstrained configuration. Splice enclosure shall be dust and weather proof.

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4.02.02 FiberOpticDistributionPatchPanel

Fiber optic distribution panels shall be provided as required. Fiber optic
distribution panels shall be of a standard wall mounted sheet metal enclosure
type. Fiber optic distribution panels shall be equipped to secure optical fiber patch
cables and pigtails to prevent damage during all operation and maintenance
functions. In general splice enclosure are envisaged. However, if no optical fiber
splice enclosures are implemented, than the fiber optic distribution panels shall
be equipped with splice trays for storage and protection of fusion splice
connections of single-mode fiber optic cable and pigtails. Each fiber optic
distribution panel shall be fully equipped with 'SC' type bulkhead connector
sleeves or equivalent. Unused sleeve ports shall be equipped with reusable caps
to prevent the intrusion of dust.

4.02.03 PigtailandPatchCord

All pigtails shall be factory SC-connectorized, and satisfy specified performance
for optical links. All unused pigtails (including spares) shall be terminated with the
connector to a bulkhead connector sleeve, protected by a reusable cap on the
opposite sleeve port, to prevent the intrusion of foreign material or dust. All
necessary connectorized pigtails shall be provided in the lengths required.

4.03.00 FIBEROPTICTOOLKIT

4.03.01 OpticalTimeDomainReflectometer

a) A recording optical time domain reflectometer (OTDR) will be utilized to test
for end-to-end continuity and attenuation of each optical fiber. The OTDR
shall be equipped with data storage, printer, help feature, compare trace
features and OTDR software. The data storage unit must include a built-in
floppy disk drive capable of storing a minimum of 100 test traces.

b) Data traces saved to disk shall include the following labels:

Fiber Identification (ID) with a minimum of 10 characters
Cable ID with a minimum of 10 characters
OTDR location with a minimum of 20 characters
Far End location with a minimum of 20 characters
Test Operator initials with a minimum of 3 characters

c) The printer shall preferably be internal. The printer shall be able to print data
traces within 30 seconds or less. The machine settings used to repeat tests
at a later time shall include: index, range, wavelength, average time, pulse
width and scale settings. The test results (on printout) shall provide
information including: loss, distance, reflectance, date and time.

d) The requirements for the compare trace feature include the ability to recall
two historical traces from a diskette and display them simultaneously for
analysis and printing. The compare trace must compute and display a single
graph representing any differences between two traces. The compare trace

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must be able to recall historical traces from a diskette and perform the same
tests on connected live fibers. The compare trace shall perform a two point
loss measurement test for any two particular fibers in a comparison analysis.
The losses between the two points on each fiber shall be displayed, and the
differences between the two readings clearly shown.

e) The OTDR must be equipped with software to support all of the required
functions. The software shall provide for printing of whole set of traces
(batch print) with minimal commands eliminating the time spent for printing
traces individually.

f) Contractor shall provide all mounting accessories, cables and connectors
required to establish data communication.

4.03.02 FiberOpticSplicer,TerminatorAndToolKitBox

Bidder shall provide new unused tools comprise of Splicer and Fusion J ointer and
tool kit comprise of cutter, stripper, polishing tool, handheld microscope, heat
shrinkable sleeve, scissor, knife etc. as required for maintenance and
commissioning.

4.04.00 TESTS

Following minimum test as per any approved standards shall be carried out on
the cables

a) Attenuation And Dispersion Characteristics Tests
b) Proof Tests
c) Macro-Bend Resistance Test
d) Mechanical Tests
e) Low And High Temperature Cable Bend Test
f) Impact Resistance Test
g) Compressive Strength Test
h) Tensile Strength Test
i) Cable Twist Test
j) Cable Cyclic Flexing Test
k) Environmental Characteristics Test
l) Temperature Cycling Test
m) Color Permanence Test Cable Aging Test

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n) Water Penetration Test
o) Lightning Test
p) Routine Test / Sample Test
q) Site Test (Like Continuity & Attenuation)



VOLUME:IIE

SECTIONVI

TECHNICALSPECIFICATIONINSTRUMENTSANDSYSTEMS


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
CONTENT DCPL-11Z02

CONTENT



CLAUSENO. DESCRIPTION PAGENO.

1.00.00 FIELD INSTRUMENTS V.II-E/S-VI : 1

2.00.00 CLOSED CIRCUIT TELEVISION SYSTEM V.II-E/S-VI : 32

3.00.00 CONTROL PANEL / DESK MOUNTED
INSTRUMENT AND ELECTRICAL
SYSTEM ACCESSORIES V.II-E/S-VI : 45

4.00.00 CONTROL VALVE, ACTUATORS AND
ACCESSORIES V.II-E/S-VI : 55

5.00.00 CONTROL DESK / PANEL / RACK V.II-E/S-VI : 59

6.00.00 DISTRIBUTED DIGITAL CONTROL & V.II-E/S-VI : 66
MANAGEMENT INFORMATION
SYSTEM (DDCMIS)

7.00.00 DDCMIS HARDWARE & SOFTWARE
SPECIFICATION V.II-E/S-VI : 112

8.00.00 COMPUTERIZED MAINTENANCE AND
INVENTORY MANAGEMENT SYSTEM V.II-E/S-VI : 126

9.00.00 HART TRANSMITTERS & MAINTENANCE V.II-E/S-VI : 128

10.00.00 ROTATING MACHINE CONDITION MONITORING
SYSTEM (RMCMS) V.II-E/S-VI : 129

11.00.00 PLANT-WIDE NETWORK V.II-E/S-VI : 134

12.00.00 CONTROL & INSTRUMENTATION CABLE V.II-E/S-VI : 136

13.00.00 ERECTION HARDWARE V.II-E/S-VI : 141

14.00.00 SPECIAL TOOLS & TACKLE AND TEST
EQUIPMENT FOR DDCMIS & OTHER SYSTEMS V.II-E/S-VI : 150



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VOLUME:IIE

SECTIONVI

TECHNICALSPECIFICATIONINSTRUMENTSANDSYSTEMS



1.00.00 FIELDINSTRUMENTS

This section provides general hardware guidelines for field instruments and
equipment to be supplied under this specification.

1.01.00 PRESSURETRANSMITTER

01. Working Principle : Smart (HART)

02. Type : 2 - Wire

03. Output Signal : 4-20 mA DC. with HART protocal

04. Signal Processing : Silicon solid state electronic circuitry

05. Measuring Element : Capsule / Diaphragm

06. Element material : AISI-316 (Stainless Steel) or better

07. Static Pressure : 150 % of maximum span continuously, without
affecting the calibration.

08. Turn-down ratio : 100:1.

09. Span and Zero : Locally adjustable non-interacting. Facility for
elevation and suppression by 100% of span

10. Enclosure Class : IP-65

11. Output Indicator : LCD

12. Nameplate : Tag number, service engraved in SS tag plate

13. Body : Forged Carbon Steel for air and flue gas
application and SS for other application.

14. Operating Voltage : 16 - 48 Volts D.C.

15. Load : 600 Ohms (min.) at 24 Volts D.C.

16. Ambient Temperature : 0 - 50
O
C

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17. Performance :

i) Accuracy : 0.1% of Span or better

ii) Repeatability : 0.05% of Span or better

iii) Response time : 100 msec or better

18. Sealing/Isolation : Extended diaphragm with 5 meters SS
armoured capillary for viscous fluid
applications.

19. Accessories : a) Universal mounting bracket suitable for
2 pipe mounting.
b) High tensile carbon steel U- bolts.
c) Siphon for steam and hot water services.
d) NPT 2-valve stainless steel manifold,
constructed from SS316 bar stock.
e) Companion flange with nuts, bolts and
gaskets.
f) Hand held configuration kit for calibration
of Smart Transmitter.
g) NPT cable gland

1.02.00 DIFFERENTIALPRESSURETRANSMITTER/FLOWTRANSMITTER

01. Working Principle : Smart (HART)

02. Type : 2-Wire

03. Output signal : 4-20 mA DC with HART protocal.

04. Signal Processing Unit : Silicon solid-state electronic circuitry

05. Measuring element : Capsule/Diaphragm

06. Element material : AISI-316 (Stainless Steel) or better

07. Static Pressure/
Overload Pressure : Maximum line (or static) pressure on either
side without permanent deformation or loss of
accuracy

08. Turn-down ratio : 100 : 1 minimum

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09. Span and Zero : Locally adjustable, non-interacting

10. Enclosure class : IP-65

11. Zero suppression /
elevation : At least 100% of Span

12. Output Indicator : LCD type

13. Nameplate : Tag number and Service engraved in SS tag
plate

14. Body : Forged Carbon Steel for air and flue gas
application and SS for other application
.
15. Ambient temperature : 0 - 50
O
C

16. Operating Voltage : 16 - 48 Volts DC

17. Load : 600 Ohms (min.) at 24 Volts DC

18. Performance :-

i) Accuracy : 0.1 % of span or better

ii) Repeatability : 0.05 % of span or better

iii) Response time : 100 msec or better

19. Sealing / Isolation : Extended diaphragm with 5 meters SS
armoured capillary for viscous fluid
applications.

20. Accessories : a) Universal mounting bracket suitable for
2 pipe mounting.
b) High tensile carbon steel U-bolts.
c) Siphon for steam and hot water services.
d) Companion flange with nuts, bolts and
gaskets.
e) Hand held configurator kit for calibration
of Smart Transmitter.
f) NPT cable gland
g) NPT generally 5-valve stainless steel
manifold, constructed from SS316 bar

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stock. 3 valve manifold for DP application
in flue gas and air.

1.03.00 DISPLACERTYPELEVELTRANSMITTERS

01. Type : Smart

02. Stages of operation : Continuous

03. Material -

i) Displacer : AISI 316 SS

ii) Suspension wire : AISI 316 SS


iii) Torque tube housing : Carbon steel or SS as per application

iv) Torque tube : Inconel

v) Displacer chamber : CS or SS as per process application

vi) Transmitter Housing : Die cast aluminium or better

04. Operating Voltage : 16-48 Volts D.C.

05. Transmission : 2-wire

06. Output Signal : 4-20 mA DC with HART.

07. Signal processing : Solid-state electronic circuitry

08. Static / overload pressure : Maximum static pressure without permanent
deformation or loss of accuracy.

09. Turn-down ratio : 10 : 1 or better

10. Zero & Span : Easily accessible (local zero & span
adjustment and non-interactive type)

11. Enclosure Class : IP-65

12. Output Indicator : LCD type

13. Nameplate : Tag number and Service engraved in stainless
steel tag plate

14. Ambient Temperature : 0 - 50
O
C

15. Load Impedance : 600 Ohms at 24 Volts (minimum)


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16. Process Connection : 2 Companion flange with nuts, bolts and
gaskets
17. Performance -

Accuracy : +_ 0.5 % of span or better

18. Accessories : a) Counter Flange, nuts, bolts, gaskets etc.
b) Weights for 5 point calibration of
instruments.
c) Vent and drain plugs
d) Special calibration tool/configurator,if any.
e) NPT cable gland

19. Preferred Features : a) Test plug connection and cutout terminals
physically separated from other
electronics.

b) Electronic Damping facility (adjustable).

1.04.00 MASSFLOWMETER

1.04.01 Sensor

01. Measuring Principle : Coriolis Mass flow.

02. Primary Element : Flow Tube of 316SS or better

03. Heating Arrangement : Integral.

04. Temperature Control : For heavy fuel oil application.

05. Process Connection : Flanged of rating as per process requirement.

06. Drain : Self-draining facility

07. Enclosure : Stainless steel

08. Accessories : Counter flanges, Mounting nuts, bolts, gaskets
etc.
1.04.02 Transmitter

01. Measured quantities : Mass Flow rate, Total Mass Flow, Density,
Temperature.

02. Input Signal Processing : Digital Processing.

03. Display : Digital Display (LCD).

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04. Output : 2 off. isolated 4-20mA DC output with HART
selectable from four measured quantities.


05. Load : < 750 ohms.

06. Power supply : 240V AC, 50 Hz.

07. Turn Down : 100:1

08. Accuracy : +_ 0.2 % of measured value

09. Housing : IP 65

10. Nameplate : Tag number, service engraved in stainless
steel tag plate

11. Accessories : a) Handheld configurator
b) Mounting U-bolts, nuts, bolts, prefab cable
etc.
c) NPT cable gland

1.05.00 PRESSUREGAUGEANDDIFFERENTIALPRESSUREGAUGE

01. Type : Bourdon/Bellows/Diaphragm

02. Sensing & Socket : AISI-316 SS

03. Movement Material : AISI-304 SS

04. Case Material : Stainless steel. IP-65.

05. Dial Size : Generally 150 mm

06. Scale : Black lettering on white in 270
O
arc.

07. Window : Shatterproof glass

08. Range Selection : Normal process pressure: 50~70 % of range

09. Over-range Protection : 125% of maximum range by internal stop.
External stop at zero.

10. Adjustment : Micrometer screw for zero. Internal micrometer
screw for range.

11. Element Connection : Argon welding


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12. Process Connection : 1/2" NPT(M) Bottom for local, back for panel
mounting.

13. Performance : Accuracy of 1.0 % of span or better.

14. Operating ambient : 0 - 50
O
C

15. Safety Feature : Blow out disc /diaphragm at the back

16. Accessories : a) Snubbers and Glycerin filled for pulsating
fluid applications and at pump discharge.
b) Stainless steel Diaphragm seals for
viscous fluids.
c) 3-Way SS316 Gauge cock for pressure
gauges.
d) 5-valve SS316 manifold from barstock for
differential pressure gauge.
e) Siphons for steam and hot water services.

17. Applicable standard : IS-3624 / 1996

19. Nameplate : Tag number, service engraved in stainless
steel tag plate

1.06.00 TEMPERATUREGAUGE

01. Type : Mercury or gas filled.

02. Sensing Element Material : Bourdon - AISI-316 SS

03. Capillary Armoring : Stainless steel flexible

04. Movement Material : AISI 304 SS

05. Bulb / Stem Diameter : 12 mm

06. Bulb / Stem Material : AISI 316

07. Capillary : Stainless Steel

08. Connection to well : NPT

09. Case Material : Stainless steel

10. Dial Size : 150 mm in general

11. Scale : Black lettering on white in 270
O
arc.

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12. Mounting : Surface/Panel

13. Over range Protection : 125 % of range or more

14. Instrument connection : Bottom for local and back for panel mounting.

15. Range : Normal temperature50~70% of range.

16. Zero adjuster : Micrometer screw adjustable from front.

17. Window : Shatterproof glass.

18. Accuracy : 1 % or better

19. Enclosure Class : IP-65

20. Capillary : 5 meters (local surface)/15.0 meters (local
panel) - armoured stainless steel

21. Compensation : Capillary and Case Compensation

22. Accessories : a) Forged barstock thermowell screwed as
per ASME PTC code. Process
connection M 33X2 (M).
Material of construction of Thermowell:

- SS 316: In general

- Inconel: For flue gas application

- Tungsten carbide: For coal mill
application.

23. Nameplate : Tag number, service engraved in stainless
steel tag plate



1.07.00 THERMOCOUPLES

01. Type : a) Type-J (Iron Constantan) / Type-K
(Chromel Alumel) / Type-R (Pt.- Rhodium
Pt.). [As per application]

b) Duplex

c) Ungrounded

02. Wire gauge : 16 AWG for Type-K, 24 AWG for Type-R


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03. Standard : ANSI-MC 96.1.

04. Protecting Tube :-

i) O.D. : 8 mm

ii) Material : 316-SS Seamless

iii) Filling : Magnesium Oxide (Purity above 99.4%)

05. Response time : a) < 20 seconds for measurement.

b) < 10 seconds for control.

06. Accuracy : 1.1
0
C up to 300
0
C & 0.4% of measured
temperature range above 300
0
C.

07. Head :

i) Type : IP-65 universal screwed type.

ii) Material : Die cast aluminum or better

iii) Terminal blocks : Nickel plated Brass - screw type/ silver plated

iv) Instrument connection : NPT
to well

v) Cable connection : NPT gland and grommet.

vi) Others : Terminal head cover with SS chain and
suitable gasket. All thermowells in the high
velocity steam service shall be checked for
Strouhals frequency limit to arrive at a safe
size and design of thermowells.

08. Accessories : a) Adjustable nipple-union-nipple [1/2 Sch
80 X NPT (M)] with thermowell
connection

b) Compression fittings/unions

c) Flanges etc. (for flanged connections
only)

d) Forged barstock thermowell as per
ASME PTC code. Process connection M
33X2 (M) in general or 1 Flanged for
Flue gas/Furnace/Air etc. application.

Material of construction of Thermowell:

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VOL-II-E-SEC-VI - 10 DCPL-11Z02

SS 316: In general
Inconel: For flue gas application
Tungsten carbide: For coal mill application.

09. Nameplate : Tag number, service engraved in stainless
steel tag plate

1.08.00 RESISTANCETEMPERATUREDETECTOR

01. Type : Platinum (Duplex), Ungrounded

02. Resistance : 100 ohm at 0
O
C

03. Base : Wound on ceramic (anti-inductive)

04. Wiring : 3 /4 Wire

05. Protecting Tube :-

i) O.D. : 8 mm
ii) Material : SS-316, Seamless
iii) Filling : Magnesium oxide (Purity above 99.4%).

06. Response time : a) < 20 seconds for measurement.
b) < 10 seconds for control.

07. Calibration : DIN 43760

08. Accuracy : 0.5%

09. Head :

i) Type : IP-65 universal screwed type.

ii) Material : Die cast aluminum or better

iii) Terminal blocks : Nickel plated Brass-screw type / silver plated

iv) Cable connection : NPT gland and grommet.

v) Others : Terminal head cover with SS chain and
suitable gasket. All thermowells in the high
velocity steam service shall be checked for
Strouhals frequency limit to arrive at a safe
size and design of thermowells

10. Accessories : a) Adjustable nipple-union-nipple [1/2 Sch
80 X NPT (M)] with thermowell
connection
b) Compression fittings/unions

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VOL-II-E-SEC-VI - 11 DCPL-11Z02

c) Flanges etc. (for flanged connections
only)
d) Forged/barstock thermowell as per
ASME PTC code. Process connection
M33X2 (M).

Material of construction of Thermowell:
SS 316: In general
Inconel: For flue gas application
Tungsten carbide: For coal mill
application.

11. Nameplate : Tag number, service engraved in stainless
steel tag plate

1.09.00 PRESSURESWITCH

01. Type : i) Piston for high pressure application

ii) Bellow / Diaphragm for low pressure
application

02. Sensing element material : AISI SS-316. All other wetted part SS316.

03. Case Material : Die-cast aluminum alloy, neoprene gasket.

04. Setter Scale : Black graduation on white linear scale.
Graduation 0-100% with red pointer for set
points.

05. Over range : 150 % of maximum pressure

06. Adjustments : a) Internal Set Point

b) Fixed Differential.

07. End Connection : 1/2" NPT (M) bottom connected

08. Switch configuration : Two SPDT

09. Switch Rating : 240V, 5A AC/220V, 0.5A DC

10. Switch Type : Snap acting, shock & vibration proof

11. Cable connection : By Plug Connector.

12. Enclosure Class : IP-65.

13. Performance : a) Repeat accuracy 1.0%

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b) Accuracy of Setting Indication of + 1.5%

14. Ambient temperature : 0 50 Deg.C

15. Nameplate : Tag number, service engraved in SS tag plate

16. Accessories : a) Remote diaphragm seal with SS-316
capillary for viscous & corrosive
application.
b) Siphons for steam and hot water
services.
c) Retention ring and screws for surface
mounting.
d) 1/2 NPT 2 Valve SS-316 barstock
manifold
e) NPT cable gland

1.10.00 DIFFERENTIALPRESSURESWITCH

01. Type : Bellows / Diaphragm / Piston actuated

02. Sensing element material : AISI SS-316. For all other wetted part SS 316

03. Case Material : Die-cast aluminum alloy with neoprene gasket.

04. Setter Scale : Black graduation on white scale with 0-100%
graduation and provided with red pointer for
set point adjustment

05. Over range : Static pressure on any one side, the other side
being open to atmosphere.

06. Adjustments : a) Internal set point adjustment

b) Fixed Differential.

07. Process Connection : 1/2" NPT (M) bottom / back connected.

08. Switch configuration : Two SPDT

09. Switch rating : 240V, 5A AC/220V, 0.5A DC.

10. Switch type : Snap acting type contacts, shock and vibration
proof.


11. Cable Connection : By Plug Connector.

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12. Performance : a) Repeat accuracy 1.0%

b) Accuracy of set point Indication: 1.5%

13. Operating Ambient : 0 - 50
O
C (Maximum Continuous)

14. Enclosure : IP-65

15. Accessories : a) Snubbers for pulsating fluid application.
b) Syphons for steam and hot water
services.
c) Retention ring and screws for surface
mounting.
d) 1/2 NPT 3-Valve SS-316 manifold
constructed from barstock
e) 1/2 NPT Cable gland

16. Nameplate : Tag number, service engraved in stainless
steel tag plate

17. Remote Seal type for
special application : a) Silicone oil / fluorolube filled remote
diaphragm seal for dirty / viscous /
corrosive fluid.
b) SS armoured capillary at least 3 meters
each.
c) Adapter flanges with nuts, bolts and
gaskets for instrument and process side.

1.11.00 LEVELSWITCH

01. Type : External cage float operated. Magnetically
coupled.

02. Float Material : AISI-316 stainless steel or better

03. Other wetted parts : AISI-316 stainless steel or better

04. External Cage : Carbon steel / Stainless steel as per process
requirements, welded type / flanged
construction. Cage pressure rating shall equal
or exceed the rating of the main vessel.

05. External cage

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mounting : Side-Side.

06. External cage
connection : 25 NB socket welded.

07. Switch housing : Epoxy coated die-cast aluminum alloy with
neoprene gasket conforming to IP-65.

08. Type of switch
configuration : 2 SPDT (two nos.)

09. Contact rating : 5A, 240V/AC, 0.25A, 220V DC

10. Accessories : a) Counter flange, nuts & bolts, suitable
gasket etc.

b) Steel globe type drain valve.

c) NPT cable gland

d) Stainless steel nameplate with alpha-
numeric engraved for service and tag.

11. Preferred feature : Switch operating point marked on cage

12. Mounting : On standpipe

1.12.00 CONDUCTIVITYTYPELEVELSWITCH

01. Type : Conductivity discrimination.

02. Application : Drain pots viz. on CRH line

03. Mounting : Flanged on external cage.

04. Probe MOC : Stainless steel with high purity ceramic.

05. Probe rating : > Maximum design pressure of vessel.

06. Input : Four independent channel with selectable
switching threshold for water conductivity.

07. Relay Output : Four isolated output relays for Hi, Lo, Hi-Hi, Lo-
Lo.

08. Contact type & rating : 2SPDT or 1 DPDT @ 5A 30V DC.

09. Local Display : Coloured LEDs for Hi, Lo, Hi-Hi, Lo-Lo, Power
& fault.

10. Power supply : Dual 240V AC, 50 Hz, 1Ph.

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11. Enclosure : IP65, corrosion resistant & wall mounting type
(Explosion proof for NEC Class-1, Division-1
area).

12. Accessories : a) PTFE cable from probe to electronics
b) Mounting accessories
c) External cage
d) Washer & gasket

13 Test pressure : Two times rated pressure

14. Cable connection : NPT with cable gland

1.13.00 CONDUCTIVITYTYPEELECTRONICLEVELINDICATOR

01. Type : Conductivity discrimination.

02. Application : HP heater level.

03. No. of Probes : 10

04. Probe Mounting : Flanged on standpipe.

05. Probe MOC : Stainless steel with high purity ceramic.

06. Probe rating : > Maximum design pressure of vessel.

07. Input : Independent channel with selectable switching
threshold for water conductivity.

08. Relay Output : Four isolated output relays for Hi, Lo, Hi-Hi, Lo-
Lo.

09. Contact type & rating : 2 SPDT or 1 DPDT @ 5A 30V DC.

10. Current output : Isolated 4-20 mA DC

11. Local Display : a) Coloured (Red & Green) LEDs for level.

b) Flashing LEDs for fault.

12. Remote Display : Red, Green & flashing yellow LEDs for steam,
Water & Fault indication respectively.

13. Power supply : Dual 240V AC, 50 Hz, 1Ph.


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14. Enclosure : a) IP65, corrosion resistant & wall
mounting type for local electronics.

b) IP-42 for remote indicator

15. Accessories : a) PTFE cable from probe to electronics
b) Mounting accessories.
c) Standpipe
d) Washer & gaskets
e) Double isolation valves on each
connection, double drain valves & double
vent valves with mechanical lock.
f) NPT cable gland

16. Test pressure : Two times design pressure

1.14.00 ORIFICEPLATE

01. Application : Low fluid velocity flow measurement

02. Design Standard : BS-1042, Part-I

03. Number of Tapings : As required plus one additional pair of taps

04. Diameter Ratio : Between 0.4 to 0.7

05. Thickness : 3 mm for main pipe diameter upto 250 mm, 6
mm for main pipe diameter above 250 mm and
10 mm for main pipe diameter of 500 mm and
above.

06. Document : Beta ratio calculation, assembly drawing and
Flow vs. DP curve.

07. Meter run pipe : Same as pipe material

08. Accessories : Flanges, gaskets, nuts & bolts, root valves jack
screw, meter run pipe, Drain & vent hole as
per application etc..

1.15.00 FLOWNOZZLE

01. Application : High fluid velocity flow measurement

02. Design Standard : ASME PTC 19.5


CPCPL-Super Critical TPP-Tharangambadi
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VOL-II-E-SEC-VI - 17 DCPL-11Z02

03. Number of Tapings : As required plus one additional pair of taps

04. Diameter Ratio : Between 0.4 and 0.7

05. Thickness : Suitable for the application

06. Document : Beta ratio calculation, assembly drawing and
Flow vs. DP curve.

07. Meter run pipe : Same as pipe material

08. Accessories : Meter run pipe, nipples and root valves.
(Inspection port assembly for nozzles used in
plant performance purpose)

1.16.00 GAUGEGLASS

01. Type : Reflex

02. Glass : Toughened borosilicate. Resistant to
mechanical and thermal shocks.

03. Body material : Carbon steel / stainless steel- As per process
requirements (Flanged Connection)

04. Pressure rating : Twice the maximum working pressure

05. Temperature rating : As required

06. Bolts and nuts : Rust proof alloy steel

07. Accessories : Suitable ball check valves of SS-304/316 body,
gaskets, companion flange etc.

1.17.00 POWERCYLINDERS(PNEUMATIC)

01. Mounting Type : a) Fixed position mounting (End mounting).

: b) Trunnion mounting

02. Control Signal : 4-20 mA DC with HART protocol to smart
positioner for modulating purposes. 24V DC
operated solenoid valve operating on
pneumatic line for open & closing purpose of
on & off drive.

03. Supply Air : 0-7 Kg / Cm
2
.

04. Selection : Based upon thrust / torque, stroke length,
angular movement, full-scale travel time,

CPCPL-Super Critical TPP-Tharangambadi
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VOL-II-E-SEC-VI - 18 DCPL-11Z02

repeatability, space factor etc. Provision for
air-to-open and air-to-close operation.

05. Casing : IP-65.

06. Accessories : a) Air lock relay

b) Hand wheel.

c) Air filter regulator with gauge.

d) Volume Booster.

e) Limit Switches.

f) Smart Positioner with Input and Output
pressure gauges, local keypad & display.

g) Solenoid Valve

h) Integral non contact type position
Transmitter (4-20 mA DC linear output).

i) Junction box with cable gland

07. Fail-safe operation : For regulating duty- stay put against power &
air fail.

08. Repeatability : Better than 0.5% of full travel.

09. Hysterisis : Less than 1% of full travel

10. Operating Temp. limit : 80 Deg. C (min.)

1.18.00 SMOKEDENSITYANALYZER

01. Type : Insitu dry visible light (through LED)

02. Principle of measurement : Transmission & absorption (Dual beam type)

03. Light source : Modulated high intensity LED


04. Display : Back Lit LCD

05. Measurement range : 0-999 mg/m
3
, 0-999 mg/Nm
3
, 0-100% opacity

06. Measurement averaging : Selectable 10 sec to 60 minutes

07. Accuracy : 0.2% opacity


CPCPL-Super Critical TPP-Tharangambadi
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VOL-II-E-SEC-VI - 19 DCPL-11Z02

08. Resolution : 0.1% opacity

09. Linearity : 0.1% opacity

10. Repeatability : 0.1% opacity

11. Flue gas temperature : 350
O
C (max 600
O
C)

12. Ambient temperature : 0 - 60
O
C

13. Operating temperature : Transmitter & receiver- 0-90
O
C, Electronic unit
- 70
O
C

14. Mounting : Transceiver on opposite side of the duct

15. Analog output : 4-20mA DC (in 500 ohm resistance) to
DDCMIS

16. Alarm output : 2 SPCO potential free rated at 230 VAC, 5A

17. Power Supply : 240V AC, 50 Hz, 1 Phase

18. Automatic misalignment : Required
detection

19. Automatic compensation : Required
of lens contamination

20. Purge air Failure : Purge air to be provided from Blower unit and
to be monitored for failure.

21. Span and Zero Check : Automatic periodic with manual override

22. Housing : Corrosion resistant painted aluminium rated at
IP-65

23. Fail safe shutter : Automatic fail safe shutter against power and
air failure

24. Input normalisation : Correction for temperature, pressure, oxygen
and water vapour to be provided.

25. Preferred Features : Power Supply On LED visible from front

26. Accessories : a) Mounting pads suitable for mounting
projector and receiver units on duct,
flanges, etc.
b) Blower unit (Purging System) with purge
fail alarm at CCR

CPCPL-Super Critical TPP-Tharangambadi
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VOL-II-E-SEC-VI - 20 DCPL-11Z02

c) Enclosure for electronic units & indicators
d) Control unit for interface with PC based
data logger

27. Application : At chimney
At each ESP oulet

1.19.00 SOX,NOX,CO,CO
2
,O
2
&MOISTUREANALYZER

01. Type : Sample Extractive Type.

02. Gases to be measured : SOx, NOx, CO, CO
2
, O
2
and Moisture

03. Principle of measurement : Infrared absorption

04. Flue gas Temperature : 350
O
C

05. Ambient temperature : 60
O
C

06. Mounting : On chimney

07. Measurement range : 0-3000 ppm / mg/Nm
3
for SOx, NOx, CO, O
2

and 0-25% for CO
2
and Moisture - fully
selectable

08. Units of measurement : PPM, mg / Nm
3
and %

09. Power Supply : 240V, 50 Hz, 1 Phase

10. Local Display : Back lit LCD / LED

11. Measurement averaging : 10 sec to 60minutes (selectable)

12. Accuracy : 2% of measured value

13. Repeatability : 2% of full scale

14. Response time : 5 seconds or better for 95% of full scale

15. Zero & Span drift : 2% per month

16. Calibration : Zero and Span calibration in manual and
automatic mode. Automatic calibration interval
shall be fully selectable.

17. Analog output : 4-20 mA DC (in 500 ohm resistor) to DDCMIS
for each channel

18. Alarm output : 1NO + 1NC rated at 230V AC, 5A


CPCPL-Super Critical TPP-Tharangambadi
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VOL-II-E-SEC-VI - 21 DCPL-11Z02

19. Input normalisation : Requiredonline with pressure and
temperature sensor and also provision for key
pad entry of inputs

20. Probe material : Stainless Steel 316L

21. Enclosure : Corrosion resistant epoxy painted aluminium
housing & enclosure rated to IP-65.

22. Accessories : a) Blower unit, tubes & fittings for calibration
and purging, purge fail alarm in CCR
b) Calibration gas cylinders for SO
2
, NO
x

CO
2
, O
2
and CO filled in 10 Ltrs. Of WC
carbon cylinder with necessary SS
regulators with pressure & flow gauges,
solenoid valve & SS tubings and SS
fittings etc. as required.
c) Mounting flanges, gasket etc.
d) Control unit for interface with PC based
data logger

23. Application : On chimney

1.20.00 STACKGASVELOCITYMONITOR

01. Type : Non contact type

02. Measurement : Flue gas velocity

03. Principle of measurement : Time delay correlation of flue gas Infrared
emission received by two detectors located at
a distance apart on the chimney.

04. Flue gas Temperature : Up to 350
O
C

05. Ambient temperature : 60
O
C

06. Mounting : On chimney

07. Measurement range : As required

08. Units of measurement : velocity- m/sec, flow- m
3
/sec

09. Power Supply : 240V, 50 Hz, 1 Phase

10. Local Display : Back lit LCD / LED

11. Measurement averaging : 10 sec to 60minutes (selectable)

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-VI - 22 DCPL-11Z02


12. Accuracy : 2% of measured value

13. Linearity : 2% of full scale

14. Response time : 5 seconds or better for 95% of full scale

15. Zero & Span drift : 2% per month

16. Calibration : Zero and Span adjustment

17. Analog output : 4-20 mA DC (in 500 ohm resistor) to DDCMIS
for each channel

18. Probe material : Stainless Steel 316L

19. Enclosure : Corrosion resistant epoxy painted aluminium
housing & enclosure rated to IP-65.

20. Accessories : a) Blower unit, tubes & fittings for calibration
and purging, purge fail alarm in CCR
b) Mounting flanges, gasket etc.
c) Control unit for interface with PC based
data logger

21. Application : On chimney

1.21.00 OXYGENANALYZER

01. Type : In-situ, Zirconium sensor, micro-processor-
based transmitter, field repairable.

02. Range : 0.1-10% / 0.25-25% by volume

03. Output : 4-20 mA DC linear

04 Probe Length : 1800 mm (approximate depending on duct
size)

05. Process Temperature : 850
O
C approx.

06. Measurement Reference : Instrument Air

07. Accuracy : 1% of F.S.

08. Response Time : Less than 5 (five) seconds

09. Amplifier Housing : IP-65


CPCPL-Super Critical TPP-Tharangambadi
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VOL-II-E-SEC-VI - 23 DCPL-11Z02

10. Calibration : Automatic periodic

11. Calibration Frequency : Once every 24 hours

12. Power Supply : 240V, 50 Hz, 1 Phase

13. Material for Gas Carrying
Components : Stainless Steel

14. Read Out : LED/LCD Local indicating meter

15. Protection : Automatic cell protection against reducing
atmosphere

16. Alarm Facility : 1 HI and 1 LO independently adjustable over
span. Contact rating 500 mA at 220 V DC
(minimum).

17. Preferred Features : a) HI and LO alarm LED visible from front.

b) Power Supply On/Failure LED visible
from front

18. Accessories : a) Mounting flanges, adaptor plate and
protection shield
b) Gasket, nuts and bolts
c) Cable with conduit from cell to amplifier
(as required) and other special cables (if
any)
d) Automatic calibration kit (complete with
all accessories and standard Gas
Cylinders)

19. Application : a) At each economizer outlet

b) At each air preheater outlet

1.22.00 CO,NOX&MOISTUREANALYZER

01. Type : Insitu Probe type combined analyser

02. Gases to be measured : CO, NOx and Moisture

03. Principle of measurement : Infrared absorption

04. Flue gas Temperature : 850
O
C (max)

05. Ambient temperature : 60
O
C

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-VI - 24 DCPL-11Z02


06. Mounting : On duct

07. Measurement range : 0-3000 fully selectable

08. Units of measurement : PPM and mg / Nm
3


09. Power Supply : 240V, 50 Hz, 1 Phase

10. Display : Back lit LCD / LED

11. Measurement averaging : 10 sec to 60minutes (selectable)

12. Accuracy : 2% of measured value

13. Repeatability : 2% of full scale

14. Response time : 5 seconds or better for 95% of full scale

15. Zero & Span drift : 2% per month

16. Calibration : Zero and Span calibration in manual and
automatic mode. Automatic calibration interval
shall be fully selectable.

17. Analog output : 4-20 mA DC (in 500 ohm resistor) to DDCMIS
for each channel

18. Alarm output : 1NO + 1NC rated at 230V AC, 5A

19. Input normalisation : Required online with pressure and
temperature sensor and also provision for
keypad entry of inputs

20. Probe material : Stainless Steel 316L

21. Enclosure : Corrosion resistant epoxy coated aluminium
housing & enclosure rated to IP-65.

22. Accessories : a) Blower unit, tubes & fittings for calibration
and purging, purge fail alarm in CCR
b) Calibration gas cylinders for NO
x
and CO
filled in 10 Ltrs. of WC carbon cylinder
with necessary SS regulator, SS gauges,
SS tubings and SS fittings etc. as
required.
c) Mounting flanges, gasket etc.

23. Application : At economizer outlet

CPCPL-Super Critical TPP-Tharangambadi
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VOL-II-E-SEC-VI - 25 DCPL-11Z02


1.23.00 H
2
+CO
2
+AIRANALYZER

01. Type : Thermal Conductivity
02. Range Selection : 3 ranges (H
2
in CO
2
, H
2
in air and CO
2
in air)
03. Range : As required
04. Output : 4-20mA DC (Isolated)
05. Operating ambient temp. : 10
O
C to 50 Deg. C
06. Power Supply : 240V AC, 50Hz
07. Sample gas flow control : Required
08. Reference gas flow : Required
09. Reference gas pressure
regulator : Required
10. Cell response : 95% of change in 30 Sec.(Appox.)
11. Accuracy : 2% of full scale
12. Repeatability : 1% of full scale
13. Local Indicator : Indicating meter of 1% accuracy
14. Alarm facility : Dual (High & Low) independently adjustable.
15. Contact rating : 0.5A at 220 V AC
16. Enclosure : Flame Proof
17. Accessories : Calibration gas, mounting accessories and
others as required to be provided
18. Application : Generator Gas Purity.

1.24.00 RADARTYPELEVELMEASUREMENT

01. Type : Radar based on Time Domain Reflectometry
02. Antena : Co axial / single rod type guided wave or Horn
type as required for the application
03. Communication : Two wire 4-20mA DC, HART or Field Bus
protocol.
04. Environmental temperature : 0 50 C

CPCPL-Super Critical TPP-Tharangambadi
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VOL-II-E-SEC-VI - 26 DCPL-11Z02

05. Enclosure : Explosion proof /IP 65 as per application
06. Cable Entry : NPT
07. Calibration : a) Self calibration with internal reference
b) Zero & Span calibration
08. Programming : Handheld programmer & Local keypad
09. Process Connection : Flanged /screwed
10. Electronic Housing : Epoxy painted Die-Cast aluminium alloy
11. Antenna / Flange assembly : 316 SS or Hestalloy (as required)
12. Output Indicator : Digital Integral Display
13. Accuracy : 5 mm or 0.1% of probe length
14. Accessories : a) Programming tool kit
b) Gasket


1.25.00 Temperature Switch

01. Type : Mercury filled-in

02. Sensing Element Material : Bellow / Bourdon AISI SS-316

03. Bulb Material : AISI SS-316

04. Capillary : Stainless steel armored

05. Movement Material : AISI SS-304

06. Case material : Epoxy coated steel plate or die-cast aluminum
alloy with neoprene gasket and clear glass
where applicable cover conforming to IP-65.
(Explosion proof for NEC Class-1, Division 1
area).

07. Scale : Black lettering on white background

08. Over range Protection : 120 %

09. Instrument connection : Bottom

10. Switch configuration : Two SPDT


CPCPL-Super Critical TPP-Tharangambadi
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VOL-II-E-SEC-VI - 27 DCPL-11Z02

11. Switch rating : 240V, 5A AC/220V, 0.5A DC

12. Switch type : Snap acting, shock and vibration-proof.

13. Adjustability : Internal Set point adjustable over span range

14. Cable connection : 3/4" ET conduit connection or compression
gland.

15. Compensation : a) Capillary compensation with invar wire
throughout the capillary length.

b) Case compensation

16. Performance :

i) Scale Accuracy : 1.0 % of full scale
i) Repeatability : < 0.5 % of full range
ii) Response time : Less than 40 seconds with thermowell

17. Capillary length : 5 meters (minimum) for local mounting/15
meters for local panel mounting.

18. Nameplate : Tag number, service engraved in stainless
steel tag plate

19. Accessories : Mounting accessories, 3/4ETcable gland.


1.26.00 ROTAMETER

01. Type : On-line up to 2. By-pass above 2

02. Metering tube : Borosilicate glass

03. Float : AISI 316-SS unless the process fluid demands
some other material.

04. Body MOC : AISI 316-SS

05. Scale : Graduated- Engraved black on white
background.

06. Process connection : Flanged

07. Accuracy : 2% of full scale detection or better for on-line
type and 4% of full-scale detection or better
for by-pass type.

08. Nameplate : Tag number, service engraved in stainless
steel tag plate

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-VI - 28 DCPL-11Z02


09. Accessories : Slip-on orifice plate of 316-SS and taps of
Stainless Steel as per application
requirements. Applicable SS Isolation valves
and SS Range Orifice - for bypass type
rotameters.


1.27.00 SMART VALVE POSITIONER :

01. Type : Smart

02. Input level : 4-20 mA DC (HART)

03. Output range : to match valve stroke

04. Body Material : Cast Aluminum

05. Enclosure Protection : IP 66

06. Max. air supply pressure : 7 Kg/ sq.cm.

07 Response Time : 5 Seconds for 0 to 90% output pressure

08 Accuracy : +_ 1.0% of Full Scale.

09. Turning Range : 50 to 90

10. Output Characteristics : Linear / Equal % / Quick Opening and provision
for user customization of output.

11. Lighting Protection : a) Peak Value of Voltage surge: 12kV
b) Peak Value of Current Surge: 1000A

12. Pressure gauges : To be provided on positioner

13. CE Conformity : a) Electromagnetic compatibility
b) EN 61326: 1997 (CE Marking)

14. Air connection : 1/4NPT internal thread.

15. Electrical Connection : 1/2NPT.



1.28.00 AIR FILTER REGULATOR

01. Filter Element : Sintered Bronze

02. Filter Size : 5 microns

03. Input Air : 10.0 Kg/Sq. cm (maximum)


CPCPL-Super Critical TPP-Tharangambadi
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VOL-II-E-SEC-VI - 29 DCPL-11Z02

04. Output : Adjustable from 0-2.0 Kg / Sq. cm or 0-7.0 Kg /
Sq. cm (continuous) as applicable for I/P
converter, control drives and control valve

05. Effect of Supply : Maximum 0.02 Kg/Sq. cm for a change
pressure variation in supply pressure of 4
Kg/Sq. cm

06. Bowl Material : Metallic cover around high temperature area /
clear transparent polycarbonate with metallic
cover for ordinary applications.

07. Accessories : 2" dial size output pressure gauge

08. Desirable Feature : No perceptible drop of pressure on opening
the drain port.

1.29.00 SOLENOID VALVE

01. Operating Principle : Electromagnetic (noiseless)

02. Coil voltage rating : 240 V AC / 220 V DC(as required. Any other
voltage, if necessary, to be arranged by
Bidder)

03. Ways : Generally 3-ways other depending on
requirement
04. Port size : 1/4" NPT all ports
05. Body : SS bar stock
06. Trim : SS-316
07. Duty : Suitable for continuous energization
08. Sealing : Airtight and leak proof
09. Ambient Temperature : 0 - 50
O
C
10. Fluid Temperature : 0-150
O
C (approx.)
11. Coil Enclosure : Stainless Steel
12. Insulation : Class-H
13. Coil Casing : IP-65 (Explosion proof for NEC Class-1,
Division-1 area)
14. Mounting : On pipe or on panel
15. Cable Connection : 3/4" ET

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-VI - 30 DCPL-11Z02

16. Accessories : Mounting brackets, nuts and bolts
17. Preferred feature : a) Solenoid valve directly integral to actuator
body shall have NAMOOR interface for
uniformity
b) Local indication for power

1.30.00 FIELD MOUNTED TEMPERATURE TRANSMITTERS

01. Working Principle : Smart (HART)
02. Type : Two wire
03. Input : Thermocouple/RTD
03. Output Signal : Simultaneous transmission of digital and 4-20
mA DC signal with standard protocol HART
04. Signal Processing Circuitry : Microprocessor based Solid State Electronic
05 Turn down ratio :
06. Span and Zero : Locally adjustable non-interacting and through
Smart configurator
07. Enclosure Class : IP-65 (Explosion proof for NEC Class-1,
Division 1 area)
08. Output Indicator : LCD type
09. Body : Die Cast aluminum
10. Operating Voltage : 16-48 V dc
11. Load : 600 Ohms at 24V DC (Min.)
12. Performance
i) Accuracy : 0.2% of span
ii) Repeatability : 0.05% of span
iii) Cold Junction
Compensation : Built-in
iv) Calibration : As per N.I.S.T Monograph 125 for T/C and
European Curve Alpha = 0.00385 for RTD
13. Accessories : a) Universal mounting bracket suitable for
pipe and surface mounting.
b) Hi-tensile carbon steel U-bolts, nuts
14. Nameplate : Tag number to be engraved on metallic tag
plate rigidly fixed to the body.

CPCPL-Super Critical TPP-Tharangambadi
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VOL-II-E-SEC-VI - 31 DCPL-11Z02

15. Feature : Shall be extremely stable against ambient
temperature variation. The accuracy figure
shall be inclusive of effect due to ambient
temperature variation between 0-50
0
C.

1.31.00 SIGHT GLASS
01. Type : Flap-type
02. End connection : Screwed / Flanged
03. Material :
a) Body : CS/SS as per process medium
b) Indicator : Stainless steel
04. Sight Glass : Toughened Borosilicate
05. Gasket : Neoprene
06. Bolts & Nuts : High tensile steel
07. Hydraulic Test Pressure : 1.5 times maximum working pressure
08. Accessories : As required

1.32.00 FLOW INDICATING SWITCH
01. Type : On line metal tube Rotameter
02. End connection : Flanged
03. Material:
a) Body : CS/SS as per process medium
b) Float : Stainless steel
c) End fittings/flange : Stainless steel
d) Other wetted part : Stainless steel
b) Casing : Di cast Alluminium
04. Accuracy : +/- 2.0% of FSR
05. Rangeability : 10:1
06. Electrical connection : ET
07. Switch type : Snap acting hermitically sealed 2 nos SPDT
08. Contact rating : 5A, 240V AC
08. Protection class : IP-65
08. Accessories : As required


CPCPL-Super Critical TPP-Tharangambadi
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VOL-II-E-SEC-VI - 32 DCPL-11Z02


2.00.00 CLOSEDCIRCUITTELEVISIONSYSTEM

2.01.00 CLOSEDCIRCUITTELEVISIONSYSTEM

2.01.01 Closed Circuit Television System (CCTV) with all equipment and accessories shall
be installed for the purpose of surveillance of major plant areas. Also, cameras
shall be installed at the Main Gate and other common auxiliary plants.


2.01.02 The CCTV system shall meet the specific functional & design requirements
towards collecting live video information from the various areas of the plant and
displaying that information at monitors.

2.01.03 Bidder shall include Digital Server based Video Manager, Camera unit, Video
Streamer, Optical fiber network cables, Network hard wares & all other accessories
including design / engineering, testing, erection & commissioning etc. for complete
functioning of the system.
2.01.04 Bidder shall consider licensed version of all application and system software
required for the system.

2.01.05 System shall be of proven design in dust laden atmosphere and of reputed make.

2.01.06 Bidder shall submit block schematic of Power distribution and wiring diagram,
CCTV network architecture drawing, hardware & software detail and other
information as necessary.

2.01.07 Requirement for minimum number of camera units and their tentative locations are
listed below. CCTV system shall include industrially ruggedized high resolution
colour day/night CCD camera, motorized zoom lenses, PAN & TILT mechanism,
Transmitter / Receiver units & video Streamer integrated to a Digital Video
Management Server for video switching, control and recording functions.

LISTOFCAMERASTOBEPROVIDEDATEACHUNIT

SL.
NO.
TYPEOFCAMERA
ENCLOSURE
CLASS
LOCATION
NO.OF
CAMERASPER
UNIT
1. CCD camera (Dome Type) IP 54 TG Hall 01
2 CCD camera IP 54 TG Hall 02
3 CCD camera IP 54 Turbine oil room 01
4 CCD camera IP 54 Boiler Feed Pumps 03
5 CCD camera IP 54
Condensate Extraction
Pumps
01
6 CCD camera IP 54 Generator seal oil system 01

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-VI - 33 DCPL-11Z02

SL.
NO.
TYPEOFCAMERA
ENCLOSURE
CLASS
LOCATION
NO.OF
CAMERASPER
UNIT
7 CCD camera IP 54 Compressor room 01
8 CCD camera IP 54 Switchgear Room 01
9 CCD camera IP 65 Boiler Firing Floor 01
11 CCD camera IP 65 Coal mill area 06
12 CCD camera IP 65 Coal Feeder area 06
13 CCD camera IP 65 ID Fan 02
14 CCD camera IP 65 FD Fan 02
15 CCD camera IP 65 PA Fan 02
16 CCD camera
IP 54
AHP control room 01
17 CCD camera
IP 65
Ash water pump house 01
18 CCD camera IP 65 Air heater area 01
19 CCD camera IP 65 ESP field area 02
20 CCD camera IP 65
Generator Transformer
Bay
02
21 CCD camera IP 65
To be decided during
detailed engineering
04

LISTOFCAMERASTOBEPROVIDEDATCOMMONPLANTAREA

SL.NO. TYPEOFCAMERA(DOMETYPE) ENCLOSURECLASS LOCATION
NO.OF
CAMERAS
1. CCD camera IP 65
Ash slurry Pump
House area
02
2. CCD camera IP 65 CW Pumps 02
3. CCD camera IP 65 ACW Pumps 01
4. CCD camera IP 65
Fire Water Pump
House
01
5. CCD camera IP 65
Fuel oil Pressurizing
Pump House
01
6. CCD camera IP 65 Fuel oil unloading bay 02
7. CCD camera IP 65
Fuel oil unloading
pump house
01
8. CCD camera IP 65 Fuel oil tank area 01
9. CCD camera IP 65 Unloading Bay of Unit 01
10 CCD camera IP 65 Main entry gate 01

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-VI - 34 DCPL-11Z02

SL.NO. TYPEOFCAMERA(DOMETYPE) ENCLOSURECLASS LOCATION
NO.OF
CAMERAS
11 CCD camera IP 65 CHP area 08
12 CCD camera IP 65 Switchyard 04
12 CCD camera IP 65 DM plant 01
13 CCD camera IP 65 Chimney 01
14 CCD camera IP 65 Cooling Tower 01
15
CCD camera
IP 65 Train entry and exit
point
01
16 CCD camera IP 65 ETP plant 01
17 CCD camera IP 65 Cable gallery 05
18 CCD camera IP 54 CCR 01
19
CCD camera
IP 54 Control equipment
room
01
20 CCD camera IP65 To be decided later 06

The unit price for the different type of camera to be indicated in the bid.

2.01.08 CCTV system shall be powered from UPS of both units.

2.01.09 System shall be time synchronized with the GPS master clock.

2.01.10 DesignandTechnicalRequirements

a) CCTV system envisaged shall have a Primary Digital Video Server along with
Four (4) off Secondary Digital Video Servers, one for each unit and one for
common area. The prime application program shall reside at Primary Digital
Video Server and shall interface Secondary Digital Video Servers & Cameras
for video and audio switching and control of the system. The Primary Server
shall have the capability to add future secondary servers to support future
expansion.

b) 2 (two) 22 LCD monitoring stations shall be provided for monitoring of the
plant. The system elements shall be able to communicate on Ethernet
network.

c) System shall store alarm and event activated recording. Features shall be
provided only to capture most needed videos. It shall also have pre-recording
feature so that videos prior to the event occurring can also be stored. The
system operation shall cover the complete view of the areas by control of pan,
tilt & zoom of the cameras. Modification of the system parameters shall be
possible from any of the above stations.


d) The system shall have following minimum controlling capability:
PTZ control with Iris level control, pre-positioning control for at least 128
cameras.
Simultaneously record and play back input from up to 128 cameras.

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Both manual and automatic mode control.

e) The system shall have capability not limited to the followings :
It shall be possible to view live video from anywhere on the network,
including over wide area network connections, through firewalls & routers.
The live output from cameras shall be viewed through a series of displays.
Sequence view of camera preset position.
Modifying settings/ record settings for a camera
Adding and deleting camera from the system.
Creating schedules for recording an video motion detection
Video recording with features like Operator Activated Recordings, Alarm
and Event Activated Recordings, Scheduled Recordings (including 24hr
recording), Video Motion Detection & Recordings and Exporting of a
Recorded video into Microsoft Windows Media Format file.
Video Server shall have video recorder with sufficient disk space for on-
line video storage and access to archiving mechanisms for the removal of
stored video to off-line media. Event shall be stored in the recorder at least
for 30 days. Recorder shall have date & time search and can playback of
recorded video.
Archiving of the recorded videos to archiving media like DVD.
Video features like Single camera viewing, Quad viewing and Sequence
viewing.
Pass word protected Security levels for the monitoring and control of
cameras to authorised users.

The system should be completely compatible to be integrated to Fire Alarm
System. When the fire is detected by a particular detector the camera
assigned should automatically focus the site of the fire. For implementation
of the same, 24 nos. potential free input contacts per unit and 24 nos.
potential free input contacts for common plant area shall be provided for Fire
Detection system interfacing with CCTV system panel. Proper
implementation of the same shall be in the scope of bidder.

2.01.11 DescriptionofSystemComponents

CCTV Management system for the plant shall be built upon industry-standard
TCP/IP open networking. The components shall be public domain products. Bidder
shall furnish latest proven model of components & accessories, not limited to the
following, for completeness of the system.

a) PrimaryDigitalVideoServer

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Request and receive live video from the streamers and the cameras.
Multicast or Unicast live video.
Receive camera control commands and send to the cameras.
Store live video (recordings) into hard drives.
Transmit previously stored video recordings to monitors when requested.
Record video on request.
Record video upon alarm trigger.
Schedule recordings and video motion detection
Provide search engines for recordings
Archive previously stored video to off-line storage media
Retrieve archived video from off-line storage media
Recording of both video and audio simultaneously for 128 channels.
Recording 18~24 frames/ second regardless of the number of streams.
Report any camera failure or recording failure
Time synchronization with the plant GPS.

b) SecondaryDigitalVideoServers

Features of the server shall not be limited to the following :
i) Limit and grant operator access to live and recorded video and audio.
ii) Send request to video server to record video and audio
iii) Provide indication of any camera which has failed
iv) Configure PTZ access
v) Configure alarm and alarm access
vi) System configuration
vii) Video transmitter and receiver configuration

c) Serverconfiguration


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SL.
NO.
FEATURE REQUIREDPARAMETER
1. Operating system Windows 2000 or latest version
2 Code Compression To be specified by Bidder
2. Processor Intel Xeon 2.4 Ghz or better
4. RAM 1 GB RAM
5. Hard disk
5 x 60GB SCSI (minimum) with
provision for future expansion.
6. CD ROM Drive 52 X or better
7. DVD writer
CD Read &write
DVD Read & write
8. Video output SXGA
9. Remote Control Full control Via TCP/IP
10. DAT Drive
Ultrium back up drive with tape
auto loader
11. Monitor 22 Colour LCD.
12. Input voltage 240 V AC 50 Hz
13. Mounting 19 rack mounting
14.
Additional software for the
Primary / Secondary
Server
Microsoft SQL Server 2000
including Digital Video system


d) Cameras

The cameras shall be rugged 1/3 inch image format or better, full performance
color CCD cameras. For Dome type camera imager may be 1/4 size.
Cameras shall provide high resolution and high sensitivity , both in natural and
artificially sighted areas. Features shall not be limited to the followings:

i) Suitable for day & night time surveillance.
ii) Manual or Automatic colour / infrared switching.
iii) Automatic picture enhancement to give a balanced picture in too little /
too much light.
iv) Remote camera setup, with on screen menu display.
v) Character generator giving up to 24 character text-in-pictures.

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vi) Backlight composition.
vii) Automatic white balance, with mode selection options.
viii) Contour correction and contrast compression control.

Technical requirements shall not be limited to the following :

COLOURCCDCAMERA

SL.NO. FEATURE REQUIREDPARAMETERS
1. Imager 1/3" Color CCD
2. Effective Pixels 752 (H) x 582 (V) PAL
3. Television System PAL
4. Horizontal resolution 540 lines
5. Focus / Iris Automatic with manual override
6. Min. illumination Color- 0.3lux 0.002 lux
7. Lens Mount CS/C with lens washer
8. Aperture correction Horizontal and vertical
9. Shutter Speed MFR standard
10. Signal to Noise Ratio More than 52dB
11. Gain control Automatic
12. White Balance 2000K to 10000K
13. BLC On / Off switch
14. Video Output 1.0V Pk-Pk, 75 Ohm
15. Power Supply AC 240V, 1Ph. 50Hz
16. Operating Temperature -10
0
~ 50
0
C
17. Humidity 0-100%

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SL.NO. FEATURE REQUIREDPARAMETERS
18. Accessories i) Outdoor type box for Power
supply unit and fiber optic
connectivity.
ii) Mounting accessories
iii) PAN and TILT mechanism
iv) Camera housing
19. Preferred Certification CE, FCC

DOMECOLOURCCDCAMERA

SL.NO. FEATURE REQUIREDPARAMETERS
1. Imager 1/4" Color CCD
2. Effective Pixels 752 (H) x 582 (V)
3. Television System PAL
4. Sync. system Internal / External
5. Horizontal resolution 460 TV Lines
6. Focus Automatic with manual override
7. Iris Automatic with manual override
8. Field of view 2.7 Deg. to 48 Deg.
9. Sensitivity For day & night surveillance
0.0005 lux in night mode slow shutter on
0.031 lux in night mode slow shutter off
0.0033 lux in day mode slow shutter on
0.25 lux in day mode slow shutter off
10. Aperture correction Horizontal and vertical
11. Optical & digital Zoom 12X
12. Signal to Noise Ratio More than 50dB
13. Gain control Off/automatic
14. White Balance 2000K to 10000K
15. BLC On / Off switch
16. Video Output 1.0V Pk-Pk, 75 Ohm

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SL.NO. FEATURE REQUIREDPARAMETERS
17. Power Source AC 240V, 1Ph. 50Hz
18. Operating
Temperature
-10
0
~ 50
0
C
19. Humidity 0-100%

20. Accessories i) Outdoor type box for Power supply
unit and fiber optic connectivity.
ii) Mounting accessories
iii) PAN and TILT mechanism
iv) Camera housing



21.

Preferred Certification

CE, FCC

e) Lens

The lens shall be minimum Auto-iris lens of 1/3 inch. with zooms facility.
Depending upon the system requirements bidder shall provide the exact zoom
lens.

i) LENS (Zoom Lens of 6-60mm)

SL.NO.
FEATURE REQUIREDPARAMETERS
1. Zoom 6-60 mm (10 X)
2. Lower focal distance 6 mm
3. Size 1/3 format
4. Iris Auto-video drive
5. Pre-set Focus, Zoom
6. Zoom Control Motorized
7. Focus Control Motorized
8. Connector to camera C or CS
9. Iris control Motorized and /or automatic

ii) LENS (Zoom Lens of 8--120mm)

SLNO. FEATURE REQUIREDPARAMETERS
1. Zoom 8-120 mm (15 X)

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SLNO. FEATURE REQUIREDPARAMETERS
2. Lower focal distance 8 mm
3. Size 1/3 format
4. Iris Auto-video drive
5. Pre-set Focus, Zoom and/or
automatic
6. Zoom Control Motorized
7. Focus Control Motorized
8. Connector to camera C or CS
9. Iris control Motorized and /or automatic
10. Interchangeability From same make with
interchangeability /
compatibility with associated
accessories.

f) CameraHousing

All the cameras and accessories shall be housed in Weather proof
environmental cases of aluminum.

The housing should also have thermostatically controlled heater kit,
continuous duty blower kit, purge air arrangement, Window wipers etc.
Features available shall be as follows:

SL.NO. FEATURE REQUIREDPARAMETER
1. Construction Material Extruded and die cast aluminum
2. Protection Degree IP65
3. View window material Fully tempered plate glass of 0.5 thick
4. Finish Grey Polyester Powder coated
5. Accessories Thermostatic heater, Defroster, Blower
and sun shroud & Should have
provision for washer and wiper for the
dust prone areas.
6. Input Voltage 240V AC
7. Camera compatibility Enclosure dimension should provide
sufficient space to house the offered
camera and lens assembly.

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SL.NO. FEATURE REQUIREDPARAMETER
8. Cabling (Housing with P/T) Internal, through Pan /Tilt assembly.
9. Cabling (Fixed Housing) Two entries for cabling with
compression gland
10. Camera Mount Removable with Sleds
11. Certification UL/CE

g) Pan&TiltUnit :

The Pan & Tilt unit should be weather proof (IP-55) type and designed to meet
harsh environment and should be constructed with corrosion resistant
hardware and with 100% duty cycle motors to permit continuous operation.
Features available shall be as follows :


SL.
NO. FEATURE REQUIREDPARAMETER
1. Pan Range 0-355 Degrees
2. Pan Speed 7 degree / Second or better
3. Tilt Range 90
0
(in vertical plane)
4. Tilt Speed 3 Degrees /second or better
5. Duty cycle 50%, 30 minute rating
6. Connectors Cables /glands to be supplied with
P/T unit.
7. Construction Aluminum plate. Internal & external
parts corrosion resistant.
8. Presets Should be available
9. Limit Switches Internally adjustable
10. Input Power 24V AC, 50 Hz
11. Operating Temperature 0 to 50 degree centigrade
12. Certifications UL/CE

h) OnsiteReceiver/DriverUnit :


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The on-site receiver/drive unit should be able to control the motor drives for
pan/tilt and cameras for zoom and aux control. These would be used in
conjunction with the Camera Streamer systems. Features available shall be
as follows :

SL.
NO. FEATURE REQUIREDPARAMETER
1. Input/Output Signal RS-422 or RS 232 or RS 485.
2. Pre-sets Minimum 64
3. Output Pan, Tilt, Focus, Zoom, Wipe,
Wash.
4. Output voltages As required by lens and PTZ unit
5. Diagnostics Built in should be available
6. Up Gradability Should operate with any industry
standard PTZ units
7. Testing of Pan/Tilt functions On site testing should be available
8. Housing Should be housed in weather
proof or explosion proof housing
as per locations.
9. Input Voltage 240 Volts AC, 50 Hz.
10. Operating Temperature 0-50 Degrees centigrade
11. Humidity 95%
12. Certifications CE/UL

i) VideoStreamers

Industry standard commercial video streamers to perform the following
functions shall be used:

Convert the analog camera video signal into a digital format
Stream the digital video onto the Ethernet network
Receives camera control commands from Digital Video Server and send
these commands to the camera PTZ head using a serial connection.

SL.
NO. FEATURE REQUIREDPARAMETER
1. Video Input 1 input, 1V pp, 75 ohms, PAL

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SL.
NO. FEATURE REQUIREDPARAMETER
2. Serial Port RS 232 or RS422 or RS 485
3. Video
compression
MPEG. H.263
4. Protocols TCP / IP, UDP / IP, IGMP (Multicast)
DHCP Client, HTTP.
5. Regulatory EN55022,EN55024
6. Input/output
ports
RJ 45 for 10/100 Mbps, RS 232/422/485
port. 4 opto isolated general inputs and 1
relay output. 1 video input (BNC) & 1 video
output (BNC)
7. Resolution 704 x 576 (Single high resolution), 352 x
250(Standard Size) or better
8. Video through
put
Upto 25 fps or better
9. Bit rate User configurable bit rates from 8 Kbps to
2 Mbps. It should be able to send CIF size
video at 18 ~24 fps at 400 Kbps.
10. Decoder The Encoder should be usable as a
decoder to give output to an analogue
CCTV monitor if required.
11. Operating
Temperature
0 to 50 degrees centigrade.
12. Input Power 240 V AC, 50 Hz.
13. Housing Should be housed in dust & weather proof
housing as per locations.

j) NetworkInfrastructure&Cable

CCTV network configuration shall be built on the Stackable Managed Ethernet
switches for better control of data traffic & performance and future expansion.
Switch configuration shall be redundant with seamless changeover without
any upset in the CCTV operation. MTBF of the switch shall be more than 20
Years. Configuration shall be automatic.





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3.00.00 CONTROLPANEL/DESKMOUNTEDINSTRUMENTSAND ELECTRICALSYSTEMACCESSORIES

3.01.00 COUPLINGRELAY

01. Type : Octal base plug-in type/ DIN rail Mounting
02. Coil voltage : 24 V D.C. in general / other as required
03. Contact : 2 NO & 2 NC (Minimum)
04. Contact rating : 250 V/5A (A.C)/220V/2A (D.C)
05. Operating range : 70 to 110% of rated voltage.
06. Insulation : 2 KV for 1 minutes between terminal & earth.
07. Mechanical life : 20 million operations
08. Coil protection : Diode
09. Indication : Coil on LED
10. Enclosure : Transparent cover
11. Connection : Screw terminals.
12. Mounting : Projection mounting inside panel / DIN rail
mounting

3.02.00 RECEIVER RECORDER
01. Type : Microprocessor Based continuous video chart
type (Paper less)
02. Display type : 320 x 240 pixels high resolution coloured LCD
graphics
03. Number of pen : 2/4 as applicable
04 Input : 4-20mA DC/1-5 Volt/RTD/Thermocouple
05. Display span rate : 1,5,10,20,30 and 60 min / div. Selectable
06. Digital indication : Measured values with engineering unit
07. Trends : Coloured display on screen
08. Colour of trends : Selectable
09. Performance :

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i) Accuracy : 0.1% of span or better (Indication &
Recording)
ii) Updation rate : 1 Sec or better
10. Input open circuit : Up/Down Scale (selectable)
11. Reference Junction
Compensation : Built-in cold junction compensation for
thermocouple inputs.
12. Power Supply : 240 Volt, 1 Ph, 50 Hz A.C.
13. Operating ambient
temperature range : 0-50
O
C (maximum)

14. Face Dimension : 144 mm (W) x 144 mm (H)
15. Depth : 300 mm (typical)
16. Construction : Case - drawn steel, Bezel-Polycarbonate
17. Readable distance : 3 meters (minimum)

18. Mounting : Flush panel

19. Accessories : Engraved phenolic nameplate affixed to front
flange to identify each recorder by tag number
and each pen by color and measured variable.
Shunt resistors, Ethernet port,
RS232/422a/485 port

20. Features : a) Hi, Hi-Hi, Lo and Lo-Lo contacts for each
channel.
b) 2 MB memory for Data acquisition and 100
MB Zip disk
c) 3 Floppy disk
d) Computation functions like linear scaling,
square root, differential and engineering
unit and all other mathematical functions.
e) Memory status display, LCD backlight
saver.
f) Event sampling typically 125, 250,
500msec

3.03.00 MULTIPOINT RECORDER

01. Type : Microprocessor Based continuous video chart
type (Paper less)

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02. Number of Points : 6,12 or 24 (as required)
03. Input : 4-20 mA/1-5V/Thermocouple/RTD
04. Recording : Channel number or dot with different color for
each channel
05. Point Selection : Programmable for any combination of points
by selection
06. Readable Distance : 3 meters (minimum)
07. Data Display : Channel number, alarm status, measured data
and engineering data (or Programming
Display) in green LEDs
08. Face Dimension : a) 144 x 144 mm (approx.) for 6 point
b) 252 x 206 mm (approx.) for 12 point
c) 305 x 380 mm (approx.) for 24 point
09. Reference Junction
Compensation : Built-in
10. Mounting : Flush Panel
11. Performance :
a) Accuracy : 0.5% of span or better
b) Ambient Temperature
effect : 0.3% of span for 10
O
C variation or better
c) Supply voltage
variation effect : 0.2% of span for 10% variation in supply
voltage or better
d) Frequency variation
effect : 0.1% of span for 2 Hz variation in frequency
or better
e) Operating Position
effect : 0.1% of span for 0-30 Deg. inclined or better
12. Input Open Circuit : Up/Down Scale
13. Power Supply : 240 Volt, 1 Phase, 50 Hz AC
14. Operating Conditions :-
a) Temperature : 0-50
O
C
b) Relative Humidity : 25%-90%
c) Supply Voltage : -15% to +10%

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15. Accessories : Engraved phenolic nameplate affixed to front
flange to identify each recorder by tag number
and each pen by color and measured variable.
Shunt resistors, Ethernet port,
RS232/422a/485 port

16. Preferred Features : a) Hi, Hi-Hi, Lo and Lo-Lo contacts for each
channel.
b) 2 MB memory for Data acquisition and 100
MB Zip disk
c) 3 Floppy disk

d) Computation functions like linear scaling,
square root, differential and engineering
unit and all other mathematical functions.

e) Memory status display, LCD backlight
saver.
f) Event sampling typically 125, 250,
500msec

3.04.00 BAR GRAPH INDICATOR
01. Type : Bar graph
02. Number of channels : One / Two (as required)
03. Input : 4-20 mA/1-5 V/Thermocouple/RTD
04. Indication : Green LED / LCD
05. Scale : 100 mm vertical one for each channel
graduated in engineering unit (linear scale)
06. Readable Distance : 3 meters (minimum)
07. Mounting : Flush panel
08. Face Dimension : 36(W) x 144(H) mm (approx) / 72 x 144 (H)
mm
09. Resolution : 1% of scale or better
10. Power Supply : 240V, 1 Phase, 50 Hz AC

11. Operating Conditions :-
a) Temperature : 0-50
O
C

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b) Relative Humidity : 5%-95%
c) Supply Voltage : -15% to +10%
12. Connection between
Indicator and Tray : Prefab Cable
13. Accessories : i) Mounting Tray
ii) Engraved phenolic nameplate affixed to
front flange to identify each indicator by tag
number and each point by measured
variables.

14. Alarm Facility : 1 HI and 1 LO for each channel independently
adjustable over span. Voltage free outputs
15. Reference Junction
Compensation : Built-in cold junction compensation for
thermocouple inputs
16. Feature : i) Alarm level indication by flashing cursor
ii) Green Digital display of parameter value in
front panel with a 3.1/2 digit display.

3.05.00 VALVE POSITION INDICATOR
01. Input : 4-20 mA DC/1-5 Volts DC
02. Indication : Pointer and Scale. Moving Coil Meter
03. Readable Distance : 3 meters (minimum)
04. Pointer Deflection : 90 Deg Sector or linear
05. Mounting : Flush Panel (Horizontal/vertical)
06. Accuracy : 1% or better
07. Protection Class : IP-42
08. Operating Ambient Temp. : 0-50
O
C
09. Scale : 0-100%
10. Bezel Size : DIN Standard

3.06.00 DIGITAL INDICATOR
01. Type : Four and half digit LED seven-segment display
with sign.
02. Face Dimension : 72 x 144 mm / 48 x 96 mm (as applicable)

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03. Display Character : 13.8 mm, Green (LED)
04. Accuracy : 0.1% of reading, 2 digit
05. Input : 4-20mA DC/1-5 V DC/RTD/Thermocouple
06. Mounting : Flush Panel
07. Power Supply : 240V 10%, 50 2.5 Hz
08. Output Contact : 2 nos SPDT, contact rating 5A at 240V AC/
0.25A at 220V DC
09. Power/Signal Connection : Screwed
Large Display (150x300 mm) indicators shall be provided for MW, MVAR and
frequency indications.

3.07.00 TOTALIZER / COUNTER
01. Type : Electronic
02. Number of digits and digit
size : Six, 9 mm high
03. Input : 4-20mA DC
04. Reset : Manual
05. Readable distance : 3 meters (minimum)
06. Mounting : Flush
07. Performance :
a) Accuracy : 0.0.5% of span
08. Operating ambient temp. : 0 - 50
O
C
09. Accessories : Engraved phenolic nameplate affixed to front
flange to identify tag number and measured
variable.
10. Preferred Features : Power supply on/failure LED visible from front.

3.08.00 PUSH BUTTON
01. Type : Shrouded square format
02. Face Dimension : 32 x 32 mm (maximum)

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03. Contact Configuration : 2 NO + 2 NC
04. Contact Addition : Add-on block up to 4 each with 2 pairs of
contacts
05. Contact Material : Hard Silver Alloy
06. Contact Rating : 500V / 10 A
07. Utilization Category : AC11 / DC11
08. Insulation Voltage : 2 KV for 1 minute between terminals and earth
09. Mechanical Life : 1 million operation
10. Construction : Aluminum shrouding with plastic lens
11. Colors : Red, Green, Yellow, Black, etc.
12. Connection ; Screw terminals
13. Enclosure Class : IP-52
14. Legend : Engraving

3.09.00 ILLUMINATED PUSH BUTTON

01. Type : Square format
02. Face Dimension : 32 x 32 mm (maximum)
03. Contact Configuration : 2 NO + 2 NC (minimum)
04. Contact Addition : Add-on-Block up to 4 each with 2 pairs of
contacts
05. Contact Material : Hard Silver Alloy
06. Contact Rating : 500 V/ 10A
07. Utilization Category : A C11 / DC11
08. Insulation Voltage : 2 KV for 1 minute between terminals and earth
09. Mechanical Life : 1 Million Operation
10. Lamp : LED with built-in resistors as required
11. Lamp Rating :-
a) Voltage : 240 V AC
b) Watt : 2 Watt (approx.)

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12. Lamp and Lens
Replacement : From front
13. Construction : Transparent Plastic Lens
14. Color : Red, Green, Amber, Yellow etc.
15. Connection : Screw terminals
16. Enclosure Class : IP-52
17. Legend : Engraving



3.10.00 SELECTOR SWITCH

01. Type : 2/3/4 position stay put type with rotary lever
actuator.
02. Face Dimension : 32 x 32 mm (maximum)
03. Contact Configuration : 4 pair of contacts
04. Contact Addition : Add-on-Block up to 4 each with 2 pairs of
contact
05. Contact Material : Hard silver Alloy
06. Contact Rating : 500 V/10 A
07. Utilization Category : AC11 / DC11
08. Insulation Voltage : 2 KV for 1 minute between terminals and earth
09. Mechanical Life : 1 million operation
10. Construction : Aluminum shrouding
11. Connection : Screw terminals
12. Enclosure Class : IP-52

3.11.00 INDICATING LAMP

01. Type : LED with built-in resistor
02. Face Dimension : 32 x 32 mm (maximum)
03. Voltage : 240 V AC
04. Watt : 2.5 Watt (approximate)

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05. Lamp and Lens
Replacement : From front
06. Construction : Transparent Plastic lens
07. Color : Red, Green, Amber, Yellow etc.
08. Connection : Screw terminals
09. Legend : Engraving


3.12.00 INDICATING METERS (A.C)

01. Type : Rectifier type
02. Face Dimension : 96 x 96 mm
03. Scale : Radial arc of 240 Deg.
04. Accuracy : 1.5% of full scale.
0.5 Hz for frequency meter
05. Input : 0-1/0-5A for current measurement, 0-240V, 50
2.5 Hz for voltage / frequency measurement
06. Zero Adjustment : Screw on meter face
07. Enclosure : Shielded Case
08. Mounting : Flush Panel
09. End Scale Suppression : 6 times the measuring range only for motor
ammeters

3.13.00 INDICATING METERS (D.C)

01. Type : Taut band moving coil
02. Face Dimension : 96 x 96 mm
03. Scale : Radial arc of 240 Deg.
04. Accuracy : 1.5% of full scale
05. Input : 0-75 mA for current measurement. Direct
reading for voltage measurement.
06. Zero Adjustment : Screw on meter face
07. Enclosure : Shielded case

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08. Mounting : Flush Panel
09. End Scale Suppression : 2 times the measuring range only for motor
ammeters.

For electrical systems meter and for synchronization, Bidder shall refer to electrical
volume of the specification



3.14.00 AUXILIARY RELAY

01. Type : Electromagnetic
02. Coil voltage : 240 V A.C / 220V DC. For any other voltage
bidder to make his own arrangement.
03. Contact Configuration : 2 NO & 2 NC (Minimum), additional contacts
as per requirement with provision for additional
contact block expansion
04. Contact rating : 250V/5A (A.C/D.C.)
05. Operating range : 80 to 110% of rated voltage
06. Insulation : 2 KV for 1 minute between terminals & earth.
07. Mechanical life : 20 million operations

08. Coil protection : Diode/surge suppressor
09. Connection : Screw terminals.
10. Mounting : Projection mounting inside panel

3.15.00 ELECTRICAL TRANSDUCER

Transducers shall be provided for conversion of AC electrical quantities such as
voltage, current and power. Transducer shall be suitable for 220V DC auxiliary
supply. Transducers shall be of low burden type having 4 20 mA DC linear
galvanically isolated output compatible with secondary indicating instrument.
Transducer shall be dual channel type. Accuracy class of Transducers shall be as
per IS14570:1998 or IEC688 :992

3.16.00 SYNCHROSCOPE

Synchroscope shall be designed to provide an illuminate and indication of phase
and frequency difference between bus voltage and Generator voltage. It shall
denote the actual frequency difference corresponding to the inverse of time taken

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for one rotation of the illuminated vector spot. The instrument shall be designed for
industrial applications, which require precise, reliable and robust instruments for
the display range and indication. Synchroscope shall be designed as per the
DIN/IEC/BS standards.


4.00.00 CONTROLVALVES,ACTUATORS&ACCESSORIES

General Technical Guidelines for the Control Valves shall be as follows :

a) Bidder shall exercise caution in selecting severe service control valves like
BFP recirculation valves, HP & LP bypass valves, superheater & reheater
attemperator valves, PRDS valves for Boiler & Turbine, Soot blower steam
pressure control valve, control valves whose down stream are connected to
vacuum such as HP/LP heater emergency level control, condenser make up
water control valve, separator level control and CEP minimum flow control
valve. For such critical applications, Bidder shall offer valves which are proven
for similar application. Above valves shall have leakage class equal or better
than class-V with metal-to-metal seating.

b) Wherever, steam conditioning calls for Pressure reducing & desuperheating,
combined PRDS type valves shall be offered.

c) Bidder shall provide redundant control valves for Main condensate flow
control, Superheat attemperation control and Reheat attemperation control as
a minimum for high availability. For other application, if the availability criteria
for the plant cannot be met even with the best established product, redundant
control valves shall be provided.

d) Control valves shall be located near floor or platform for ease of access and
with adequate clearances for maintenance and lay-down and shall be placed
as station with upstream motorized isolating valve, down-stream isolating
valve, inching duty motorized bypass valve and manual drain valves. Each
redundant control valve shall have its upstream motorized and down-stream
manual isolating valves. Where quick shut off requirement is foreseen such as
in case of SH & RH attemperation valves, upstream isolation valve shall be
pneumatic type.

4.01.00 GENERAL

4.01.01 Control valves for regulating service shall normally be globe body, preferably cage
guided, metal-to-metal seated, pneumatically operated and shall be provided with
characterized plugs having ANSI leakage class-IV except for the control valves
indicated above.

4.01.02 Where the operating time is critical for the operation of the plant, as in case of HP
or LP bypass valves, hydraulic actuators with electro-hydraulic interface shall be
offered.

4.01.03 Bonnet joints for all control valves shall be of flanged and bolted type.


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4.01.04 Flanged valve shall be rated at no less than class 300 Ibs.

4.02.00 VALVEBODY/ENDCONNECTIONS

4.02.01 Valve end to end dimension and connection shall be according to ANSI standard,
straight through pattern. However, Bidder may offer angle body valve for high
pressure drop applications. For high pressure drop applications, construction of the
valve shall be such that the gland is not exposed to inlet pressure.

4.02.02 Control valves of 40 mm. size and above with line pressure up to 50 Kg / Sq. cm
may have flanged or welded end connections.

4.02.03 Control valves, used in high pressure services shall have butt welded end
connections for size 65mm and above and socket weld end connection for size 50
mm or below.

4.02.04 Control valve body shall be selected as per the ISA guideline. Generally control
valve body shall be cast and machined for pressure rating up to 1500 lbs. Above
1500 lbs, valve body shall be of forged steel. For Demineralized Water application,
valve body shall be Stainless Steel.


4.02.05 The direction of flow shall be clearly engraved on the body.


4.02.06 Valve Body Material

SR. NO. SERVICE MATERIAL
1. Non corrosive, non-flashing and non
cavitating service for fluid
temperature upto 275C
: Cast carbon steel ASTM A216
Gr. WCB
2. Non corrosive, non-flashing and non
cavitating service for fluid
temperature above 275C
: Cast alloy steel ASTM A217 Gr.
WC9
3. Severe flashing / cavitating services : Cast alloy steel ASTM A217 Gr.
WC9
4. Low flashing / cavitating services : Cast alloy steel ASTM A217 Gr.
WC6
5. DM water application (condenser
hotwell normal, emergency make up
etc.)
: Cast type 316 stainless steel
ASTM A351 Gr. CF8M

4.03.00 VALVESIZE

The control valve sizing (Cv / Kv) shall be based on following guidelines :

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a) The valves shall pass normal flow (MCR condition) with 60 to 70 percent
opening for linear characterised valves and between 70 to 80 percent
opening for equal percentage characterised valves.
b) The valves shall have adequate rangeability to pass the minimum and
maximum flows at 10% and 85% of the valve opening respectively. Valve
stem travel range from minimum to maximum flow condition shall not be less
than 50% of the total valve stem travel.
c) Valve Cv shall be selected in such a way that the valve shall be capable of
handling at least 120% of required maximum flow.
d) The valve selection shall be based on the highest size dictated by the above
considerations unless noise, flashing or other factors dictate the final
selection.
e) Trim outlet velocity for the control valves shall be no more than 7 m/sec for
water service and Mach number less than 1/3 for steam and air service
application.
f) The sizing procedure followed shall be as per latest edition of ANSI/ISA or
equivalent standard.

4.04.00 VALVETOPWORK

4.04.01 Top work shall be sized so that the valve shall operate properly when upstream
pressure is 10 percent above maximum inlet pressure and downstream pressure is
atmospheric.

4.04.02 Extended bonnet/Finned bonnet and high temperature packing shall be used for
high temperature application.

4.04.03 The gland material shall be chosen to suit the operating temperature. PTFE may
be chosen for lower temperature application (232C maximum) and for high
temperature application graphited asbestos glands are to be provided. For
vacuum services, the glands shall be of dry seal type.

4.05.00 VALVETRIM

4.05.01 Valve trim for applications up to leakage class-V shall be stainless steel 316 SS for
pressure drop up to 7 Kg/ Sq. cm. For pressure drops above 7 Kg/Sq. cm hard trim
(stelliting or equivalent) shall be used. Other alloys or treatment such as nitride
shall be used if severe erosion is expected.

4.05.02 Balanced trim valves shall be offered for high shut-off pressure or high pressure
drop condition to reduce the size of the actuators.

4.05.03 For flashing services and two stage mixtures, the trim material shall be 17-4 PH SS
or equivalent.


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4.05.04 If cavitating condition is foreseen, Bidder shall offer multistage or labyrinth trim
valves. Trim of severe service valves shall be of multistage and multipath design
with number of discrete pressure drop stages to eliminate the chances of erosion,
cavitation, noise and vibration throughout the control range of the valve.

4.05.05 Quick replacement type trim shall be considered for easy maintenance.

4.05.06 Trim Material

SR. NO. SERVICE MATERIAL
1. Non corrosive, non-flashing and non
cavitating service for fluid temperature upto
275C.
: SS 316 stellited

2. Non corrosive, non-flashing and non
cavitating service for fluid temperature
above 275C.
: SS 316 stellited
3. Severe flashing /cavitating services : 440 C
4. Low flashing /cavitating services : 17-4 PH SS
5. DM water application (condenser hotwell
normal, emergency make up etc.)
: 17-4 PH SS



4.06.00 NOISELEVEL

The equivalent sound level measured at 1.5M above nearest floor level in elevation
and 1 M horizontally from the control valve expressed in decibels to a reference of
0.0002 microbar shall not exceed 85 dBA. If the calculated noise is more than the
above limit, even with low noise trim design, diffusers shall be included. Diffusers
shall be made of stainless steel and shall be integrally connected to the control
valve with spool piece. The spool piece shall be in conformity with the main line
piping specification.

4.07.00 VALVEACTUATORS


Spring-diaphragm type actuators shall generally be used. Piston type actuators
shall be offered in case of high shut-off pressure & quick response requirement.

4.07.01 The actuator shall be designed for 150% thrust required for the valve (at shut-off
pressure) at an air line supply pressure of 5.5 Kg/Sq. cm.

4.07.02 Diaphragms shall be designed for 200% maximum operating pressure.

4.07.03 Nylon reinforced neoprene is preferred as diaphragm material.
4.07.04 Valve actuators shall be capable of operating at 80
O
C ambient, continuously.

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4.07.05 Entire actuator assembly shall be painted with corrosion inhibiting paint.

4.07.06 Air connection size shall be 1/4" NPT (F) unless otherwise dictated by process
response time. Integral tubing shall be stainless steel.

4.07.07 Bidder shall indicate the stroking time of the valve assemblies with positioner and
ensure that the stroke time shall meet the process and equipment dynamics and
shall be better than 20 seconds.


4.07.08 All actuators shall be of fail safe design signifying that the spring direction will tend
to move the valve (open or close) in a direction safe for the process. Failure to
Open or Failure to Close shall be marked on the actuator.

4.08.00 VALVEPOSITIONERS

4.08.01 Regulating duty valves shall be offered with Smart Electro Pneumatic Positioners
with HART Compatibility to ensure accuracy and repeatability of response.

4.08.02 Positioners shall have integral non contact type position transmitter, input and
output gauges, local keypad & display.

4.08.03 Positioners shall be capable of functioning under hot, humid and vibrating
conditions.

4.08.04 Positioner casings shall be dust tight, corrosion resistant and weatherproof.

4.08.05 In general, positioner shall operate at signal range 4 - 20 mA DC

for the full travel
of the valve. Remote calibration from control room shall be possible through
management station.

4.09.00 VALVEACCESSORIES

Accessories shall include side mounted hand wheels, limit switches, junction
boxes, airlock relays etc.. Solenoid valve wherever required shall be furnished.

5.00.00 CONTROLDESK/PANEL/RACK

5.00.01 Convenient and logical approach to operational interfaces and aesthetics in the
overall view of the panel /desk shall be considered.
5.00.02 For items susceptible to vibration, suitable anti-vibration padding shall be provided
to prevent damage or malfunction.
5.00.03 All items inside the panels/cabinets shall be neatly arranged with easy access/
maintenance approach.
5.00.04 Incoming power supply feeders shall be duplicated. Alarm shall be provided for
failure of a power supply feed.

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5.00.05 Desk / panel shall be provided with interior illumination, utility receptacles with plug
and cooling fan.
5.00.06 panel / Desk shall have gland plate at cable entry to panel. Thickness of gland
plate shall not be less than 3 mm.
5.00.07 Wire shall be routed/laid through covered trough.
5.00.08 Crating of the panels and desks shall be suitable for protection against shock,
vibration, inappropriate handling and inclement weather conditions during
transportation and warehousing. Mounted equipment shall have adequate
protection against damage during handling, transit and storage. Suitable desiccant
shall be used inside the packing case.
5.00.09 Nameplate
a) Nameplate shall be provided for instrument or device mounted on the panel.
b) Nameplates for panels shall be provided both in front and rear.

5.00.10 All local control panels shall be housed in air condition environment.

5.01.00 CONTROLDESKS

5.01.01 Devices mounted on the desks shall be flush type. Devices shall be so mounted
that their removal and replacement can be accomplished without interruption of
services to others.

5.01.02 Desk shall be ergonomically designed to suit working on a 24 X 7 basis.
Aesthetics, ergonomics and illumination shall be considered while positioning of
the desk, large video screen and panels in control room.

5.01.03 Control desk shall be free standing floor mounting type of table-top design with
compartments for locating the hardware. Desk shall be constructed from aluminum
extrusion with high pressure laminate MDF board for work surface of approved
colour. Aluminium structure shall be anodized or powder coated paint finish.

5.01.04 Monitors with retractable keyboard, emergency push buttons shall be provided on
the desk. Desk shall be arranged in arc-like shape without any sharp edges. Edges
shall be extruded PVC or rounded post-formed laminate..
5.01.05 Desks shall be of modular, scalable and industrially ruggedized design and shall
have Telephones and Intercom connections.
5.01.06 Desks shall have concealed cable trays for wire dressing.
5.01.07 Design shall include Earthing bolts.
5.01.08 Back installed items shall be suitably concealed from front view.

5.02.00 BACKUPPANEL

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5.02.01 Construction shall be from sheet steel of thickness not less than 3mm.
5.02.02 Electrical upright Panel construction & design shall be similar to back up panel.
Control switches, meters, indicators, synchronizer, excitation control switch,
annunciation window etc. along with associated mimic diagram, as recommended,
shall be provided for manual synchronization of generator.

5.03.00 CABINETS/ENCLOSURE/PANELS

01. Material of construction : Cold rolled steel sheet

02. Thickness of Sheet : a) 3.0 mm for faces supporting
instruments / terminals.
b) 2 mm for other sides and top.

03. Construction : Welded throughout as per approved
National Standards.

04. Panel height : 2300 mm (approx)


05. i) Corners : 7 mm inner radius

ii) Dimensional
Tolerances : a) In height & length - 3 mm

b) In height between adjacent sections
- 2 mm.

c) Total for a group - 6 mm

06. Doors : Double, recessed, turned back edges

i) Thickness of Sheet : 2 mm

ii) Hinges : Stainless steel

iii) Door latches : Three point type

iv) Door gaskets : Neoprene rubber on fixed frame to result
dust proof/weatherproof enclosure.

v) Opening of the doors : Outward

vi) Louvers : With removable wire mesh to ensure dust
and vermin proof.

07. Color of interior : Brilliant white

08. Colour external : Light grey 631 to shade IS 5

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09. Painting : Epoxy powder coated or better

10. Gland plates : Removable 4 mm thick (bottom)

11. Cable entry : Bottom

12. Hardware : a) Anti vibration pad- 15 mm
b) Predrilled base channel ISMC - 100
or equivalent for all sides.
c) Stainless steel buff- finished 2 mm
thick kick plate for all sides.
d) Stainless steel scratch strips along
desk edges fixed with pan-head
recessed screws.
e) Rubber strips to ensure air tightness
between kick plate and finished floor.
f) Lifting hook / Eye bolt
g) Drawing pocket
h) Door switch, lamps, thermostat,
heaters and fans

13. Enclosure Protection : As per environment condition of the area
of installation. Refer section-I of this vol.

5.04.00 LOCALINSTRUMENTRACKS&ENCLOSURE

5.04.01 GeneralRequirements
a) Devices located in the field shall be grouped and installed in the enclosure
(Closed Rack) in outdoor areas such as Boiler area etc. and in Open Type
Rack in covered areas such as TG Building.
b) Racks and enclosure shall be factory prefabricated & painted and shall
complete with internal piping, tubing, manifold, isolation valves, blowdown
valves, integral junction box, illumination etc,.
c) No more than six instruments shall be grouped in a single rack /enclosure.
d) Racks shall be installed above the tapping points for air, flue gas and coal air
mixture application whereas for applications such as for water and steam,
racks to be installed below the source point.

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e) Attention shall be paid in the layout to avoid air traps in liquid piping and water
accumulation in air /gas piping.
f) Welding of impulse lines shall comply with the provisions of the latest
applicable ANSI Code for Pressure Piping.
g) Instrument piping and tubing shall be hydrostatically tested at one and
one-half times the maximum system pressure except for low pressure and
vacuum measurement for which the test pressure will be as per piping
standard.
h) Service air connection shall be provided for continuous and intermittent
purging of impulse pipe in dusty medium. Continuous purging shall be
adopted for differential pressure measurement such as flue gas and coal air
mixture application. Pressure measurement shall have only intermittent
purging whenever required. In case of continuous purging, an air header shall
be formed which shall receive service air through isolation valve and air filter
regulator. Air shall be fed from the air header to both the impulse pipes near to
take off points through isolation valves and flow regulators. Air header shall be
constructed from stainless steel. Impulse pipe for such applications shall have
a four-way valve. One port of the valve shall have an adaptor to connect
flexible stainless steel braided nylon hose to the service air. Rating of the
hose shall not be less than 10 Kg/sq.cm. Four way valve shall have two
position operations. One position for service and other one for purging.
Required pressure gauges shall be provided for monitoring of air pressure.
Complete purging arrangement shall be integral to the enclosure and racks.
i) Gate or ball type (full ported) instrument isolation valve and globe type blow
down drain valve adequate for duty requirement and for withstanding
continuous design pressure and temperature of main process medium shall
be provided in the hook up plumbing. For process pressure equal or above 40
kg/ sq.cm single instrument isolation valve and double blowdown valves shall
be used before connecting to blowdown header. Whereas for line pressure
less than 40 kg/ sq.cm, single instrument isolation valve and single blow down
valves can be used before connecting to blow down header. Instrument
manifolds shall be non integral and shall be installed close to the instrument.
j) Drawing for typical arrangement of Local instrument enclosure and rack to be
submitted with the bid.

5.04.02 ClosedInstrumentRack

a) Enclosure shall be free standing type. Racks shall be adequately reinforced to


ensure true surfaces and to provide support. Major load-bearing posts shall be
suitably supported by gusset plates or moment members.

b) Enclosure outer shall be constructed from at least 3 mm thick steel plate and
epoxy painted to shade gray. Base frame shall be made of ISMC 100 and
black colour finish.

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c) 2 NB galvanized pipes shall be laid horizontally and supported at two end
channels to mount transmitters at accessible height. Center posts or any
member, which would reduce access, shall be avoided.
d) Double leaf interlocking front opening doors with three point locking shall be
provided and shall be arranged for maximum possible access to the interior.
Key shall be of identical for all enclosures.
e) Doors shall have concealed quick removal type pinned stainless steel hinges
and locking handles. Gaskets shall be used between all mating sections to
achieve dust and weather proof enclosure rated for IP-65 including the
internal junction box.
f) Removable type bulkhead plates of thickness not less than 6 mm shall be
mounted at the racks with suitable high temperature gasket Impulse lines
within the enclosures shall be properly clamped.
g) All internal wirings between the instruments and junction box shall run through
flexible conduits.
h) Racks shall have a common blowdown drain header, which will connect
individual instrument blowdown line after suitable pressure breaking through
regulating globe type blowdown valves. Header shall be of 2 NB ASTM A
106, Sch-80 Gr. C installed at a slope of 1:25 and extended beyond the rack
for connection to plant drain header.
i) Each rack shall be provided with one receptacle, light fixtures each at
instrument & Junction box compartments with wire guard.

5.04.03 OpenInstrumentRack

a) Rack shall be free standing type constructed from 6 mm thick steel channel
frame provided with a canopy to protect the instrument from dripping water or
falling objects and shall be epoxy painted. Rack Major load-bearing posts
shall be suitably supported by gusset plates or moment members. Suitable
protective grill shall be welded to the end-posts of the rack to outline a
boundary beyond which no mounted equipment shall project. Canopy shall be
of CRCA steel sheet of at least 3 mm thickness. Center posts or any member,
which would reduce access, shall be avoided.

b) 2 NB galvanized pipes laid horizontally and supported at two end channels
shall be employed at working accessible height for mounting of instruments.

c) All internal wirings between the instruments and junction box shall run through
flexible conduits. No exposed wirings are admissible.

d) All racks shall have a common blowdown drain header, which will connect
individual instrument blowdown line after suitable pressure breaking through
regulating globe type blowdown valves. Header shall be of 2 NB ASTM A
106, Sch-80 Gr. C installed at a slope of 1:25 and extended beyond the rack
for connection to plant drain header.

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5.04.04 JunctionBox

Junction boxes of metallic construction.
a) Junction box shall be provided at a dry compartment at one side of the
enclosure / rack with front opening type door. Junction box shall be of sheet
steel construction with thickness not less than 2 mm. Earth stud shall be
furnished at rack for safety grounding.
b) Terminals shall be screwless cageclamp type of reputed make and 20% spare
terminals shall be furnished in the junction box.


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6.00.00 DISTRIBUTEDDIGITALCOMTROL&MANAGEMENTINFORMATIONSYSTEM(DDCMIS):

6.01.00 SYSTEMFUNCTIONALDESCRIPTION

6.01.01 Integrated functionally & geographically distributed and hierarchically structured
real time control (both binary and modulating), Data acquisition, Man machine
interface, Historization units and Management Information System (MIS) system
synthesized from one general family of identical interchangeable multifunction
hardware has been envisaged.

6.01.02 System shall be highly reliable with the availability of not less than 99.7% with
adequate redundancy and fault tolerant configuration.
6.01.03 The system shall be unitized and connectivity with other plant control system &
Plant wide network has been envisaged.
6.01.04 Remote input output stations as a data concentrator for acquisition and monitoring
of non critical parameters like Boiler metal temperature and Generator winding
temperature etc, are foreseen. RIO shall be industrially ruggedized and shall be
provided with integral air conditioner considering the harsh environment.
6.01.05 For Power supply to DDCMIS system refer Volume IIE Section I.
6.01.06 Controls of some plant auxiliaries such as CW & ACW Pumps and Fuel oil heating
& pressurizing system controls shall be realized with Remote Processing Unit
(RPU). RPUs consisting of redundant multifunction Controllers, redundant
communication modules and input / output units with their local operator stations
shall be located in the respective air conditioned local area control rooms. RPUs
shall be considered as an extension of the DDCMIS node/network and shall be
complete with redundant optical fiber cable connection and accessories.
6.01.07 Selected data from Owners off site & BOP plants such as Ash Handling Plant,
Raw water & Pretreatment plant, Demineralized water plant and Coal Handling
Plant etc shall be displayed/historized in CCR.
6.01.08 Similarly, unit auxiliaries such as micro controller based air compressor control and
PLC based Mill reject system shall also have interface with DDCMIS. Bidder shall
furnish the DDCMIS gateways, optical fiber cables & interface for collecting data
from the above stations.
6.01.09 The system shall be of open architecture type with support for OPC and other
industry standard connectivity and shall be modular, expandable and upgradable to
meet technological advancement.
6.01.10 The control and monitoring hardware and peripherals for the unit shall be located in
the Central Control Room (CCR) & Control Equipment Room (CER) of the units
(both air-conditioned).
6.01.11 The DDCMIS shall be configured to broadly perform the following basic functions: -


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a) Automatic sequencing of the start-up, shutdown and load swing of equipment
and auxiliaries including group / plant level start-up to minimize operator's
intervention under normal operating conditions ensuring safety of man and
machine as well as to ensure high plant availability (OLCS & Sequence
functions).

b) Automatic regulation of various valves and dampers to achieve guaranteed
performance of various controlled variables and to achieve most fuel-efficient
operating regime (CLCS functions).

c) Acquisition, alarms, sequence of events, display, real time & history trend,
logs, report generation and archiving of plant data and maintain historical data
for a defined period (DAS functions).

d) Gateway for collection of selected data from plant auxiliaries and off-site
plants and interface with stand alone systems like Rotating Machine Condition
Monitoring System, Continuous Emission Monitoring system etc..

e) Presenting salient plant parameters to plant executives to display the health
and condition of the plant and to aid the decision making (MIS functions).

f) Energy management and audit of the plant and equipments by measuring
consumption of power of all salient equipment and measurement of fuel,
steam, water and all other relevant cost-bearing parameters.

h) System should have the feature for off line system configuration, simulation of
control loops and logics, control loop tuning and debugging.

i) System shall have the tool for automatic generation of documents like loop &
logic diagrams. Logic & loop diagram such prepared can be functional in auto
CAD environment.

j) Interfacing between the unit DDCMISs for common data exchange and MIS
function.

6.01.12 The DDCMIS shall consist of the following broad sub-systems.

a) Input / Output Subsystem
b) Controller (OLCS & CLCS) Subsystem
c) Data Acquisition Subsystem (DAS)
d) Historical Storage Subsystem (HSS)
e) Plant optimization & Performance Calculation Station (PCS)
f) Human Machine & Peripheral Interface (HMI) Subsystem
g) Engineering and Diagnostic Station (ES)

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h) Sequence of Event Monitoring Subsystem (SOE)
i) Management Information System (MIS)

The above sub systems shall be connected together through redundant and fault
tolerant real time high speed internal Data Highways through redundant switches.
High speed information network shall also be considered at MIS level for reports,
logs, history etc,.

Mutual interdependence between the subsystems shall be limited to sharing the
global database of the plant, which shall be resident at various locations, to
facilitate rapid response. The same database will be accessed, shared and
updated by various consumers, seamlessly and transparently.

6.01.13 The system architecture of the DDCMIS shall, by and large, be unitized with unit
systems performing in a manner independent of one another with limited data
exchange for common systems.
6.01.14 Commissioning of the units will be executed in phases and commissioning
activities at one unit shall not interfere with the functioning of the other running
units.
6.01.15 Additional operators stations of unit ESP controls shall be installed in the central
control room in addition to local control room.
6.01.16 Dual power supply feed shall be considered for all cabinets. Power supplies to
systems common for all units shall be such that non-availability of power supply
from one unit (under complete shutdown) shall not impose any limitation on
functioning of the system.
6.01.17 The unit control networks and the station auxiliary network shall be bridged into a
common high-speed network with authorized data access between the sections.
6.01.18 The system shall present pre-selected plant parameters selected nodes on the
company local area network (LAN) or wide area network (WAN) or at remote
location via ISDN or equivalent connections. The exact nature of the interface shall
be finalized during detailed engineering. At least 80 MIS stations shall be
considered within the plant area for the entire station. To protect against any
unauthorized access of the network, adequate security in the form of Firewall etc.
shall be deployed.
6.01.19 Web based MIS subsystem with HTML compatible display format for accessing
plant graphics / data shall be provided. The system shall support limited access for
soft users for viewing the static display of plant information / graphics and at least
ten premium users viewing the information / plant graphics with automatic refresh
of data.
6.01.20 For coordinated machine control (CMC), the DDCMIS shall interface with Load
Demand & other signals from Owners Central Load Dispatch center. Detailed
scheme for the CMC shall be furnished for Owners approval.

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6.01.21 Bidder shall furnish all required equipment and materials including system
hardware and firmware components, peripherals and operator work station, all
necessary licensed software platforms - compilers, interpreters, builder packages
etc; programming, diagnostic and test routines, instruments and equipment;
development of application software, data base, screens, graphics and other
functional programs; establishing the network structure, debugging and loading;
develop and follow a quality assurance plan, system integration, simulation and
checkouts; offering the system for Owner's shop inspection and testing including
hardware, software and heat-run tests, packaging for transportation, delivery at
plant site, unloading, warehousing, installation, site integration, program loading
and documentation, system check-out, interconnection with field inputs, pre-
commissioning checking, commissioning including tuning of control loops and put
the complete system in operation with necessary site modifications, conduct
performance guarantee tests, system availability test and develop as-built
documentation.
6.01.22 Bidder shall supply all related documentation including original software manuals,
application software manuals, operation and maintenance manuals, instruction
handbooks for graphic and data-base building and other related documents and
manuals in hard copies as well as in soft medium. Bidder shall furnish the entire
plant database and configuration in as-built condition in CDs for reloading/ record.
6.01.23 Bidder shall also supply maintenance and trouble shooting tools viz. test
instruments, extender cards, cassettes / floppies / CDs containing programs
including virus detection and elimination programs, blank cassettes, streamer
tapes, CD writers, floppies and CD for copying, diagnostic programs etc.
6.01.24 Bidder's scope of supply shall include the supply of commissioning, recommended
and mandatory spares as per guidelines given in the specification.
6.01.25 Bidder's scope of work shall also include the training of Owner's personnel at
original equipment designer / manufacturers office and providing the warranty for
the equipment supplied.
6.01.26 Suggested configuration of the DDCMIS is illustrated in the Drawing no. CPCPL-
11Z02-DWG-I-221.

6.01.27 All wiring to and from the DDCMIS whether they are from field or other cabinets
located in and beyond control equipment room, shall be through Termination
Cabinets.

6.01.28 There shall be functional duplication for HMI fall back so that in case of outage of
any operators station, other operators station can take up its entire assigned
function transparently, without any sacrifice in performance and without the need
for rebooting. However, for normal operation, assignment for HMI, severs and
other peripherals are envisaged as follows. Printers shall have graphic capability
and any printer shall be accessible from any workstation.

a) Steam Generator Control Stations (2 per unit) For closed loop, open loop
and sequence controls of SG integral control & monitoring, alarm and SOE
within boiler area.

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b) Burner Management System Stations (1 per unit)
c) Turbine Generator Control Stations (2 per unit) - For closed loop, open loop
and sequence controls of TG integral control & monitoring, alarm and SOE
within turbine area.
d) BOP stations (2 per unit)- For closed loop, open loop and sequence controls
of Station C&I / Balance of Plant control & monitoring, alarm and SOE.
e) Electrical Distribution system (2 per unit) - For logic, monitoring, alarm and
SOE.
f) Large Video Screen Display unit with LCD/Digital Light Processing and
Projection unit, Interface unit with DDCMIS to display salient plant
parameters, graphic & alarm (04 nos. per unit).
g) Engineering cum diagnostic Terminal (2 per unit) one located in Computer
Room next to Control Room and other next to CER - with one (1) Color laser
jet printer (A3 size) each.
h) Unit performance Calculation (One per unit)- located in Computer Room
i) Plant Performance Analysis, Diagnostic & Optimization system Terminals -
(one for each unit).
j) Management Information System (MIS) (Plant View Server) Total 80 off
located all over the plant including service building, shift charge engineers
room etc.
k) Shift charge Engineers Station (1 per unit)- with printer
l) Training Simulator Terminal One (1 no) Common for three units..
m) Printers shall be network ready and freely addressable from any operators
station. Printer configurations for each unit shall not be limited to the following:
The qty of printer shall be as indicated the DDCMIS configuration
drawing
In addition to the above there shall be HMI not limited to the following:
Rotating machine condition monitoring station- with colour laser printer -
for each unit.
HART management system-with printer- for each unit (in case the function
is not integrated into DDCMIS)

6.01.29 The DDCMIS System shall have the following capabilities, as minimum: -

a) Scan, acquire, validate, time-tag, process, store, update, archive, retrieve and
display all analog and digital data and parameter.

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b) Monitor real and calculated variables for multi-level alarm conditions.
c) Accept and execute operators commands and pre-programmed routines and
run-times.
d) Perform all open and closed loop control functions.
e) Display plant mimics, bar-graphs, control faceplates, point description, trend
graphs (real time & history) in interactive mode with the operator.
f) Prepare and print logs and reports.
g) Performance calculation based on real-time and manually entered data.
h) Dynamically reconfigure itself on command from engineering station.
i) Run diagnostics, program hang up checks, system checks and routines.
j) System information and diagnostic alarm like failure of I/O module,
Multifunction controller, communication modules, node failure, CPU loading,
Network loading, workstation diagnostic etc..
k) Dynamic data exchange through OPC /MODBUS etc with other systems.

6.01.30 Remote service center

Bidder shall provide the necessary hardware and software required for connecting
the DDCMIS system to Bidders remote service center , through which the
diagnostics and fault analysis of the DDC MIS system can be carried out .The
method of connection shall be as per the Bidders standard practice. However, it is
preferred to have the connection through a single point in the plants DDCMIS
system. The fixed charges and running cost till warranty period shall be included in
the Quoted Price .The running cost there after shall be separately indicated.

6.02.00 GPSMASTERCLOCK

The Master Clock system shall be GPS based, receiving synchronizing pulses from
the Global Positioning Satellite system to form a common time reference.

Master Clock system shall Synchronise the entire system for uniform time
stamping of all parameters of all units as well as electrical system and other sub-
systems of the plant.

System shall comprise of receiver antenna, redundant master clocks and slave
clocks, interconnecting cables, cubicles, redundant power supplies & other
accessories. Failure of the antenna will lead to systems falling back to internal
master clock.

A minimum of 10 external slave display devices (receiver clocks) of 6-digit display
of digit size 100 mm approx shall be located at various strategic locations of the
plant.

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All the microprocessor based control systems shall be time synchronized with the
master clock system. IRIG B or any suitable ports shall be made available from the
system for the synchronization of Owners control systems beyond this package. In
addition, the system shall also have 10 (ten) nos. of additional spare ports for time
synchronization of future power units.

6.03.00 CONTROLSYSTEMDESCRIPTION
6.03.01 DDCMIS shall be configured such that degradation of performance in the event of
a single failure of control equipment shall be eliminated. However, such failures
shall be suitably annunciated to draw the attention of the plant personnel.
Multifunction controllers, Communication Processors and Power supply modules
(both for control and field supplies) for all open- and closed- loop controls shall be
hot redundant to minimize risk arising out of failure. All redundant modules shall be
hot-withdrawable and hot-insertable.
6.03.02 Single multi-loop controller pairs based on 32-bit processor shall handle OLCS,
CLCS & Sequential functions of specific plant areas as per the functional grouping.
6.03.03 The hardware and software for the DDCMIS shall be from the latest proven design
for real-time environment meeting the pre-qualification requirement of this
specification.
6.03.04 Comprehensive automatic diagnostic system shall periodically verify the integrity of
the system and shall cause auto-transfer to the stand-by equipment without any
loss of data or shall lead to fail-safe situations in case of catastrophic failure of the
station with reporting at higher level.
6.03.05 Maximum permissible loading of various components shall be as follows:

a) Multi-loop Multifunction Controller 60%.
b) Input / Output - 80%
c) Console 80%
d) Historical Storage - 75 %
e) Data Highway / communication link 60%
f) Other computing modules 60%
6.03.06 Control functions shall be judiciously assigned to various controllers such that,
a) Controllers are uniformly loaded and partitioned as per functionality of the
process and equipment.
b) Loops are assigned logically to the controllers so that peer-to-peer active
data transactions are kept at minimum and a simple correlation exists
between plant equipment / system and corresponding controller.

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c) Complete failure of a controller partition can only affect a portion of the plant
and equipment and which shall be manageable by the operator without any
outage of the unit.
6.03.07 Response time of the control system should be adequate to maintain control over
the process under all regimes of operation. Response time shall include the delay
and dead time both internal and external to DDCMIS. Response time pertaining to
DDCMIS shall include the IO scan time, data communication time, processing time
etc. Maximum permissible response time for various functions are as follows:

a) CLCS - 200 msec for fast loops and 250 msec for others.
b) DAS- 500 msec to 5 sec
c) SOE - 1 msec
d) OLCS - 100 msec
e) Protective logic- 100 msec.
f) Refresh real time data on screen - 1 sec
g) Operators command execution time - 1 sec
Faster response is required for some critical equipment and systems such as
Turbine generator control, HP/LP Bypass control, MFT etc. and for those systems,
requirements for scan time shall be guided by the respective equipment and
systems dynamics.

6.03.08 Input / Output sub systems shall have features not limited to the following:
a) Interface with field sensors, Signal conditioning, A/D conversion, Signal
validation, Diagnostic, Engineering conversion, Time stamping, Limit value
monitor etc.
b) Interface with smart transmitter though smart interface module with optical
and galvanic isolation. Alternatively, standalone field bus management system
shall be used.
c) Channels individually addressable during routine diagnostic check.
d) Failure reporting.
e) Replaceable under system power on condition.
f) I/O bus and I/O communication processor shall be redundant.

6.03.09 Controller sub systems shall have the features not limited to the following:
a) 32 bit CPU with RAM more than 256 MB with at least 360 hrs. battery backup
and Flash memory of size 32 MB or better for real time multi tasking.

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b) Redundant communication ports with speed of 100Mbps or more.
c) Deterministic and peer-to-peer Communication with other controllers.
d) Redundant controllers placed separately and no sharing of motherboard.
e) Redundant Controllers, redundant power supply, redundant communication
modules.
f) Hot-withdrawable and hot-insertable.
g) Remote IO support
h) Processing time of parameter freely configurable.

6.03.10 For CLCS function, controllers shall have system resident library functions
including linearizers, characterizers, square root extractors, signal limiter, one-out-
of-two selector, Median selection, averaging, PID block, logical functions, Auto /
manual selector and other software configured mathematical blocks to be strung
together to form the desired strategy for control. Synthesizing, configuring, tuning
or adjusting control loops should not involve writing elaborate programs.

6.03.11 Open Loop Control System (OLCS) shall perform interlocking, protection,
sequential functions including individual drive control function with their associated
safety protection. OLCS shall provide adequate and reliable protection & safeguard
for various equipment and shall assist the operator in easy, safe & efficient starting,
stopping and tripping of various drives in the plant.
6.03.12 OLCS shall perform drive control functions like permissive, start, stop, auto-start,
auto-stop, wait- and step-timing control, drive interface and other related binary
functions. It shall also check the drive status feed back like On, Off, Fault, Local &
Remote selection, Normal & Trial selection, Switchgear disturbance, Electrical
protection operated, Safety interlock operated, standby mode etc. and display on
the screen.
6.03.13 For OLCS function, controllers shall have system resident library functions
including logic functions, timers, registers, counters, Boolean operators, encoders,
one-out-of-two selector, two-out-of-three voting system, logical functions, HT/LT
drive control and other software configured mathematical blocks to be strung
together to form the desired strategy. Synthesizing, configuring or adjusting control
loops should not involve writing elaborate programs.
6.03.14 Multi-loop controllers, interfacing with the redundant control bus, shall cater to a
group of related loops and shall have its own in-built communication function.
6.03.15 In case of redundant controller configuration, main and the hot stand-by
controllers shall be identical in all respects. Any one of the two controllers can be
selected as 'main' controller. Control shall automatically flip from main to stand by
transparently without any upset in the process in case of failure of main controller.
During normal operation, output of the stand by controller shall be disabled.

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However, standby controller shall receive and update its database from field inputs
and main controller.
6.03.16 When a controller is put back after removal for maintenance or if a new controller is
put in service, there shall be provision for high speed down loading of data from the
hot controller without affecting the main highway traffic.
6.03.17 In case of internal diagnostic failure of a multi-loop controller pair, all concerned
loops shall trip to manual and drive will go to its fail safe position dictated by the
process.
6.03.18 The functional capabilities of the controllers shall not be limited to the following :-

a) Accepting commands from and providing feedback to Operators Terminal.
b) Interact with other subsystems via Control System Bus.
c) Carry out computation.
d) Carry out control actions.
e) Perform binary and sequential operations.
f) Self-monitoring and auto-diagnostic leading to changeover to stand-by and
reporting of failure.
g) Program modification and configuration via Engineering Terminal, on line.
h) On line system tuning and setting.
i) Testing and simulation.
j) Signals shall be verified against cable failure.


6.03.19 Transfer of control mode from automatic to manual and vice-versa shall be
procedureless and bumpless by incorporating output tracking facilities.
6.03.20 The controller's gain shall automatically and accurately adapt to the number of
drive units in a given subsystem that are on auto mode to maintain constant loop
gain.
6.03.21 Excursion of a control signal beyond acceptable values shall cause the
corresponding control loop to trip automatically to manual mode with the control
output latching-in at the last value, until manipulated in manual mode.
6.03.22 Controllers shall not act without validation check of the field inputs.
6.03.23 Artificial intelligent adaptive control for critical loop such as SH & RH temperature
control loop shall be provided. Bidder shall furnish write up on the same.
6.03.24 Controller assignment /partitioning shall be judiciously decided considering
minimum manageable outage of the equipment /system in case of failure of a

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functional group. Bidder shall refer to the following functional grouping as a
guideline for Bidding purpose. Bidder shall furnish his partitioning scheme based
without changing the intent of grouping delineated below, for Owners approval
during detailed engineering.
SGSYSTEM

i) MFT 1, 2, 3 Channel : 3 nos.
ii) Purge & other common logic : 1pair (or part of above)
iii) Pair Elevations Oil & Coal, mills, feeders : 1+X number mills.
iv) SADC & APRDS : 2 pair
v) SBC & Drain : 1pair
vi) HP Bypass : 1pair

TGSYSTEM

i) Turbine Protection/ EHG control Channel-1 : 1 no.
ii) Turbine Protection/ EHG control Channel-2 : 1 no.
iii) Automatic Turbine Tester : 1 pair
iv) Generator/ exciter Protection CH-1 : 1 no.
v) Generator/exciter Protection CH-2 : 1 no.
vi) Generator auxiliary monitoring : 1 pair
vii) ATRS Turbine & Drain / LP Bypass : 1 pair
viii) ATRS oil & vacuum system : 1 pair
ix) TD BFP-1 : 1 pair
x) TD BFP-2 : 1 pair

STATIONC&I/BOPSYSTEM

Function Group (FG)-1 : 1 Pair

i) ID Fan-A
ii) FD Fan-A
iii) Furnace Draft Control

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v) SCAPH-A control
vi) Primary APH A
vii) PA Fan A
viii) DMCW A (Boiler)

FG-2 : 1 Pair

i) ID Fan-B

ii) FD Fan-B

iii) Air Flow Control

iv) Fuel Flow Control

vi) SCAPH-B control

vii) Primary APH B

viii) PA Fan B

ix) DMCW B (Boiler)

FG-3 : 1 Pair

i) Co ordinated Master Control
ii) PA Header Pressure Control
iii) Boiler Circulating Pump C
iv) Boiler Tube Metal Temperature
v) Economizer valves
vi) Separator Level Control
vii) MDBFP & Scoop Control
viii) Boiler vents & drains
ix) MS Stop Valves & Drains
x) Bypass warm up
xi) SH & RH Temperature Control
xii) SH & RH Drain & Vents

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xii) SH & RH Shutoff Valves

FG-4 : 1 Pair

i) Drain & Flash tanks
ii) Condensate Storage tank
iii) Condensate & GSC valves
iv) CEP-A & recirculation
vi) DMCW A (Turbine)
vii) MS / CRH/ HRH line drain
viii) Generator auxiliaries

FG-5 : 1 Pair

i) Deaerator with drain & vent
ii) HP Heaters
iii) Hotwell
iv) PRDS
v) CEP-B & recirculation
vii) DMCW B (Turbine)
viii) Aux. steam & extraction steam valves

FG-6 : 1 Pair

i) LP Heaters
ii) Dozing OLCS/CLCS
iii) MD BFP OLCS
iv) CEP C & Recirculation
vi) DMCW-C (Turbine)
vi) DM Service water & Misc. water
vii) TG area metal temperature


FG-7 : 1 Pair

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ACW pump and Condensate transfer system



FG-8&9 : 2 Pairs

Electrical HT/LT control & Metering

RemoteProcessingUnit(RPU)

FGRPU04 : 1 Pair
FOPH (common system)


6.03.25 System operation and control philosophy:

The control system shall be based on integrated functional group level control
philosophy. It shall be possible to perform the Automatic Unit Start-up and Shut-
down and respond to the changes in load by issuing minimum number of
commands from the Operator Work Station (OWS), though ideally possible if not
from single command at unit level it shall be from functional group level.

The unit level start-up sequence shall execute following ten major functional group
in steps, till synchronization and loading.

i. Plant start-up preparation
ii. Circulating water system
iii. Drains and Vents
iv. Boiler Draft system
v. Fuel system
vi. Boiler light-up
vii. Condensate & Evacuation system
viii. Feed water system
ix. Pressure and temperature control
x. Turbine start-up synchronization and initial loading


The unit shut-down sequence shall execute 7 major functional groups in steps.

i. Load down programme
ii. Turbine shutdown, Turbine Ramp down/ Shut down.
iii. Boiler shutdown / HP LP by pass system and drains & Drains & Vents control
iv. Boiler draft system shutdown
v. Feed water system shutdown
vi. Condensate & Evacuation system shutdown
vii. Circulating water system shutdown.


Each of above groups shall receive commands from functional group level
sequence and execute the start-up / shutdown programme in a predetermined

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order according to logic criteria in conjunction with BMS, ATRS, Open loop control
system (OLCS) & Close loop Control System (CLCS) of DDCMIS.

The groups shall also be operated manually from OWS (Operator work station)
after fulfilling the permissive conditions.

The first step of plant start-up preparation ensures all permissive are met to enable
unit to start. Successive steps shall be switched on only if the commands in the
previous step have been executed and confirmed by relevant feedback.
Appropriate bypass conditions shall be envisaged to take care of varying process
conditions.

Pre-start manual operations / line-up activities for plant start-up preparation shall
be carried out by operator. Before initiating the start-up sequence, as a measure of
abundance precaution the operator is advised to check and ensure pre-start
conditions.

In addition to automatic start-up / shutdown control, some sub-loop controls (SLC)
such as SCAPH control, drains and vents controls shall be realized with facility for
manual operation. These SLC can be operated independently through OWS.
These SLC will be automatically get reset when APS is started or can also be reset
through OWS.

Unfulfilled criteria display shall be provided for the entire start-up / shutdown
sequence to enable the operator to follow the progress of the sequence.

Interface to Boiler and Turbine integral control:
Functional group shall interacts with Boiler Management system during Boiler start-
up. It closely associates with Boiler Master and sets Main steam pressure target
and Rate value as per Boiler / Turbine start-up curves depending upon starting
mode (Hot start mode / cold start mode).

Creation recording and maintenance of Data acquisition system:
On issue of commands from TG functional group , the ATRS( Automatic Turbine
Run up system) in conjunction with Turbine governing system and turbine stress
evaluator accomplishes the various functions like turbine drains control, warm-up
control, steam and metal temperature matching, acceleration and Auto
synchronization and initial block loading.

6.03.26 Data Acquisition Sub-System, meant for acquiring the plant data for monitoring
purpose shall be implemented in multi-loop processor and shall acquire, process
and store the following types of plant data for display, performance calculation and
monitoring purpose. Data acquisition subsystem shall also include various
gateways capable of acquiring, processing and storing data from third party system
data highways.

6.03.27 The Real time Data Highway shall be a high speed communication network with
communication speed of 100 Mbps or more. This data highway shall link all the
stations /control nodes in the system in the ring topology so that highest network
availability is achieved. Data highway and links shall be redundant and fault
tolerant.

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6.03.28 Information /MIS network shall be of speed of 100 Mbps or more.

6.03.29 The DDCMIS networks shall be secured from the interconnected private and public
networks by incorporating suitable proven hardware and software firewalling and
antivirus protection.

6.03.30 Each network element shall have two independent couplers linking the dual data
highways. All messages received through dual highways shall be validated
individually for error and between themselves for fidelity of both the highways.
Faulty data highway shall be automatically isolated, without any loss of data but
with appropriate alarm. Erroneous messages shall be flagged and rejected.


6.03.31 Communication protocol shall conform to OPC compliant ISO 7-layer protocol in
master less, token ring or token bus (as per IEEE-802.4) or any standard proven &
accepted protocol in deterministic mode. In case of Ethernet network, it shall be
fast and full duplex type. Extensive error checking (CRC-16/12) or error correcting
codes shall be used in these levels to improve the reliability of communication.

6.04.00 HISTORICALSTORAGEUNIT(HSU)

6.04.01 HSU shall augment the global memory in the system and will archive data and
parameters for logs and historical records including trends, alarms and events.
These will be used for analysis, data presentation and performance calculation.
The historical storage unit shall be a stand-alone unit on the data highway
performing as network server.
6.04.02 Redundancy for Historical Storage Unit shall be provided either by dual disc
imaging or by dual servers so that failure shall not lead to complete loss of
historical data.
6.04.03 While the historical data storage shall be performed in HSU, some invariant
application programs / data like mimic diagram (the static part) may be resident in
HSU provided the display latency requirements can be fulfilled. The latency
between addressing a display to its appearance on screen shall be less than 1
seconds. The latency for historical trend display shall be less than 10 seconds. If
these latency criteria cannot be met, the data shall be globally distributed for faster
response.
6.04.04 Data to be stored in HSU shall include alarm, event list, periodic plant data,
selected logs/reports such as start up, trip analysis logs, shift logs, daily logs etc,.
Bidder shall indicate the frequency of data storing and time for retrieval.
6.04.05 Data can be stored in the HSU on exception basis whenever any deviation from
last stored data takes place. Module shall also have the capability of storing both
snapshots and average value.
6.04.06 System shall be provided with DVD writers for long term data archiving.

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6.04.07 Sizing of the HSU shall be carried out in such a way that at least 25% over the
installed configured tags can be added in future.
6.04.08 Historical storage should permit trending of analogue inputs with time scale
selectable as 1Sec, 10 Sec, 30 Sec, 1 min, 4 min., 20 min., 2 hours, 8 hours & 24
hours. Vertical scale (parameter range) shall be freely programmable. It shall be
possible to map the real time and historical trend on the same trend group display.
History data storage shall be for minimum 30 days and after expiry, data shall be
automatically/manually transferred to the external storage device such as DVD
writer. Data related to plant life shall be stored in the HSU for the complete plant
life.

Logs:(provisional)

i) Hourly Log - 60 plant data and 10 computed data

ii) Shift Review Log - 40 plant data and 15 computed data

iii) Daily Log - 20 plant data and 15 computed data

iv) Monthly Log - 20 plant data and 15 computed data

v) Yearly Log - 20 plant data and 15 computed data

vi) Alarm Log - 1000 plant data and 15 computed data

vii) S.O.E. Log - 500 Inputs

viii) Boiler Start-up Log
(event based /manual)
- 30 Analog, 80 Digital and 10 computed
data (1 minute interval for 3 hours /
boiler start-up)

ix) Turbine Start-up Log
(event based /manual)
- 30 Analog, 80 Digital and 10 computed
data (10 seconds interval for 1 hour /
Turbine Start-up)

x) Synchronization /
Loading Log
(event based /manual)
- 40 Analog, 80 Digital and 15 computed
data (10 seconds interval for 1 hour
/synchronization)

xi) Generator Trip Log
(event based)
- 40 Analog, 80 Digital and 15 computed
data (15 second interval for 15 Minutes
/ GCB trip or GLR operated)
xii) Turbine Trip Log
(event based)
- 40 Analog, 80 Digital and 15 computed
data (15 seconds interval, for 30
Minutes / Turbine trip)

xiii) Boiler Trip Log
(event based)
- 40 Analog, 80 Digital and 15 computed
data (15 second interval for 15 Minutes
/Boiler trip)


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xiv) HP Bypass Log
(event based)
- 20 Analog, 15 Digital and 20 computed
data (15 seconds interval, for 30
Minutes /Bypass open)

xv) Pre-Trip & Post Trip Log - 1 second interval for 10 seconds

xvi) Maintenance logs - For the equipment with motor rating 30
KW and above.

Apart from the above logs, not less than ten other logs are anticipated. Such logs
shall comprise of computed data typically like running hours of drive, fuel
consumption, water consumption, auxiliary power consumption, maximum metal
temperature (about 40 points), calculated values like efficiency & heat rate etc.
Logs shall be configurable and reconfigurable at site.

6.04.09 There shall be various other logs corresponding to equipment / drive start-up & trip.
Menu of the logs shall be chosen to record parameters related to the drive under
consideration.

a) Instantaneous Logs (Manual Actuated)

i) Boiler : 100 Analog, 10 Computed

ii) Turbine : 50 Analog, 10 Computed

iii) Generator : 50 Analog, 10 Computed

iv) Auxiliaries : 25 Analog, 10 Computed

b) Trends : Analog input trends for at least 300 points with the data rate as
follows.

i) Pressure & Vacuum - Once every second

ii) Flow - Once every second

iii) Separator, Hotwell, HP Heater &
Deaerator Levels
- Once every 2 seconds
(other levels once every 5 seconds)

iv) SH & RH steam temperature - Once every 2 seconds

v) Other Temperature Once every 5 seconds

vi) SWAS parameters - Once every 2 minute

vii) Vibration - Once every 5 minute

viii) Electrical parameters - Once every second

6.05.00 ALARMDISPLAY

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At least 1000 alarm points with paging feature shall be provided. Keyboard shall
have the function keys such as alarm acknowledge, reset, paging, summary
display etc. Format of the alarm page display shall be finalized during detailed
engineering.

6.06.00 SEQUENCEOFEVENT(SOE)

SOE shall be an integral function DDCMIS with 1msec. time resolution. Number of
SOE points shall not be less than 500. SOE inputs shall be sourced directly from
the primary switches and primary relay / contactors for real time time-stamping
following tripping of major equipment, sub-systems and the plant as a whole. SOE
shall be available on demand at all the operator stations on the network with
printing on occurrence of any status change of contact. SOE report shall include a
list of major equipment trip in chronological order and also include the points which
initiated the SOE collection. Storage capacity for SOE in HSU shall not be less
than 3 months.

6.07.00 ONLINEPERFORMANCECALCULATIONS&PLANTOPTIMIZATION

6.07.01 Performance calculation

a) Performance calculation executed automatically by retrieving data from the
global plant data base or from the HSU and will perform plant efficiency, heat
rate and other calculations as per ASME Power Test Code and other
relevant standards.
b) The plant performance calculation package shall also embody programs and
routines to generate parameters to provide expert guidance to the plant
operator. Suitable prompts and guidance messages shall be generated to
guide the plant operator towards optimal plant performance.
c) Calculations shall use high level language. Calculations shall be made using
floating-point arithmetic. The equations shall be changeable on-line at the
job site. Calculation results shall automatically be quality coded according to
the quality of the inputs. The results of these calculations shall be available
through the database for appropriate logs and operator displays.

d) Required curve fitting shall be performed at polynomial exponent for
accuracy. Averages used in calculations and/or logging shall be true "load
weighted" averages (load weighted with the proper variable to give true
averages over the given time period). The ASME Steam Tables shall be
employed.

e) The plant performance computation are broadly subdivided into two classes
of calculations :

Class (I) - Equipment protection calculations (software generated alarms)

Class (II) - Plant and equipment efficiency and Heat rate calculations.


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i) ClassICalculations

Class-I calculations are made every scan cycle for the purpose of
detecting and alarming unit malfunctions. The following lists typical Class-
I calculations that shall be required.

Cold reheat steam approach to saturation temperature.
Superheat spray outlet approach to saturation temperature.
Turbine steam metal temperature differences
Turbine metal temperature rates of change
Excess air deviation from standard
Separator water saturation temperature rate of change.

ii) ClassIICalculations
Class-II Calculations shall be performed in the real time for displaying and
subsequent logging using data, which is accumulated over a period of
time. This time period shall be adjustable from 10 to 60 minutes. The
operator shall be able to manually input coal analysis data and other data
for Class-II Calculation.

Class-II calculations shall include the following :

Boiler efficiency (Input/Output & Heat loss)
Net Turbine heat rate
Gross Turbine heat rate
Net unit heat rate
Gross unit heat rate
H.P. turbine enthalpy drop /efficiency
I.P. turbine enthalpy drop /efficiency
L.P. turbine enthalpy drop /efficiency (using dry exhaust)
Feed water heater terminal temperature difference
Feed water heater drain cooler approach
Condenser performance
Economizer performance
Air heater performance

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Deaerator performance.
Deviation from expected value for each calculation

6.07.02 PlantPerformanceAnalysis,DiagnosticandDataOptimization(PADO)

a) PADO system has been envisaged for the plant to enhance operational
efficiency, carry out process and equipment diagnosis to ensure against
performance degradation and facilitate optimal controller tuning. The
advanced algorithms shall utilize fuzzy logic concept where fixed algorithms
do not apply.
b) The system shall combine the thermodynamic models of the plant
components with cost & revenue related parameters like electricity sale,
amortization, variable and fixed costs.
c) The thermo-economic optimization shall take account of important constraints
of operation and shall be able to update on current equipment performance
by adjusting model parameters from the database, adaptively. It shall predict
and optimize the optimal setting of controllable parameters based on
equipment performance. The system shall be enriched with the designed and
operational feedback data from manufacturer. It shall also include an off-line
manual (What-if) analysis tool that will enable the user to conduct model-
based analysis of plant operation.
d) To achieve the above objectives, PADO system shall comprise of various
modules and which shall not be limited to the followings :

i) Performance analysis and monitoring of systems and components
ii) System and performance diagnostic
iii) Boiler Performance Optimization package including optimized operation
of soot blower system
iv) Boiler stress analyzer and service life monitoring
v) System and performance optimization
vi) Regenerative /power cycle performance optimization
vii) Water chemistry management
viii) Emission analysis & monitoring
ix) Merit Order Rating System
x) Miscellaneous Calculations


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e) The calculations and analysis shall be based on process signals, equipment
status, equipment & system design data and manual input data. Required
software modules to achieve the above functions shall be furnished.

(i) Performance analysisandmonitoringofsystems&components

It shall conduct performance evaluation of Heat rate, Plant & Equipment
efficiency and Controllable losses in real time for the entire thermal
cycle and shall provide answers to "what if" queries for operator
interaction and guidance. Performance calculations shall be carried out
at specified intervals based on time-averaged data during steady state
operating conditions.

The module shall have the functions not limited to the following:

Turbine performance evaluation considering efficiency,
enthalpies, steam flow and gland leakage flow estimation.
Boiler performance evaluation considering efficiency, excess air
and cleanliness factors of super heater, evaporator, re-heater and
economizer.
Air pre heater performance involving efficiency and pressure
losses.
Condenser performance based on heat duty and heat transfer
coefficient and cleanliness factor.
Deaerator performance.
Performance of regenerative LP & HP heaters by computing
extraction flows, drain flows, terminal temperature difference and
drain cooling approach.
Gross Evaluation of entire thermal cycle covering gross plant heat
rate, net plant heat rate and computation of controllable losses.
What If" module shall assist the operator to review the impact of
incremental changes of the parameters on the performance.

(ii) SystemandperformanceDiagnostic

The purpose of System and Performance Diagnosis is to pinpoint root
causes of abnormalities in the process and guide the operating
personnel to attend the same and thus to avoid possible unit trip,
maintaining process parameters within the safe limits and thereby
enhancing the life of the equipment

Functions of this module shall not be limited to the following :


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Alerts to the operating personnel about malfunctioning of
equipment and process such as high low pressure, temperature,
level and vibration.
Detect degradation of the overall system performance and
individual equipment viz. Boiler, Turbine, Condenser, Feed water
and Regenerative heating system and suggest corrective action
Detect instrument degradation for on-line measurements during
steady-state operation of the plant.

The module shall be based on expert system which shall draw
inferences founded on the knowledge base, on-line measured data and
computed performance indices and shall generate recommendations to
guide the operator to take corrective action.

(iii) Boiler performance optimization including optimized operation of soot
blower system

Boiler Performance Optimization Module

The module shall predict the performance of boiler under actual
operating conditions, which may be different from the design
conditions and shall enable operating personnel to improve boiler
performance and optimize fuel consumption. The module shall take
into consideration the performance of furnace, super heater,
economizer, evaporator, air heater, and mills.

Soot Blowing Optimization Module

This module shall compute the level of slag / soot formation in each
heat transfer section of the boiler and convey to the operator the
section-wise requirement of soot blowing. The module shall facilitate
assessment of extent of fouling of heat recovery surfaces for the
steam generator and recommends selective soot blowing for the
fouled sections.

(iv) Boilerstressanalyzerandservicelifemonitoring

This module shall monitor thermal stresses and assesses residual life in
thick-walled components like Separator, final super heater outlet header
and reheater outlet header. The software shall compute the thermal
stress values and estimate the expended life due to low cycle fatigue
and creep. During the boiler start-up and shut-down, the software shall
guide the operator to modulate the actions so that the rate of heating or
cooling of metal is controlled within the limits.

(v) Systemandperformanceoptimization

This module shall have the following objectives:

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Heat rate improvement
Reduced auxiliary power consumption
Reduction CO and NOx levels
Cleaner furnace walls and convective pass

The module shall assist in operating the plant under optimum conditions
at current load and to obtain the best efficiency. This will be based on
individual subsystem optimization in the framework of Rankine cycle
optimization. The package shall cover optimization of Turbine,
Condenser, Feed water heaters and Deaerator as well as Boiler
Performance Optimization System (BPOS). The system shall
recommend optimum controllable parameter settings viz. set point for
excess air, Main steam temperature etc. to optimize the process under
operating regimes between 50% and 100% load conditions. This
module in conjunction with BPOS enables plant optimization as a
whole.

(vi) Regenerativecycleperformanceoptimization

This module shall consist of the following :

The deviation of performance of the turbine cycle
Actual efficiency of individual stages of turbine.
Evaluation of LPH and HPH performance by comparing current
values to the reference values.
Heater level evaluation.

(vii) Waterchemistrymanagement

It shall monitor the quality of water and steam, at certain predetermined
points in the flow path and advise the operator on the actions that have
to be taken to sustain their permissible limits. This expert system based
diagnosis shall enable the operator to do appropriate chemical dosing,
oxygenated water treatment and carry out further investigations as
advised by the module.

Software based interactive program shall monitor various parameters of
water and steam and warn the operator about any distinct aberration
and shall advise on precautionary as well as corrective actions to be
taken.

The system shall comprise of "decision trees" and "fault trees" for each
parameter to diagnose variations in controlled parameters, in order to

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find the root cause and advise corrective actions. Program module shall
ensure proper dosing chemicals to maintain its chemical balance.

Module shall also assist to minimize make-up water consumption,
decrease in consumption of dosing chemicals, prevention of carry-over
of impurities into the turbine, decline in degradation of turbine
components, lessening of boiler tube scale formation and reduction in
energy consumption.

(viii) Emissionanalysis&monitoring

Emission analysis and monitoring module monitors and recommends
the optimal setting of damper positions to minimize the NO
X
level at the
stack, while maintaining the CO value and un-burnt carbon below the
desired permissible limits. Alarms will be annunciated whenever values
of NO
X
and CO exceed the specified limit values.

(ix) MeritOrderRatingSystem

Merit Order Rating System facilitates scheduling of optimal load of the
individual units of a power plant with minimum total generation cost.

The salient features of this module shall be as follows:

Optimum load scheduling to meet the load demand with minimum
generation cost.
Consideration of unit constraints
Cost function generated automatically from the generation cost
entered by the operator at three different loads.

(x) MiscellaneousCalculations

Number of Start & Stop of various drives
Running hour computation of various rotating machines.
Cumulative time the TG runs below/above alarm level of steam
temperature.
Cumulative time of a bearing running above alarm level of vibration.
Number of hot, warm and cold starts of the turbine performed
Plant life calculation
Revenue calculation
Frequency excursion time beyond limit.

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Plant availability and load factor calculation
Unit availability calculation
Operating cost and cost of generation calculation
Variable alarm limit calculation

Counter shall have provisions for manual resetting.

f) PADO system shall comprise of Servers, Workstations and Printer. The
servers shall acquire live data for calculations through suitable interface from
DDCMIS. At least three workstations, one for each unit, shall be connected to
these servers in a LAN network to display various PADO display screens.
System shall be OPC compliant. Typical PADO system hardware
configuration is shown in drawing K8A06-DWG-I-0010.

g) The system shall be proven as laid down in the specification.

6.08.00 HUMANMACHINEINTERFACE(HMI)ANDPERIPHERALS

6.08.01 Operators window to the process shall be various workstations with color LCD
monitors, Keyboard, mouse, dot matrix & colour laserjet printers, large video
screen monitors, multimedia beeper/buzzer etc.

6.08.02 Operators terminals shall permit the operation and monitoring of the unit under
normal condition and in all emergencies.

6.08.03 Each terminal shall be independent with its hardware including adequate local
memory for resident database. The resident data shall be continuously updated at
all terminals. Operator station shall have auto reboot feature.

6.08.04 HMIs shall be built for high performance with non-proprietary open system
configuration.

6.08.05 Operation shall be menu driven in latest windows environment. Display screens
shall be user friendly and no special software knowledge shall be required to
operate the system

Each HMI shall be adequate with all operators function such as quick access to
plant & process. Complete operation of the unit shall be possible from any operator
station. Multiple active windows, not less than 4 (four) nos., simultaneously, shall
be displayed on the HMI screen.

Display navigation shall be with least number of keystrokes or steps.

Functional requirements shall not be limited to the followings:

a) Issuance of control command like start/stop, set point adjustment,
auto/manual, increase / decrease etc.

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b) Plant graphic, overview display, area display, loop/drive display, control
related displays, other standard displays for monitoring, trending of
parameters.
c) Display & print of SOE/Trend/Graphic / System Diagnostic.
d) Alarm display & acknowledgement.
e) Print of screen, logs, operator message, etc.
f) Last command call.
g) Copy & paste.
h) Display of sequential / logic and tag with facility of forcing through suitable
password
i) Multiple pop up faceplate for drive control & point detail.

6.08.06 LargeVideoScreen

a) Bidder shall supply four (04) numbers of 67 inch or similar Large Video
Screen (LVS) display unit in 1 (one) row and 4 (four) column placed upright in
front of the operator with seamless integration with DDCMIS for monitoring
salient plant parameters, plant status, alarms, graphics etc.. The LVS
controller/s shall interface with DDCMIS for monitoring and display of real time
information.

b) The system shall display complete and partial overview of the plant, alarms in
the form of normal window appearance, important parameters of the plant and
the electrical system in the form of SLD etc.

c) Large Video Screen system shall be based on Digital Light processing
Technology or LCD. Controller shall operate in Windows NT environment or
higher. The software shall have capability to display multiple windows on the
screen. The system shall have facility to zoom on any part of the display.

d) The display program shall be such that the entire viewing area of the screens
are utilized and sides are not left blank. It shall be possible to call up a
screensaver display to show Owners company logo when the screens are not
in active operation.

6.09.00 ENGINEERING/CONFIGURATIONCUMDIAGNOSTICSTATION

6.09.01 It shall perform programming /configuration of complete system and HMI and
perform system diagnostic. System shall be adequately protected with software &
hardware locks etc., against any inadvertent and un-authorized access. Two nos.
of such stations shall be provided per unit.


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6.09.02 It shall be capable of storing data, loading, editing, testing, tuning, and monitoring
all the controllers. System shall be complete with monitor, keyboard, mouse and
colour LaserJet printer.

6.09.03 Programming technique shall not require any special knowledge on programming
and shall be easy to learn.

6.09.04 It shall archive all the addresses, setting parameters, screen statistics etc. for
future downloading in case any controller/operators terminal is replaced by a new
one or any data is lost or during rebooting of the system. The unit shall remain on-
line and serve as the administrator for the entire network, if required.

6.09.05 Bidder shall also provide minimum of two laptop computers with latest hardware
configuration and loaded with suitable operating and application program as a
backup programming and configuration station.

6.09.06 Each station shall execute the functions not limited to the followings:
a) System configuration
b) Data Base configuration
c) Graphics display generation and modification
d) OLCS/CLCS Control algorithm generation and modification
e) Report/Log configuration and modification
f) System access configuration
g) Downloading of program
h) High level programming language.

6.09.07 Each station shall be equipped with a DVD writer for archiving of the configuration.

6.09.08 The station shall be capable of generating all real time graphics, trends, plots etc,
necessary for optimum tuning of the controllers. This feature shall also be
duplicated in the operators station.

6.09.09 Open loop configuration shall be programmed in the Engineering Terminal in
simple ladder or in symbolic form.

6.09.10 Engineering /configuration stations also serve as Diagnostic unit to perform system
maintenance functions. This station shall serve as an aid to the maintenance
engineer for system diagnostics and fault location.


6.09.11 The system maintenance function shall not be limited to the followings:

a) Station status overview.

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b) System alarm message display.
c) Individual station status display.
d) Data base equalization.
e) Date and time setting.
f) Network status display

6.10.00 PLANTOPERATIONALDISPLAYS

6.10.01 The data presented in plant operational and monitoring displays shall be easily
understandable, comprehensive and presented in soothing colors so that
prolonged exposure to the screens do not lead to eye fatigue. Screens shall be
glare free.

6.10.02 Operational displays shall have distinct header and footer areas allocated to
display specific plant parameters, irrespective of the display called up on screen.
The header shall typically display in alphanumeric form, the generated MW, MVAR,
Frequency, turbine speed, generation demand, time, date etc. The footer may
display unacknowledged alarms of the entire unit so that all the plant operators are
aware of anomalies within the unit even if the event does not relate to their primary
assigned area of responsibility.

6.10.03 There shall be provision for customizing at least 50 additional screens by Owner in
future for specific operational convenience. There shall be provision for multiple
windows & pop ups. Typical pop-up windows shall tentatively be as follows (I)
display of some latest alarms, (ii) window to display messages for illegal key
operation, (iii) HELP window to display user defined help messages. Over and
above, all screens shall display a fixed header carrying salient information about
the plant like MW generation, frequency, time & date, power factor, load demand
etc, and an alarm footer to represent any major alarm in the plant

6.10.04 Control room furniture shall be of ergonomic design so that no strain is caused to
the operators & engineers. The illumination in the control room & engineers room
shall typically be about 600 lux and in the control equipment room about 1000 lux.

6.10.05 ControlOverviewScreen

a) Overview display screen - Display of status & values of all analog control loops
in one screen in color graphic form. The display shall present all the controlled
parameters in color bar graph representing the value on a 100% span scale
and/or the control deviation in a center-zero scale. The color of the scale shall
indicate the alarm / healthy / control status of the variables. The point address
code shall associate with each bar to enable the operator to select parameter
display by direct addressing.
b) Group display screen - group of related control loops, and or measurement
parameters and / or related drives displayed in one screen. The display can
be in controller face plate form showing the controlled variable, A/M status of

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the controller; engineering value of measurement parameter on a 100 % span
bar graph form; status of binary drives etc. Typically, a group screen shall be
composed of 8 parameters or loops.
c) Individualdisplayscreen - displaying one control loop, tag number of associated
elements, schematic representation of the loop, trend of the controlled
variable/s, alarm history, sectional plant sub-system display related to the
loop, various settings including tuning parameters, alarm / trip settings etc.,
representing a complete data bank for the loop. Similarly, for binary drives, the
representation shall include a sectional mimic for the drive area, control
ladder, status of the drive, tag number, different delay and other settings etc.;
all in one screen.
d) Plant sub system display - mimic diagrams meant for direct operation by
vectoring cursor on the screen .The display shall have a fixed part
representing the P&I diagram and a dynamic part refreshing parameter values
and status of drives. There will be an overall plant sub-system display from
which operator shall zoom into the specific area of interest. Additionally,
operator shall be able to directly address specific displays by their area
identification code. The displays shall be animated to represent changes.
Extensive color coding shall be utilized to represent status of drives, alarm
conditions, open / close status etc., together with the color coding for various
lines carrying different fluids.
e) Flow chart / logic / ladder screens - meant for sequence logic operations to
represent the progress of the sequence, time-out conditions, forced or bypass
conditions, hang-ups and prompts.
f) Operator's guidance message screen - displaying process flags and prompts to
the operator to assist in selecting course of action in the events of start-up and
emergencies.
g) Trend Display - System shall be capable to display at least eight (8) numbers
of real time trends with eight (8) different colors per page with selectable time
frame to implement variation in resolution. The facility to magnify trend on
Y-axis by 1, 2, 5 & 10 and scrolling within the range 100% shall be provided.
Also the facility to magnify X-axis by 1, 2, 4 or 8 and scrolling shall be
provided.
h) Screen Partitioning - The system shall be capable to implement screen
partitioning to facilitate easy comparison of trending between two or more
assigned screens and also display of X-T and X-Y trends on the same page
and other combinations as per the requirement of operating personnel.
i) Multiwindows - The system shall have facility of multi- windows & pop ups to
allow related information to be displayed in different windows. The types of
windows shall be tentatively as follows :-
i) Alarm window for display of all acknowledged & unacknowledged alarms
in different colours. Alarm priority shall also be distinguished by colour.

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ii) System help window for display of messages corresponding to illegal key
operations.
iii) Help windows for user defined help messages.
iv) Trend window display with trend recording graphs.
v) Faceplate window to display Instrument faceplate of called tag number.
vi) Process window for display of process data.
vii) MIMIC, System Diagnostic, Engineering menus etc.

6.11.00 SECURITY

Multiple security levels with hard and soft key lock shall be provided with two (2) or
more at operator levels and one (1) at Engineer level to make it possible to restrict
access to critical parameters and minimize the possibility of operator errors.

6.12.00 PLANTOPERATION
The modes of operation from the operators terminal shall be as follows.
6.12.01 Manipulation of set point shall be permissible from the Operator's terminal in
incremental mode.
6.12.02 It shall be permissible to transfer a loop from "auto" mode to "manual' mode or vice
versa from operator's terminal. All such transfers shall be bumpless and
procedureless. During transition from "auto" mode to "manual", the output to the
final element shall be maintained until manipulated from the operator's terminal.
Similarly, during transfer from "manual" mode to "auto"; when effected from the
operator's terminal, the auto output shall take-off from the last value and shall
regulate the final element in a predetermined and adjustable ramp to final
computed value as per the control loop algorithm. This will necessitate continuous
auto-tracking between "auto" mode and "manual" mode outputs.
6.12.03 Binary control shall be implemented in hierarchical structure. It is proposed that the
following points of control shall be available.

a) Local Control Station (LCS) for trial start & emergency stop operation
b) Operator's terminal for normal operation
c) Control Panel (wherever applicable)

6.12.04 Switchgear and MCC shall be equipped with TEST, TRIAL and NORMAL
operation.
6.12.05 In "TEST" mode, operation shall be performed from the MCC / Switchgear only to
verify the integrity of electrical system. No actual operation of the main equipment
will take place.

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6.12.06 In "TRIAL" mode (for local maintenance), control can be affected from local control
station. To start a drive from LCS, apart from the electrical protections critical
process/drive related safety protections, if any, shall have to be ensured for safety
during trial operation.
6.12.07 In "NORMAL" mode drives are operable from remote (CCR). During operation from
remote all process, sequence and basic safety-related permissive and interlocks
shall be in place.
6.12.08 The STOP functions at all points shall be active at all time, irrespective of the
selection.
6.12.09 The drives, which are part of a sequence, shall be operable in sequence mode
from Operator's terminal. In sequence mode, a single command shall initiate
predetermined sequence of operation. Following information, as a minimum, shall
be available at the monitors.
a) All permissive
b) Start & Stop sequence
c) Start sequence complete
d) Stop sequence complete
e) Sequence fail
f) Stepwise sequential progress of operation indication with permissive for each
step to enable the operator that for particular step all permissive are met and
the step is executed.
g) Disturbance indication
h) Sequential operation indication on monitor in the form of ladder logic diagram
i) Override of hold-up sequence as per operators discretion.

6.13.00 FUNCTIONALDESCRIPTIONOFAUTOCONTROLLOOPS

6.13.01 GeneralRequirements

The open- and closed loop controls shall interact closely between themselves to
guide the plant operation towards optimal functioning. In general, frequent
operators intervention shall be avoided and the control intelligence built into the
system shall be adequate to perform routine functions. However, each Control
Loop shall have an auto / manual selector station and setter to allow operators
intervention during abnormal plant conditions.

Coordinated master Control shall receive and react to the signal from Owners load
dispatch center. The signal of unit status shall be answered back. The details of

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interface shall be decided during detailed engineering stage between Owner and
Contractor.

Plant demand load set point or Target Megawatts shall be set and adjusted in
remote automatic mode from load dispatch center according to grid control
demand with frequency variation control signal as feed forward or in manual mode
by the plant operator (during start up or emergencies) adjustment from the unit
load setter at unit control room. Load setting shall be auctioned for plant
contingencies like run backs in case of a major auxiliary outage. Control system
shall be designed to respond quickly for load demand and load changing rates and
it shall also meet large output variations against ramp-type load variation demands
as permitted by the response time and thermal stress of major equipment.

There shall be provision for Block increase and Block decrease as directional
blocks in case either some equipment are in limiting conditions or in case reduction
of load may lead to instability of the system.

Start-up pattern i.e whether the plant condition is cold, warm, hot or very hot or the
shut-down pattern i.e whether it is turbine cooling shut-down or normal shut-down
shall be selectable under guidance from physical parameters like metal
temperature.

Fuel flow control, air flow control, feed water flow control, EH governor control, etc.
shall be properly tuned and controlled to meet constant or ramp load variation. The
equipment shall be capable of coordinating the action of the controls in the boiler /
turbine / generator unit so as to produce safe and stable operation automatically
and maintain generator output, steam temperature, steam pressure, excess air
(oxygen) at their desired set values. The control shall produce stable combustion,
low values of unburned carbon in fly ash, and no black smoke under the steady
load and load-variation.

Automatic control and adjustment of load shall be carried out in between load
range 35% and 100% rated load in Automatic Plant Control mode.

Automatic runback operation in coordination with coal mill & burner control system
and various others control systems shall be performed in the event of failure of
major auxiliary equipments and others which require sudden reduction in output.

Starting up and preferential shutting down of coal mills under varying load
conditions shall be under automatic sequence control based on set priorities and
shall not require any operator assistance other than notifying the operator about
the actions being initiated. Complete automatic control shall be possible with
automatic plant control system in coordination with mill-burner control system.

The necessary locking devices at the air failure and power failure shall be provided
for all regulating duty pneumatic control to maintain plant load under failure
conditions with notification to plant operator.

Automatic operation at any mode of the plant including the unit starting up and
shutdown, the unit runback, the load rejection and so on shall be achieved by
means of the automatic switching of the control mode (auto / manual auto-tracking

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mode at each control loop, the boiler follow mode, the turbine follow mode, the unit
coordinated mode, etc.), the automatic changing of the various set points, the
various function generators and so on. Transfer between one mode to another
mode shall be bumpless without disturbing the process.

Control stations on operators station shall be grouped logically in functional blocks
for compactness and ease of operation.

Protective interlocking circuits shall be provided for safety against erroneous
manipulations.

Protective circuits against control system internal faults such as modules and
operating ends shall be furnished.

The basic function of the Automatic Plant Control shall be, but not limited to the
followings :

Bidder shall furnish the scheme of control loops & write up on his system for
approval of Owner.

6.13.02 UnitMasterorCoordinatedMode

Plant demand load set point or Target Megawatts signal shall manage the load
and throttle pressure by sending parallel demand signals to the boiler master and
turbine-generator master controllers. Demand signal shall be modified for
frequency error and shall be limited by auction when the unit capability is reduced
for any reason such as the loss of an auxiliary like one draft fan, a boiler feed
pump, and so on. Load control station shall have maximum and minimum
adjustable load limits set administratively as well as limit of load changing rate
guided by thermal stress limits of major equipment.

During normal operation, coordinated control shall be exercised aggregating boiler
and turbine inputs by target load and load change rate commands (central load
dispatching commands, or manual setting), with various corrections made to
enable Boiler control and Turbine control.

Directional blocking of the unit demand (increase/decrease of load) will be provided
based on the extreme operating status of equipment and applicable process
conditions.

The run up and run down actions shall be provided for reducing the deviations
when the respective final control elements are in the extreme positions and are
unable to correct the error. Run up and run down actions shall override the unit
demand signal till the adverse conditions are cleared.

The system shall provide automatic run-back facility based on the load demand
signal on loss of critical auxiliary equipment. The limits and rate of run back shall
be pre-determined according to the individual capacity of each auxiliary equipment
and shall be supervised by Turbine Stress Evaluator. The control system shall
have capability for implementation of the functional requirement with true
characteristics of equipment.

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In case of full load rejection, the turbine-generator shall remain in service,
supplying the station service power (house load operation). The boiler steaming
capacity shall be quickly reduced to correspond to the capacity of HP and LP
bypass systems plus the house load and operation is to be carried on at sliding
pressure mode.

The unit load demand shall also be corrected by deviation in system frequency.
This correction provides a change in unit load demand equivalent to the expected
change in megawatt output due to any deviation in system frequency.

The boiler master controller demand shall be used as a feed forward signal to the
feedwater master controlling the feedwater flow and the firing rate master
controlling the fuel and air flow to adjust to unit energy demand.

Feed forward signals will be calibrated initially to produce a specific relationship
between turbine steam flow and boiler firing rate on one hand and unit output on
the other hand. However the relationship may change due to changes in system
parameters such as cycle efficiency, heating value of coal, feed water temperature
etc. When such a change occurs, it will be reflected in a steady state error in
megawatt output. A controller shall be provided to automatically recalibrate the
feed forward signals by reducing the steady state error to zero.

In addition to providing operator with the ability to set and observe unit load, the
Unit Coordinated Control master shall allow the operator to select either constant
or variable (sliding) pressure operation. The sliding pressure mode shall be
adopted during start-up and reduced load operations principally to avoid erosion of
throttling valves. Sliding pressure operation shall allow the turbine valves to be
maintained at optimum position as the unit shall be ramped to load. Sliding
pressure operation shall be permitted with Unit Coordinated Control master in auto
mode.

When Unit Coordinated Control master shall be in Boiler Follow Mode-2 or Turbine
Follow Mode-2, described below, Unit Coordinated Control mode shall be selected.
Two sub-modes shall be permitted as follows:

In Coordinated Boiler Follow Mode boiler master and turbine master shall be in
auto mode. Boiler master shall control the boiler demand to control throttle
pressure. The turbine master shall modulate the EH governor using UCC demand
as feed forward trimmed by turbine MW controller. The UCC demand shall track
the MW to eliminate MW error.

In Coordinated Turbine Follow Mode boiler master and turbine master shall be in
auto mode. The turbine control shall use feed forward based on UCC demand
trimmed by turbine throttle pressure controller. The turbine master shall modulate
the EH governor to control throttle pressure. Boiler master shall control the fuel
firing rate based on feed forward from UCC demand trimmed with the boiler MW
controller. The UCC demand shall track the MW to eliminate MW error.

As per the provision of Indian Electricity Grid code 2010, the thermal generating
stations of capacities 200 MW and above should operate in restricted Governor

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Mode Operation (RGMO) to maintain grid discipline, Grid Stability and Grid
security. This requirement needs to be complied with while designing the governor
control.

6.13.03 BoilerFollowMode

6.13.04 In the boiler follow mode, boiler throttle pressure master controller trims the
megawatt load setting to maintain the throttle pressure at set value. When, for
example, the throttle pressure is below the set point, the fuel, feedwater and air are
increased by ramping up the boiler master demand and vise versa. Two variants of
Boiler Follow Mode are foreseen.

In Boiler Follow Mode-1 the boiler master shall be on automatic mode and turbine
master shall be left on manual mode. The boiler master controls the throttle
pressure and the turbine governor control is adjusted by the operator. The UCC
(Unit Coordinated Control) demand tracks the governing valve position in a
characterized algorithm linking it to MW.

In Boiler Follow Mode-2 the UCC demand shall be extended to both boiler master
and turbine master, both and the UCC in automatic mode. Target load shall be set
at UCC. Boiler master shall control the throttle pressure based on UCC signal with
throttle pressure controller trim. Turbine master shall only receive the UCC signal
without MW trim.

If runback occurs in this mode, the system shall automatically transfer to turbine
following mode when turbine governor is on automatic.


6.13.05 TurbineFollowMode

6.13.06 Turbine master shall be in charge of throttling the EH Governor valves. In the
turbine follow mode the UCC demand shall be trimmed by turbine throttle pressure
to create turbine master demand. Two variants of Turbine Follow Mode are
foreseen.

In Turbine Follow Mode-1 the turbine master shall be on automatic mode and
boiler master shall be left on manual mode. The turbine master controls the throttle
pressure and the operator shall control the load manually by changing the Boiler
master demand. The UCC shall track the Boiler master for smooth transfer of
Boiler master to auto.

In Turbine Follow Mode-2, the UCC demand shall be extended to both boiler
master and turbine master, both and the UCC in automatic mode. Target load is
set by UCC. Turbine master shall control the throttle pressure based on UCC
signal with turbine throttle pressure controller trim.

In the turbine following mode the megawatt control shall be the responsibility of the
boiler and throttle pressure shall be controlled by the turbine control system. In this
mode the unit demand shall be subject to maximum and minimum limits, rate of
change, interlocks and run backs etc.


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When turbine following mode is in automatic, all runbacks, run-ups limits and rate of
change shall be automatic.

6.13.07 ManualMode&BaseMode

Manual mode shall be the lowest level mode in the hierarchy. In this mode the Boiler
Master Control including the air, fuel and feedwater loops and Turbine Master
Control are switched over to manual mode and the unit will be controlled manually.
Generation error and Frequency error will not affect the demand signal. As a variant,
in base mode, the Boiler Master and Turbine Master Control shall be in manual
mode. However, one sub-loop either air, fuel or feedwater as well as the firing rate
ratio will be on automatic mode. This shall help internal tracking of the UCC.

6.13.08 BoilerMasterControl

Boiler outlet temperature and pressure shall be maintained stable under all load
conditions. The pressure control shall be based on regulating the feed water flow,
while the superheat temperature shall be regulated by firing control, in the long term.
Feed water to firing rate ratio control shall maintain constant attemperation flow.
Cross-limiting of between the feedwater flow and the firing rate shall ensure that
the ratio between the two remain within permissible limits. While transient
conditions persist at load changing, the boiler master signal shall be transiently
modified in order to achieve over or under firing. Such the transient signal
modification shall be applied for the fuel flow control, the air flow control, the steam
temperature control and other necessary control loops in order to maintain the
various parameters safe and stable during any mode of the operation.

Boiler master shall develop the demand signals for feedwater flow and firing rate
(fuel flow) to the boiler. The demand for firing rate (fuel flow) shall be modified by
feed flow to firing rate ratio function.

The boiler master control station shall be designed to allow manual control of the
boiler input demand.

6.13.09 TurbineMasterControl

The MW demand signal from unit master shall compare to the actual MW signal and
the deviation signal shall be transmitted to EHG Load controller. This controller
produces the governor control valve position demand signal.

During the unit initial start-up the manual mode (the auto-tracking mode) shall be
applied followed by sliding pressure mode until the turbine valve transfer is
completed during which the turbine EHG speed controller shall control the turbine
speed, the initial block loading and the valve transfer. And then the turbine load
control shall be handed over to the unit master control and the turbine master shall
automatically set on auto mode.

Beyond the sliding pressure regime, the main steam pressure is maintained constant
and the machine load shall be controlled by throttling the turbine governor value.


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Under fixed pressure operation, the turbine governor control valve controls MW but
when the main steam pressure controller, overseeing the control finds pressure error
larger than the set limit, control mode of this valve shall be transferred to the main
steam pressure control to unload the machine as necessary for pressure recovery.
The main steam pressure control shall also be used when the boiler master is on
manual mode.

Turbine master control signal shall be transmitted to the digital electro-hydraulic (EH)
governor system.

6.13.10 FuelFlowControl

The fuel flow control shall regulate the supply of coal and oil (is load carrying gun is
employed) to the furnace to maintain optimum efficiency at any load condition.
During combustion of coal, some modulating influence shall be introduced to take
account of responses of mills and boilers, clogging of coal, and variations in coal
properties.

The feed water side of the boiler master cross-limiting circuit shall use two selectors
to compare the feedwater demand (Boiler Master) to total fuel flow to the boiler. If the
fuel flow increases, the ratio control shall increase the feed flow accordingly and
vise-versa.

Similarly, the firing rate side of the boiler master shall use two cross-limiting
selectors circuits to compare the fuel flow demand (Boiler Master) to total feedwater
flow. If the feed flow increases, the ratio control shall increase the fuel flow demand
accordingly and vise-versa

Since the ratio function is incorporated only in the firing rate side of the cross limiter,
correction shall be made in the selectors to account for the ratio to keep the
selectors in balance. A dead-band shall be introduced in all the cross limiters to allow
limited excursions during rapid load changes. The cross limiters shall be limited, in
turn by absolute limits to circumvent runaway condition of feedwater pumps.

A mill master, heavy oil control and light oil control stations shall permit manual
operation of the pulverized coal flow and fuel oil flow respectively.

For coal burning, the summation of total coal flow shall be compared with the fuel
flow demand signal, the error signal modulates the output of the coal feeders. The
feeder speed reset signal shall be derived from the differential pressure across the
mill.

Means of correcting control disturbance due to changes in the calorific value of the
fuel shall be provided.

The process of changing of operation from firing light fuel oil to firing heavy fuel oil
and from heavy fuel oil to exclusive firing of coal at the time of loading up the boiler
and the reverse from exclusive firing of coal to heavy fuel oil at the time of unloading
the boiler preparatory to shutting down, i.e. switching of fuels, shall be carried out

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automatically. However, the mill system start-up / shutdown group sequence control
shall be manually initiated.

The fuel mixing ratio set point station shall be used to obtain the desired proportion
of the fuels used i.e. oil / coal during mixed firing operation of the boiler based on
quantities and calorific values.

Comparison of the signal with total air flow and total fuel flow shall be continuously
carried out to prevent an unsafe (air deficient) condition from arising at any time.


6.13.11 AirFlowControl

In order to achieve safe and efficient combustion the correct fuel air ratio shall be
maintained at all times and an air rich mixture shall always be present when
increasing and decreasing load. Oxygen and BTU corrections shall be included in
the air side to ensure proper combustion, minimize heat losses and reduce carbon
oxide presence in flue gas stream.

The firing rate signal from the fuel master shall be high selected with fuel flow on the
airflow demand side and low selected with air flow on the fuel demand side.

The lead-lag selector mentioned above shall maintain the proper relationship
between fuel and air flow by correcting the firing rate signal on the air side only.

Excess Oxygen in the flue gas shall be measured at economizer outlet. This analysis
shall be used to form part of the automatic air fuel ratio control system. The
measured values shall be validated in a two-out-of-three algorithm before being
applied to the loop. The measures Oxygen shall be compared with a load dependent
set point in a PID controller. The auto/manual station shall permit the operator to
manually set the desired bias and corrections.

After the lead/lag auctioning, the air demand shall be trimmed for excess air and
BTU. BTU correction shall be performed by calculating the difference between input
energy (total fuel in) and energy output (total steam flow). This adjustment shall have
a long time constant to ignore mismatches during transients.

The corrected air demand shall (i) be compared with temperature compensated
airflow and the deviation shall be used to reposition the forced draught fan pitch
controls to satisfy the airflow requirements, (ii) correct the fuel flow demand by
adding correction factor to actual fuel flow calculation and (iii) shall incorporate a
minimum airflow limit, set normally at 25% to ensure safe boiler operation at low
loads.

The actual total air flow being the sum of primary air and the secondary air, at two
different temperatures, mass flow shall be computed by compensating for density by
measuring the flowing temperature. In case of failure of a temperature
measurement, the computation shall fall back upon boiler rated parameter with an
alarm flag.


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Directional blocking shall be applied to the air flow loop from the furnace pressure
control. If furnace pressure is already too positive, there shall be a raise inhibit on air
flow signifying that the load increase shall be blocked. Similarly, the reverse will
occur when the furnace pressure is already too low.

Directional blocking shall be extended to UCC if air flow is too much or too less
compared to the demand, FD vanes are driven to extreme. FD vane shall not be
permitted to be set on auto mode in case the furnace draft control is on auto mode.
Synchronizing circuit between the two fans shall be provided for equal or unequal
sharing (by biasing) with respect to vane position or motor current or air flow etc on
each side.

Bidder may offer fine tuning facility of excess air based on carbon monoxide in flue
gas.

6.13.12 FurnaceDraftControl

Furnace pressure control shall generally adjust the regulating inlet dampers of ID
fans and the fan speed to maintain constant negative pressure at the furnace
chamber. Speed adjustment will come into picture when the pressure excursion will
be beyond certain limit. Bidder can furnish any alternative scheme for his system
offered.

Average FD fan demand, through a characterizer, provide the feed forward signal for
the ID Fan inlet dampers. The PID controller shall compare and maintain the furnace
pressure at the desired set point. The non-linear gain of the controller shall be
desensitized near the set point to avoid minor oscillation.

It shall be possible for the entire operational process from starting of the draught
system at the time of starting a unit to stopping of the system during shutting down of
the unit to be automatically controlled in accordance with the pressure set for the
interior of the furnace.

A safety override feature shall act as a counter-measures against explosions and
implosions for safe operation of boilers. The override shall come into operation on
high pressure deviations to adjust the demand signal for the ID fans. The safety
circuit shall quickly bias the inlet dampers, based on air flow, when MFT occurs. The
override shall withdraw itself when the furnace pressure comes within its Norman
excursions. The safety system will requisition MFT when predefined limits of
pressure are exceeded.

In the event of any limitation occurring in the draught plant capability, the draught
plant shall continue to operate under automatic control at or close to the new
operational limit, and the unit generation shall be automatically ramped down to
match the group or subgroup constraint in an orderly manner.

The control system and means of measurement shall be designed to enable
accurate repeatable automatic control of combustion to be carried out over the load
range from 35% rated output to boiler MCR.


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VOL-II-E-SEC-VI - 106 DCPL-11Z02

Forward path steady state and dynamic compensators whose parameters are load
dependent and which account where necessary for the number of draught fans in
operation shall be incorporated in the furnace pressure modulating loop.

Directional blocking shall be extended to UCC if furnace draft is too much or too
less compared to the set value, ID dampers are driven to extreme.
Synchronizing circuit between the two fans shall be provided for equal or unequal
sharing (by biasing) with respect to damper position or motor current etc on each
side.

6.13.13 MillOutletTemperatureControl

Mill outlet temperature shall be maintained at set value by varying positions of hot air
damper and cold air damper.

6.13.14 DeaeratorandHotWellLevelControl

Deaerator level shall be maintained by regulating condensate flow control valve in
the main condensate line to deaerator. This will be 3 E control consisting of
Deaerator level, Feedwater flow including SH & RH attemperation flow and
condensate flow alongwith extraction steam flow to deaerator and HP heater drain
flow to deaerator. Hotwell level will be maintained by regulating the valves DM water
make up to hotwell and Dump to condensate tank.

6.13.15 SuperheaterSteamTemperatureControl

Superheater Steam Temperature Control shall be capable of dealing with sudden
load changes and other disturbances with a minimum variation in steam
temperature which will also mean a minimum variation in super-heater tube metal
temperature and thus the stress.

The system shall include those features necessary for safe operating practice and
shall provide stable control during transients conditions.

Such feature as anticipatory control based on state variables shall be applied to the
loop in for anticipatory and immediate action when the boiler load is varied.

The superheat control loop shall also include a technique for quick restoration of
temperature by boosting the spray flow when load changes have occurred.

The final boiler steam temperature shall be controlled by two independent
methods. First, since the boiler acts as a heat exchanger, the ratio between the
heat input (firing rate) and heat takeaway (feedwater flow) shall affect the final
temperature. Second, spray water introduced in the superheater section also
impacts the final steam temperature.

The overall temperature control scheme shall coordinates the two methods as
follows :


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01) The feed water / firing rate ratio stations shall control the long term final
temperature which in turn shall control inputs to the ratio function between
the boiler and firing rate masters.

02) The spray valves shall control the short term final temperature.


In this scenario the sprays shall always be available for transient (short term)
temperature control.

Under the correct feedwater / firing rate ratio, the interstage final temperatures
shall be controlled to setpoints derived from the boiler load index. The final (boiler
outlet) temperature shall be controlled to the boiler design temperature.

Boiler design temperatures shall be controlled using cascaded type control
schemes. The upstream controller PID shall control the temperature leaving a
superheater section (interstage or boiler outlet) by adjusting the setpoint of the
downstream controller PID. The downstream controller shall be controlling the
temperature immediately after the spray that is entering the superheater section.

The feedwater flow to the firing rate ratio shall also be controlled by a cascaded
control scheme.

The downstream controller shall control the waterwall temperature (separator
temperature) and shall quickly impact the firing rate (and waterwall temperature)
since it is adjusting the firing rate demand from the Boiler Master to the firing rate
master.

The upstream controller shall directly control the spray flow to the superheat
sections through the firing rate.

If the spray flow is found greater than setpoint at a given load and with a final
temperature at setpoint, the upstream controller shall reduce the setpoint for the
downstream controller (waterwall temperature). The resulting reduction in firing
rate in turn shall reduce the final temperature. The sprays shall adjust (reduce) to
bring the final temperature back to setpoint and in doing so, shall also bring the
spray flow to setpoint. This loop shall be slow acting and shall be meant to keep
the sprays in play so that they can active during boiler load changes.

The spray flow setpoint shall be derived from the boiler load index and calculated
to be a percentage of the current boiler load.

When the spray control shall be set in manual, the feedwater to firing rate ratio
shall be automatically transferred to directly control the final superheat temperature
through firing rate adjustments.

Since the downstream PID controller in this scheme is actually controlling the
waterwall temperature, protection can be added to this loop to keep the waterwall
temperature within limits.


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To improve the performance of the loop the temperature measuring wells shall be
designed for fast response

6.13.16 ReheatSteamtemperaturecontrol

Reheat Steam temperature control shall primarily be done by proportioning gas
dampers through parallel damper biasing system.

Reheat attemperator water shall only function as an emergency measure to bring
down hot reheat temperature. During normal operation there shall not be any reheat
spray flow.

6.13.17 LoadRunbackVariables

In case of major plant internal disturbance the unit shall carry on operation at a
reduced load level and the grid frequency control system shall be taken out of
service.

The load shall be reduced by the automatic run-back system which reduces or holds
the unit load according to the capacity of main auxiliary systems.

The failure of any of the following plant systems or plant variable are to be included
in the run-back system :

a) I. D. Fans
b) F.D. Fans
c) P.A. Fans
d) Air preheaters
e) Boiler circulation water pumps
f) Boiler Feed Water Pumps
g) H.P. Feed Heaters
h) L.P. Feed Heaters
i) Condensate extraction pumps
j) Coal Mills
k) CW Pumps
l) Load Shedding

6.13.18 IslandedOperation


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In the case of the load rejection due to the external disturbances, the unit shall
carry on operation at the minimum boiler load operating the turbine bypass system.

The load shall be reduced to the minimum boiler load by the automatic run-back
system. Items not limited to the following shall be taken into account to make sure
the safe and stable operation :

a) The quick opening of the HP and LP Turbine Bypass System.

b) Fuel fast cut back maintaining stable flames at the residual burners.

c) Sufficient spray water to the HP and LP bypass system shall be available.

6.13.19 Balanceofplantcontrols

Other balance of controls not limited to the following shall be provided :
a) HP Heater level control- normal & emergency drain
b) LP heaters level controls- normal & emergency drain
c) GSC level control
d) Deaerator pegging steam pressure control
e) Flush tank level control

6.14.00 ELECTRICALDISTRIBUTIONMANAGEMENTSYSTEM(EDMS)

6.14.01 The purpose of the EDMS is to provide Control and Monitoring of the unit and
Station in-plant Electrical Distribution System from the DDCMIS dedicated HMI
Station for Electrical System
6.14.02 Also the separate Energy management system is envisaged as detailed in
electrical section specification for the purpose of Energy accounting and Audit
(MEAA) as per latest CEA regulation. The Energy management system shall
collect electrical parameters data V, A, PF, MW, MWH, MVAR, F, harmonics from
all electrical meters in HT, LT switchgear and metering& relay panel. The energy
management system shall generate following reports.
Power generation report
Power consumption report
PLF report
Single line diagram
Breaker status
Load flow
Reactive power flow.


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[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-VI - 110 DCPL-11Z02

The functionality covered in Energy management system need not be duplicated in
DDCMIS based EDMS system. EDMS shall control and monitor the electrical
distribution system. The Energy management system shall have Modbus
connectivity with DDCMIS for exchange of data as required.

6.14.03 Control configuration for EDMS shall not be limited to the following :
a) Dual redundant multifunction controllers.
b) Two operator stations for each unit. Common system shall be executable from
common plant terminal.
c) DDCMIS Historian will be used for collection of events, analog values.

6.14.04 EDMS shall display the followings as a minimum:
a) Animated single line diagram of the electrical network
b) Alarm summary.
c) Display of analog & digital parameters.
d) Display of breaker status (local/Remote, Service/Test, Spring charge etc.)
e) Display of faceplate.
f) Real time and history trend of all analog and critical digital parameters.

6.14.05 The maximum time taken from issuing a circuit breaker close / open command at
the HMI keyboard to observe a change of status on the screen shall not be more
than 1.0 Second.

6.14.06 All binary and analog inputs shall be hardwired. Similarly, output from the system
connecting to different switchgear units shall also be hardwired. Non-critical
interlocks can be implemented in DDCMIS.

6.14.07 EDMS shall control the following functions as a minimum:

a) 11kV & 3.3 KV System

Incomers, bus tie, Bus coupler and Outgoing feeders except HT motor
feeders, which will be controlled through process partition of DDCMIS. The
detailed requirement for the alarms and indications refer electrical
specification VOL-II-F1/SEC-V

b) 415V System

i) For PCC / PMCC


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Incomers & Bus couplers of all PCC / Switchgear, Outgoing (ACB operated)
feeders to MCC except motor feeders which will be controlled through process
partition of DDCMIS.

ii) For 415V MCC

All ACB operated incomers and Bus couplers. The Alarms and
Indications shall be as detailed in Electrical Specification VOL-II-F1/SEC-
VII

c) The other Electrical System requirements please refer relevant section of
Electrical Specification.

6.14.08 Control system shall control all the Bus Tie, Transformer Feeders, Incomers and
Outgoing feeders stationed at operation building. Upstream breakers for the BOP
and common system like Ash Handling Plant, Desalination & DM Plant, CW &
ACW system, Coal handling plant located at power House building shall also be
controlled from the control system.


6.14.09 Electrical Network stationed at outside power house such as network of Ash
Handling Plant, CW & ACW system, Desalination & Demineralisation Plant, Coal
handling plant shall be controlled from their respective PLC System HMI station in
addition to local switch board operation. Any interlocking between the switchgear
unit at powerhouse and common system switchgears located outside powerhouse
shall also be hardwired.

6.14.10 Engineer shall be able to carryout engineering & diagnostics functions from
DDCMIS engineering station.

6.14.11 Status / Monitoring for the power distribution network

Refer electrical Specification VOL-II-F1 & F2.

6.14.12 Interposing relay shall be provided in the respective switchgear unit.

6.14.13 For details on control functions to be performed in EDMS refer Volume II-F
(Electrical).

6.15.00 PLCGATEWAY

6.15.01 FunctionalDescription

Interface between Offsite PLC networks and DDCMIS system for remote
information and monitoring of offsite plants data, shall be carried out by a dual hot
redundant PLC gateway. Proposed Gateway shall operate as a node pair, one in
operating and the other shall be in hot standby, serving as its redundant partner,
with an exact up-to-date copy of the database and ready to take over full operation
should the operating member of the pair fails or be taken out-of-service. The
gateway shall provide the data conversion, buffering, and sequencing to provide an

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efficient interchange of information between the DDCMIS network and the
programmable controllers.

6.15.02 Communication link in between the DDCMIS and the Programmable logic
controllers shall be dual and optical fiber based.

6.15.03 Data communication shall be in MODBUS or OPC as per requirement.

6.15.04 20 % tag handling capacity over the configured tags shall be kept as spare for
future expansion.

6.15.05 Nodes shall be time synchronized with GPS master clock.


7.00.00 DDCMISHARDWARE&SOFTWARESPECIFICATION

7.00.01 This section generally describes the hardware and the software features of the
Distributed Digital Control System. Modules shall be environmentally ruggedized
and tropicalized.

7.00.02 Bidder shall furnish information of the system not be limited to the following:
a) System architecture and BOM to establish completeness of supply.
b) Write up and catalogues
c) Expected duty cycle of each controller with the proposed assignments.
d) Capacity (baud rate) of each level of highway and expected data traffic at
each level under normal and worst-case situations.
e) Failure analysis of the complete system detailing the MTBF and MTTR. The
analysis shall be projected to system availability computation.
f) Spare capacity in respect of controller, IO modules, network, operator station.
g) Number of displays and logs offered.
h) Response time from initiation to execution of a command.
i) System auto start up and initialization time.
j) Operating limit of temperature, humidity, voltage, frequency of the
system/modules, susceptibility to contaminants in the ambient etc.
k) Hot repairing of modules

7.01.00 HARDWARESPECIFICATION

7.01.01 SystemCabinet


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General specification for panel and cabinets described elsewhere in this volume
shall apply.
a) The electronic modules located within Operators terminal shall be completely
enclosed type for protection from dust and / or mechanical damage.
b) Electronic cards and modules located in cubicles shall be neatly arranged in
sub-racks. Each racks shall have power supply modules catering to the cards
mounted in the sub-racks.
c) The modules shall be arranged logically and sequentially in the sub-racks.
Modules associated with a closed loop / open loop controller viz. input cards,
output cards etc. shall be housed together with the corresponding controller
in the same cabinet.
d) If, after housing a controller with associated cards in a sub rack 25 % or less
card slots are left vacant, the same shall not be used to accommodate any
card related to any other system. Adjacent slots to dissipative cards shall be
left vacant for proper cooling air circulation within the panels. For future
modification 10% spare module slots shall be provided to accommodate 10%
spare modules specified elsewhere in this volume.
e) If cards related to a particular controller spill over beyond one sub rack at
least 4 cards slots shall be kept vacant before cards related to other systems
can be placed in the sub rack. Vacant slots shall be covered with blank
plates.
f) Cards, in a sub rack, shall be uniformly grouped, type-wise and functionality
wise.

7.01.02 Termination&RelayCabinet
a) Incoming cables originating from beyond the control room and control
equipment room area shall be routed through the termination cabinets (TC)
located in control equipment room except for the cases like special cables,
network /hiway cables, thermocouple cables where standard termination
concepts are not applicable.
b) Termination cabinets shall be free standing, closed type, bottom entry, front
and rear accessible cabinets with terminal blocks arranged in vertical rows
on side walls and partition walls. Panels shall be provided with internal
illumination operated through door switch. Adequate area shall be provided
for glanding field cables.
c) In no case the number of terminal blocks accommodated in each section
shall exceed 1000. Terminal blocks shall preferably be arranged in four
vertical rows in two sidewalls with two sets of cable troughs (one for
incoming and one for outgoing) arranged on two sides of the terminal block.
At least 20% terminal blocks shall be left as spare. This shall be in addition
to the terminal blocks for 20% wired channel.

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d) Troughs shall be slotted PVC type. The gland plate shall be removable and
shall be in sections. Signals of different voltage levels shall be clearly
segregated by providing separate rows to each type of signal and by using
terminal blocks of different color for each type of signal and by providing
barrier strips between them.
e) Terminal assignment in the termination cabinet will be such that cables
originating from a field junction box shall be terminated in one termination
cabinet only. This will facilitate use of multi-core cable for field wiring. For
each incoming cable an additional terminal block shall be provided adjacent
to signal wire termination point for termination and continuation of cable
screen.
f) Relay used for interfacing with other system shall be modular, plug in type
and provided with snap on transparent cover. Rating shall be of 24V DC and
shall have at least 2 changeover contacts. All contacts of the relay shall be
terminated in terminal blocks. Each relay shall be provided with Coil on
indication LED and coil protection diode. At least 10% of installed capacity
shall be kept as spares.
Panel specification is described elsewhere in this volume.

7.01.03 PrintedCircuitCards

a) Printed Circuit cards shall be suitable for operation at 50 C (maximum) and
95% RH (non-condensing) ambient condition.
b) Card failure status shall be indicated in the module front panel.
c) Cards/module shall be polarized to eliminate possibility of wrong insertion.
d) Similar and interchangeable cards may be marked similarly.
e) Modules shall be replacable from front and hot replacable.
f) On-card volatile memory shall be battery backed for at least 90 days.
g) All Printed Circuit card connectors shall be gold plated.

7.01.04 GeneralInput/OutputInterfaceForDDCMIS

All cards shall be in standard 19" sub rack format with the following features.

a) Modules shall be available to accept all requied signal levels and all module
should reject the common mode voltages that might appear between sensor
ground and A-D converter ground.

b) Manual adjustment or calibrations should be minimized by automatic
calibration, automatic zeroing and automatic ranging.

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c) Modules shall be designed in a manner, to prevent damage or maloperation if
installed in wrong cage slot.
d) Fuses shall be accessible for inspection and replacement from front without
removing the module from service..
e) Isolation of 1500 V AC in between inputs and outputs.

7.01.05 ProcessInterfaceModulesofDDCMIS(Analog/BinaryModules)

a) The process interface section of DDCMIS shall comprise of various signal
interface modules. I/O processing shall be totally independent of control
processing so that IO scan rates are independent of controller loading.
Interface modules shall be intelligent and shall form common IO bus
connected to the controller/s they are catering to. Generally the following
types of modules shall be included:

i) High level analog input modules
ii) Low level analog input modules
iii) Binary input modules (Fast & Slow scan)
iv) Pulse input modules
v) Smart transmitter interface modules.
vi) Modbus & other serial modules
vii) Analog output modules
viii) Binary output modules

b) Function performed by the input & output modules shall not be limited to the
following:

i) Digital outputs shall be short circuit proof and overcurrent protected
ii) Analog modules shall scan and acquire data with time stamping.
iii) Data validation check and quality tagging.
iv) Generation of interrupts and error code
v) Data processing like linearization, A/D conversion, multiplexing, noise
filtration, Engineering Unit conversion, limit value detection etc.
vi) Extensive self check & diagnostics with reporting at MMI. Diagnostic,
communication and status lamps at module front.
vii) Automatic start up.

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viii) Automatic calibration of analog input modules during start up and
periodic to compensate temperature effect.
ix) Calibration of analog output modules during start up.
x) Contact interrogation and transmitter power supply shall generally be
24V DC unless the system design calls for other voltage level like 48V
DC.

c) Spare requirement

Bidder shall provide at least 20% or minimum two numbers, whichever is
higher, spare channels as hot on rail spares in each configured IO modules.
In addition to this 10% or minimum one number, whichever is higher, extra
assigned complete spare IO modules mounted on rails in sub racks as hot
on rail spare for each category of installed IO modules shall also be
provided. Spare modules shall be distributed over each controller group.
Spare channel and modules shall be fully wired upto termination cabinets.

7.01.06 Controller

01. Type : Microprocessor based, multi-loop and
multi-function

02. Number of loops/Controller : 40

03. Word length : 32 bits

04. Register add cycle time : 1 microsecond

05. Instruction cycle time : 75 microseconds (maximum)

06. I/O address capability : 256 points (minimum)

07. Memory : RAM 256 MB (Battery backup) or better

08. Redundancy Supported : Yes

09. Switch over time : 5 milli sec.

10. Power supply : 24 V D.C /5V DC as required

11. Mounting : Sub-rack

12. Configuration : From hand-held station through front plug
and from Engineering Terminal.

13. Diagnostics : Invalid command checking, (Automatic
periodic illegal address detection, routine
check and memory parity check, watch
dog report to engineering terminal) time -

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out checking, processor status display
LED, processor fault.

14. Indication : Processor status and fault display

15. Features : i) Power fail hold
ii) Automatic restoration on power


7.01.07 Operators&EngineeringStation

a) OperatorsStation /EngineeringStation(PCBased)

01. Processor : 2
nd
Generation Intel( R) Core i5-2400
Processor (3.1GHz, 3MB Cache) / Latest /
Equivalent.
02. Architecture : Genuine Windows@7 64 bit / Latest /
Equivalent.
03. RAM : 6GB DDR3 SDRAM at 1333MHz 2
DIMMS.
04. Hard drive : 1000GB SATA Hard Drive (7200RPM)
05. Video Card : 2GB
05. Optical Drive : BluRay Combo SATA & DVD - R/W.

06. Graphics : Integrated based on Intel Chipset /
Equivalent.

07. Type : DDCMIS work station

08. Audio card : Integrated 5.1 high definition audio
(Standard) up to AX920 Creative Sound
Blaster / Equivalent.
19. Ethernet : Integrated 10/100/1000 with RJ45 port
with ASF, WOL & PXE / Latest.
10. Ports : a) Internal I/O
PClex16 Full Height Card, (3) PClex1,
(4) Internal USB 2.0

b). Front Port
(2) USB2.0, 8:1 Media Card Reader,

c) Rear Ports

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(6) USB 2.0, (1) VGA, (1) HDMI,
standard audio jacks for 5.1 Audio
Support, (1)10/100/1000

11. Slim tower : Height 37.79cm (14.8)
Width 10.6cm (4.2)
Depth 43.31 (17.01)
Weight Starting at 7.3kg (16.1lb)

12. Thermal Design : Minimum 3 fans. ATX chassis with tool
less opening features.

13. Power Supply : Minimum 230 watts with PFC

Pre installed OEMs management agent with the following features

14. Manageability : Asset tag, DIMM Serial Presence detect,
Serial number, Model and Manufacturer
for System Monitor and HDD, ROM and
system board revision levels.

15. Security : Removable media boot control, Serial,
parallel and USB interface control, power-
on password, setup password, and
Memory change alert (through BIOS, in
windows environment & on management
consoles). Internal smart cover lock &
sensor for securing internal components.
Kensington slot on chassis for physically
securing the chassis

16. Compliance : For OEM ISO 900:200, 14001
For Desktop OS certification (WLP 2.0
from Microsoft website), DMI 2.0
certification (From DMTF website),
EMI/FCC compliance, Energy star
compliance & UL compliance

17. OS Certification : MS Window 7 or higher.

18.. Onsite Warranty : 3 year comprehensive on site, backed
by manufacturer support, with OEM
certified spare parts.

19. Software Required : Antivirus & Fire Wall
Norton / McAfee / Trend Micro corporate
Edition for 50 users

MATLAB, AUTO CAD, ORACLE, Photo
shop (all latest with teir individual licence
and products)

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20. Software updates : Shall be given for not less than 3 years, at
no extra cost from the owner.

Note: The system should have been field proven on similar application

b) Monitor

01. Type : TFT LCD colour monitor with touch screen
facility

02. Screen diagonal : 24 flat

03. Display : Super Video Graphic Array

04. Resolution : 1600 X 1200 or better

05. Degree of protection : IP-30

06.. Brightness : 300cd/m
2.


07.. Contrast : 800:1

06. External Controls : Brightness, contrast, Horizontal / Vertical
amplification & shift

07. Power supply : 240 V, 50 Hz, 1 phase

08. Ambient temperature : 0-50
O
C

09. Humidity : 95% non-condensing.

10. Version : To suit industrial application.

c) KeyBoard

01. Type : Flat spill proof membrane type or Positive
depression type.

02. Different keys : a) Soft and user defined function keys for
software/ programming including text
correction, scan rate alteration,
zooming/ flashing color selection etc.

b) Panel select keys for alarm summary,
control loop display, overview, trend,
graphic, operator guide message etc.

c) Standard Alphanumeric keys

d) Alarm acknowledge keys

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e) Cursor keys

f) Mode/loop status switching keys

g) Setting change keys

h) Print-out command keys

i) Other keys as required to operate the
system

03. Key lock : Lockable type push button mounted on
keyboard

04. Life Expectancy : 50 million cycles per key

05. Version : To suit industrial application

d) LaserPrinter

01. Type : Electro-photographic laser, tabletop

02. Printer Memory : 256 MB (min.)

03. Speed : Monochrome 24 ppm - A4
Color 6 ppm - A4

04. Resolution : 1200 x 1200 DPI in color

05. No. of color (Basic) : 4 (four) minimum

06. Duty cycle : Monochrome 75000 pages / month

07. Power supply : 240 V, 50 Hz, 1 phase

08. Ambient temperature : 0-50 O C

09. Humidity : 95% non-condensing.

10. Size of paper : Letter, A4, Legal, Ledger, A3

11. Print media : Plain paper, transparencies, thick stock,
glossy stock, envelopes

12. Accessories : i) Adapters
ii) Connector Cable
iii) Multiplexer switch (4 point)


7.01.08 StackableManagedSwitch

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DDCMIS data highway shall be of high speed Ethernet and full duplex
configuration. Network shall be built on the Stackable Managed Ethernet switches
for better control of data traffic & performance and future expansion. Switch
configuration shall be redundant with seamless changeover without any upset in
the process or equipment. Failure reporting shall be available at HMI. MTBF of the
switch shall be more than 20 Years. Configuration shall be automatic.

7.01.09 Furniture

Bidder shall include a complete set of furniture for the Control Room and computer
Room of ergonomic design from reputed manufacturer especially designed for
computer peripherals. The set of furniture shall include but not be limited to control
desk, chair, printer table, computer tables etc, all necessary furniture for Computer
Room peripherals, cabinets for storage of manuals / booklets/recorder charts,
storage racks for special tools/ diskettes and Shift Charge Engineers
desk/chair/side rack etc.

7.02.00 SOFTWARESPECIFICATION

7.02.01 General

The system shall utilize a readily upgradeable, public domain software platform
proven for real-time operation environment at the control and monitoring level
overlaid with a relational database program. The desirable features are
enumerated below.

a) The operating system shall be suitable for real-time operation both at process
as well as HMI end.
b) The software system shall be fully modular.
c) The software shall meet the following general requirements.
i) Simple, easy-to-learn language for editing and on-line operation.
ii) Wide range of peripheral support.
iii) Effective task scheduling and support of multiple priority structure
including event based interrupt etc.
iv) Effective debugging.
v) Provision for on-line editing and program development without
interrupting on-line functions.
vi) Self-diagnostic routines.
vii) Efficient memory management and effective utilization of system time.
viii) Quick start-up and loading.

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ix) Support of multiprogramming and multi-user operation.

7.02.02 MemoryManagement/OperatingSystem
a) The main memory capacity shall be adequate to minimize swapping.
b) Individual task shall reside in partitions, which can be split into sub-partition
for parallel task handling.
c) The operating system shall automatically perform housekeeping functions
including file management.
d) Task swapping shall be dynamic.
e) Programs called frequently or requiring rapid access shall remain as resident
in main memory.
f) Individual program partitions shall be suitably linked.

7.02.03 DeviceSupport

The operating system shall support the following devices.
a) Floppy /CD R/RW /DVD R/RW /Pen drives.
b) Magnetic tape (if necessary).
c) Monitors.
d) Printer, key board ,mouse/trackball.
e) Random Access Memories.
f) Communication interface (10/100 Base-T Ethernet , TCP/IP etc.)
g) Controller and other 32 bit systems
h) DVD Writer etc.

7.02.04 I/OManagement

The I/O Management system shall have the following features.
a) Device independent address processing.
b) Peripheral diagnostic.
c) Retransmission on request.
d) Exclusive, shared and priority mode of device assignment.
e) Flagging of device failure, etc.

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7.02.05 ProgramDevelopmentandSystemGeneration

The operator shall have the flexibility to customize or develop program to suit the
system requirement.

a) The system generation shall be on-line without interruption to the program
under processing.
b) It shall be possible to introduce new programs dynamically.
c) The program development system may include its own assembler, editor,
loader etc.
d) The program development process shall be conversational and shall reject
faulty or erroneous entry with proper flagging.
e) New programs shall be automatically integrated into the system by interfacing
with existing programs.

7.02.06 PowerFailureRestart
a) I/O transfer stoppage shall not be abrupt.
b) Provision shall be there for manual restart and auto-restart on resumption of
power supply.
c) In case of power failure interrupt the boxing-up sub-routine shall be
automatically initiated.
d) In case of power failure, all data including register content, volatile memory
content etc. shall be transferred to the bulk memory.
e) The program status shall be latched.
f) On resumption of supply. registers shall be loaded and programs shall start
from the status where they were latched earlier.

7.02.07 CheckRoutines&SystemFailure

On-line diagnostic routine shall be run continuously or periodically, as applicable.
Detected failures shall be displayed in monitor & printer. The following checks shall
be performed.

a) Peripheral failure.
b) Memory Failure/ Error.
c) Parity Error, Interrupt Error.
d) Program Hang-up.

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e) Power Supply Failure.
f) Module Failure.
g) Interface Failure.
h) SC/OC failure
i) Controller Failure
j) Highway failure and communication failure etc.
k) Failure shall lead to graceful degradation of the system.

7.02.08 DatabaseandDatabaseManagement

Data shall be keyboard addressable. It shall be safe-guarded against unwanted
and unauthorized manipulation of data.

The database management system shall have the following salient features.

a) Open to integrate third party software program, Modular expandability,
dynamic partitioning.
b) Sequential and random access to data and files.
c) It shall be possible to update, display, dump (selectively), create, search data
by simple keyboard entries.
d) The editing language shall be simple and easy-to-learn type, requiring no
detailed programming.
e) Easy to install through windows procedure.


7.02.09 UtilityPrograms

The utility program shall constitute a modular system. The priority status of lengthy
routines shall be as low as to be interrupted from operators terminal. Individual
functions in the routine shall be amendable. Provision shall be there to initiate utility
program from user programs. Broadly, the system shall perform the following
functions by utility requests.

a) Selective dumping.
b) Dump memory (file to file or file to peripheral)
c) Execute a program selectively.
d) Tracing and break-pointing errors.

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e) List debug commands and error messages.
f) Change debug input devices.
g) Operation on octal or hexadecimal numbers.
h) Memory search by interactive editor.
i) Reschedule job priorities, etc.

7.02.10 ProgrammingLanguage

The programming languages shall support Relational Data Base Management in a
global and truly distributed Client-Server environment and shall have the following
minimum features.

a) Modern high-level block structures type.
b) Powerful, compact syntax.
c) Logical organization that facilitates documentation, modification and
maintenance of programs.
d) Early detection of errors at compile and run time.
e) Fast debugging.
f) Improved program reliability.
g) Clearly defined data structure complemented by flexible user- declared data
types.
h) Fast execution.

7.02.11 EditingFunctions

a) The following editing functions shall be performed on the variable via on-line
database editor. The editing of an access to the database shall be by simple
English like easy-to-learn language.

b) For analog inputs the variables shall have different scan rate, linearization
options, software filtering option etc. and can be assigned externally via the
keyboard.

i) Assigning scan frequencies.
ii) Continuous scan and store in working/main memory and display or
print-out on demand. Changing the scanning rate for trend display.
iii) Continuous scan, store and printout of values at a specified interval as
routine.

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iv) Execute immediate scan for a specified interval with or without display
and/or print-out.
v) Assign abbreviated engineering unit in display and print-out along with
absolute value.
vi) Assign Hi and Lo alarm limits.
vii) Assign Hi and Lo transducer range limits.
viii) Points to be deleted from and restored to scan status.
ix) Check whether the variable is within a specified limit and at a slow
scan rate and immediate restoration of storage status at a higher scan
rate in case of anomaly.
x) Specify individual coded sub-routines, which shall be executed when
any alarm or return-to-normal message occurs.
xi) Define time averaging of analog inputs.
xii) Assign significant change/increment alarm limits.
xiii) Assign alarm dead bands.
xiv) Assign rate of change alarm limits and dead-bands.
xv) Provision to specify software filtering constant individually.
xvi) Linearization routines by polynomial approximation with specified or
adaptive coefficients up to 5th order.
xvii) Assign an alphanumeric point value to each analog input and each
calculated point.
xviii) Rounding-off facility when fed to MONITOR, graphic or digital display
units.
xix) Serial tabulations on demand in time sequence with HH :MM :SS tag.
xx) Storage of maximum and minimum value amongst specified values or
within a specified interval of time.


8.00.00 COMPUTERISEDMAINTENANCEANDINVENTORYMANAGEMENTSYSTEM

8.00.01 A proven and fully computerized web server based system shall be provided for
computerized Maintenance & Inventory Management of various equipment of the
plant. The system shall be proven for industrial application and shall be organized
in a local & remote area network. The software license shall be provided for at
least fifty (50) clients. System shall comprise of modules like Work order, PTW,
Preventive maintenance, Purchase, Inventory, Equipments condition monitoring &

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maintenance, Maintenance schedule preparation, Report generation as a
minimum. Functions of the CMIMS shall not be limited to the following :

a) Co-ordination between maintenance personnel of all disciplines.
b) Co-ordination between warehouse and Maintenance Departments.
c) Inventory Control of main warehouse and departmental stores.
d) Tracking of the status like purchase requisition, purchase order etc.
e) Create Preventive Maintenance schedule and records, generate work order,
resource plan and compliance assurance features.
f) Equipment database.
g) Store information of each equipment and generate reports related to
schedules of maintenance and replacement of parts, labour, maintenance
cost incurred.
h) Update on line stock position of spares.
i) Separate alarm reporting on exhausted stock (Minimum Ordering Level) and
create work order.
j) Failure and defect analysis of various equipments, codification of different
types of troubles and corresponding corrective measures by Maintenance
Department. Codification of a type of trouble which may not have occurred or
conceived earlier.
k) Prioritization of preventive maintenance related to specific equipment and its
sub-system.
l) Build hierarchies of work orders for inspection.

8.00.02 System software for this package shall be Web based & HTML compatible.

8.00.03 Server configuration & database building & editing tool consisting of latest
configuration PC with 24 LCD monitor loaded with latest windows software shall
be furnished.

8.00.04 Bidder shall be responsible for software development, co ordination and complete
implementation including data base generation of equipments, preventive
maintenance scheduling, alarm set for equipment condition monitoring, store
inventory, etc.of the above package.

8.00.05 System database shall be based on latest version of relational database program.

8.00.06 Bidder shall provide one (1) set of database backup management and disaster
recovery software & hardware tool for taking backup to facilitate fastest & simple
restoration of a downed server.

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9.00.00 HARTTRANSMITTERS&MAINTENANCE

Configuration, Maintenance, Diagnostics & Record-Keeping facility for
Transmitters and Analysers.

The Contractor shall provide a dedicated and standalone PC based system with
suitable interface to DDCMIS system for each of the generating units for
centralized configuration, maintenance, diagnostics & record-keeping for all
electronic transmitter temperature transmitter and analyser.
For this system, suitable HART interface modules, power supply modules etc. shall
be provided, suitably mounted in cabinets for hooking up to the above dedicated
PC Station and Colour Ink-jet printer to be provided by the Contractor. Each of the
transmitters shall be terminated in marshalling/termination cabinets to be provided
by the Contractor. The signals from each of the transmitters shall be wired in
parallel to Control System and to HART interface modules. The Control System will
necessarily use 4-20 mA analog signals and superimposed digital signal shall be
used in HART interface modules.
The multiplexed signal from HART interface modules shall be hooked upto a PC
through associated communication modules, converters, etc. The communication
module shall provide data on RS-485 link at a minimum speed of 19.2 K baud. If
the Contractor's standard HART interface module has integral communication
module to provide RS-485 link, the same shall also be acceptable. In all HART
interface modules, provision for connecting at least 20% extra transmitters over
and above the engineered quantity shall be kept for future additions.
An RS-485 to RS-232 Converter shall be provided for interfacing HART data of
transmitters to PC station. This converter shall also provide proper isolation to
ensure data integrity.
Any failure/short/open-circuit and/or removal of any of the cards/devices/cables in
this centralized configuration, maintenance, diagnostics and record keeping
system, including failure/removal of HART interface modules, communication
modules, converter, etc. shall in no way affect the 4-20 mA analog signals being
used in Control System. Further, the HART interface modules shall be organized in
such a way that separate cards are used for signals going to different DDCMIS
cabinets.
Suitable redundant & diode auctioneered 24V DC power supply packs/modules
and redundant feeders shall be provided to feed all modules/devices. These power
supply packs/modules shall be fed from redundant feeders of Contractor's UPS
system or from 24V DC power supply system.
All modules/cards/power supplies shall be mounted in cabinets to be located in
Control Equipment Room. The PC station and printer shall be located in Control
Room.
All cables/links for connecting system described above shall be provided by the
Contractor on as required basis within quoted price.

The Bidder shall provide following functionalities as a minimum through software:

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a) Constant scanning to monitor faults or changes to instrument configuration.
b) Employer-defined and standard calibration and configuration procedures for
all transmitters.
c) Constant signal data collection facilities to maintain continuously updated
records.
d) Automatic tracking of configuration changes made in the field, such as may
be introduced by hand-held communicator. All configuration function
associated with hand-held communicators shall be available in the system.
e) Event and log reports on screen as well as on printer.

f) Any addition/deletion of transmitter will be reported on printer and logged in
hard disk.
The above system shall handle all the HART transmitters supplied by the
contractor for this project. Further the system shall be able to handle 25%
additional transmitters for future requirement. Necessary hardware for this
requirement is to be provided.
In case Contractor's DDCMIS has facility to acquire the HART signals through
analog input (4-20 mA) cards and carry out the communication to the above PC
based system through DDCMIS hardware (i.e. controllers, communication
controllers, HMIPIS etc.), the same is also acceptable for transmitters /
analysers being connected to Control System of Contractors DDCMIS only.
However, all functionalities as specified above shall be available in all cases. In
case the above mentioned facility is not available through DDCMIS hardware,
the HART system specified above shall be provided.

10.00.0 ROTATINGMACHINECONDITIONMONITORINGSYSTEM(RMCMS)

10.00.01 RMCMS shall acquire data related to the mechanical health of rotating equipment,
perform analysis in a proven software platform and display vibration and other
machine data for Turbine, Generator & exciter, BFP drive turbine & pump and all
HT motor & their driven equipment like Motor driven Boiler Feed pump & motor,
Condensate Extraction Pumps & motors, Circulating cooling water pumps for
condenser cooling & motors, Auxiliary cooling water Pumps & motors, ID fans &
motors, FD fans & motors, PA fans & motors, Coal Mills motors, Boiler circulation
water pumps & motors etc. during all regimes of operation. System shall be proven
and from latest product range of the manufacturer. System shall be supplied on
unit basis.

10.00.02 There shall be hardwired data exchange from RMCMS to DDCMIS for display,
trending, alarming and interlocking / protection. Similarly there shall also exchange
of process data from DDCMIS to RMCMS for analysis.

10.00.03 The system shall have the following sub systems :

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a) Field Transducers
b) Data acquisition, condition management and display
c) On line Machinery Protection and Monitoring
d) Automated machine diagnostic with decision support system.
e) Data Interface with DDCMIS

10.00.04 The system shall be complete with sensors, proximitors, monitors, relay modules,
networking hardware, machinery condition management server, dual redundant
power supplies, special cables etc.

10.00.05 In all cases vibration shall be measured in both X-Y direction alongwith key
pahasor for phase reference.

10.00.06 The system shall have feature to bypass a relay contact in the event of sensors/
proximitor failure.

10.00.07 In all cases power supply modules and incoming power feeders shall be dual.

10.00.08 Critical measurement shall be in 2 of 3, 2 of 2 or 1 of 2 as per the requirement.

10.00.09 Similarly, critical alarm & trip relay output shall be configured in 2 of 3, 2 of 2 or 1 of
2 voting logic as required for the machine criticality.

10.00.10 Contact of alarm & trip relays shall be hardwired to the respective control system.

10.00.11 Each trip channel shall be configured in separate modules to avoid single failure.

10.00.12 Analog output to DDCMIS shall be in the form of isolated 4-20 mA DC and contact
output shall be potential free.

10.00.13 Following type of transducers shall in generally be used:

a) ForSteamturbine:-

- ShaftVibration: Non contact proximity transducers with mounting position
reference to the bearing.
- Bearing pedestal Vibration: Seismic vibration transducers with mounting
position close to shaft vibration transducers.
- Keyphasor: Non-contact type proximity transducers for phase reference.
- Axial Thrust position: Non-contact type proximity transducers for observing
the axial position of rotor.

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- Differentialexpansion: Non-contact type proximity transducers to observe the
differential expansion of HP / IP / LP turbine.
- Eccentricity: Non-contact type proximity transducers to observe rotor bow.
- Speed & overspeed: Non-contact type proximity transducers to observe the
speed of the turbine.
- CaseExpansion: LVDT type transducers

b) ForGenerator&Exciter:-

- ShaftVibration: Non contact proximity transducers with mounting position
referenced to the bearing.

- Bearing pedestal Vibration: Seismic vibration transducers with mounting
position as close as shaft vibration transducers.

Bidder shall refer to section-IV of this volume for measurement detail of Turbine
& Generator and BFP steam turbine.

c) ForothermachineswithJournal&Thrustbearing :-

- BearingpedestalVibration: Seismic vibration transducers

- Key phasor & Speed: Non-contact type proximity transducers for once per
revolution phase reference measurement.

- Axial Thrust position: Non-contact type proximity transducers for observing
the axial position of rotor with respect to thrust bearing.

- Gearboxvibration: Seismic vibration transducers.

10.00.14 Transducer data Interface and the machine monitoring & protection subsystem
shall be a complete programmable on-line real time system. It shall be capable of
collecting data from machine transducers and from other external devices such as
DDCMIS and shall provide it to Condition Monitoring System to assess machine
condition.

a) The system shall comprise of standard instrument rack mounted in panel, dual
power supply modules, monitoring modules, relay modules, interface
modules, communication modules and required software.
b) Communication module shall be connected to external machine condition
monitoring server for configuration of monitor modules, relay modules and to
monitor static & dynamic data. Data shall be transferred with high integrity and
without any loss of data.
c) Hard key shall be provided to prevent unauthorized access to the system
configuration.

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d) Sequence of event and machine data shall be archived in the system for long
term storage.
e) Communication processor shall be capable of collecting data better than once
per second.
f) System shall be time synchronized with the GPS clock.
g) Removal & replacement of module shall be possible to carry out in system
power on condition.
h) It shall be possible to test all the monitors in the rack. The trip and alarm relay
shall be automatically bypassed during testing to prevent alarm and trip.
i) 24 LCD colour monitor & colour laser printer for system configuration,
graphic, local display of data, local alarm, system & machine diagnostic shall
provided.
j) All racks shall be connected in a network and some of the racks shall be
located in remote location such as at CW pump house area. Networking shall
be made through optic fiber cable & ethernet data highway cable.
k) Input supply to the system shall only be taken from the UPS system in the
nearby area.
l) System shall be capable of operating from 0 to 50 C and at 95% non-
condensing moisture.
m) Panels in off site area shall be fitted with local air conditioner if the area is not
air conditioned.
n) Sensors shall be dust proof & weather proof rated to IP-65 and suitable for
work in harsh environment.
o) Sensors, proximitors and monitors shall be fully compliant to API.

10.01.0 MONITORRACKS/CABINET

10.01.01 System mounting racks shall be furnished to house monitor modules, indicating/
display units, power supplies, test and calibration equipment. Grouping of modules
in racks shall be equipment wise. The mounting racks shall be fully factory wired.

10.01.02 The front of each mounting rack shall house a monitor test-switch, test condition
indicating lamp and power on indication lamp.

10.01.03 Each vibration monitor and mounting rack shall have nameplate engraved to
indicate the main equipment to which the module is catering and the bearing
details.

10.02.0 LOWNOISECABLEANDCABLECONDUIT


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10.02.01 Each transducer shall be furnished with flexible conduit and low noise cable.
conduit fittings shall be furnished for connection to transducer. The other end of the
flexible conduit will be connected to a suitable junction box.

10.02.02 Junction box shall be corrosion, dust & weather proof rated to IP 65.


10.03.0 MACHINECONDITIONMONITORINGSTATION:

10.03.01 System shall be knowledge based and guide the maintenance engineer & operator
to detect the fault and to take corrective action. System shall have the software for
Configuration, Data Acquisition, Open Database like SQL and display builder etc.

10.03.02 Machine Condition Monitoring server shall be capable of running several software
on single platform and interfacing with multiple machinery protection racks using
ethernet communication link. Configuration and downloading of programs for
different modules shall be executable from this server with at least two levels
password protection.

10.03.03 Data collected in the system will also be accessed by CMIMS resident on the plant
wide area network for condition based maintenance.

10.03.04 The system shall generate easy to use custom rules. The system shall be
developed with automated advisory capability of the system. Rule generator shall
reject any rule, which is not syntactically correct.

10.03.05 Bidder shall supply licensed version of all the applicable softwares in run & edit
mode for the system and for integration of his system with third party device.

10.03.06 Features provided in the system shall not be limited to the following:

a) Bar graph and point display indicating the setpoints.
b) Graphical plant and machine area presentation with location of sensors and
their current value.
c) Diagnostic of the system and machine data.
d) Current and history trend.
e) Spectral band and waveform plotting.
f) Multiple trends display including process value for data correlation.
g) Orbit and time base plotting.
h) Shaft centerline plot indicating position of a machine rotor.
i) Bode and polar plot.

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j) Automatic auditing of the equipment health upon alarm / periodical / on
request. The audit shall guide the operator regarding location of fault, type of
fault, severity of the fault, time of occurrence and recommended actions. As a
minimum, malfunctions like Shaft bow, high vibration, rotor rubbing, high
runout, loose rotating parts etc shall be provided. The system shall have the
facility to take a backup of the malfunction for future use.
k) Date & Time stamped alarm list.
l) Log & Report generation.
m) Provision for beeping icon in case of appearance of alarm.
n) Duplex redundant communication link with the DDCMIS shall be provided.
o) Electronic documentation.

10.04.0 SPECIALTOOLS&TACKLE

10.04.01 A Portable data collector shall be provided for taking periodic collection of non
critical machine data. Machine condition monitoring system shall be capable to
analyze the data. Instrument shall be microprocessor based and ready for use in
harsh environment. Integral LCD display shall provide the necessary display of
readings & spectral data. Minimum 02 channels along with additional input for
phase reference measurement shall be available with the instrument.

10.04.02 Instrument shall include necessary accelerometers and other devices with
accessories for collection of machine parameters. A long life Ni-Cd battery pack
shall be used. Replacement of battery shall not lead to loss of stored data.

10.04.03 Shaker table shall be provided for testing & calibration.


11.00.00 PLANTWIDENETWORK

11.00.01 A plant wide Fiber-optic 100 Mbps/ 1 GBPS high-speed backbone has been
envisaged. Said network shall be used by different users of the plant for over
viewing selective Plant Graphics & data, historical data & trends and MIS reports
such as Plant Generation, Unit Heat rate, Auxiliary Power consumption, DM make
up water consumption, Coal / Oil stock & consumption etc. and other day to day
online maintenance, Inventory & purchase related functions of CMIMS.

11.00.02 Web based & HTML compatible servers shall be provided for Management
Information System and Computerized Maintenance & Inventory Management
system. These shall provide necessary resources to different workgroups / users in
the plant. Work group shall also have the access to e-mail & Internet.

11.00.03 A Router with firewall shall be provided on the network for remote access of data
from Corporate office / remote location and for e-mail & Internet connectivity. A
leased line shall be provided by Owner for the same.


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11.00.04 Bidder shall consider a Fiber-optic network spread over the entire plant covering
the Unit control rooms, GM office (Located outside the plant), GS office &
Technical Building (Located close to power house), CHP control room, CHP
maintenance Building, Stores, DM plant, AHP control room and Switchyard Control
room etc. for accessing MIS and CMIMS functions.

11.00.05 Bidder shall provide required PCs with colour ink jet printers, router, switches, OFC
cable, optical patch cord, transceiver, connectors, couplers, network switch
enclosure, UPS, network server, UTP cabling, computer furniture etc. as required
for completeness of the system.

11.00.05 Bidder shall provide one PC and printer at owners head quarter and shall be
hooked up with plant local area network via dial-up connection.

11.00.06 Bidder shall consider licensed version of required software for complete functioning
of the network and PCs.

11.00.07 Required computer furniture for servers, PC & printers as required shall be
furnished.

11.00.08 Specification of PC

CPU : 2
nd
Generation Intel( R) core i3-2100 Processor
(3.1GHz, 3MB Cache)

Type : Tower

Main Memory : 6GB DDR3 SDRAM at 1333MHz 2DIMMS

Drives : 3 Floppy drive and CD ROM

Hard Disk : 1000GB SATA hard drive (7200RPM)

Monitor : 24 colour LCD

Communication port : a) Internal I/O

(1)PClex16 Full Height Card, (3) PClex1, (4)
Internal USB 2.0.

b). Front Port

(2) USB2.0, 8:1 Media Card Reader,

c) Rear Ports
(6) USB 2.0, (1) VGA, (1) HDMI, standard audio
jacks for 5.1 Audio Support, (1)10/100/1000

Expansion slot : 5

Connectivity : Ethernet LAN

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Operating system : Windows 7 Professional 64-bit or higher.

Softwares : Latest version of MS office, Clients Software and
other softwares as required

Features : 101 keys keyboard and mouse

Accessories : Furniture, Mouse pad


12.00.0 CONTROL&INSTRUMENTATIONCABLE

12.00.01 Cables shall be flame retardant low smoke (FRLS) type. In hazardous areas cables
of suitable R/L ratio shall be provided for intrinsic safety.

12.00.02 Durable marking shall be provided on the surface of the cable at intervals not
exceeding 5 mtrs. Marking shall include Manufacturers name, Year of
manufacture, Voltage grade, Type of cables (Conductor size & no. of pairs / triads /
type of compensating /extension cable), Insulation material, FRLS etc.

Sequential length marking shall also be provided at every meter interval on outer
sheath of cable.

12.00.03 Standard seasoned wooden drum containing minimum 500 /1000 M 5% length.
Drum shall be anti rodent, anti termite and smooth finish. Both end of cable shall
be capped by means of non hygroscopic sealing material.

12.01.0 THERMOCOUPLEEXTENSION&COMPENSATINGCABLE

01. Conductor : Solid conductor
02. Conductor size : 16 AWG (1.31 Sq. mm)
03. Type : KX (Extension) (Chromel Alumel) RX
(Compensating) (Copper-Copper alloy) JX
(Extension) (Iron Constantan)
04. Conductor Insulation : HR PVC Type-C (IS-5831,1984) 0.6 mm
thick
05. Operating Voltage : 300V /500V RMS (Core to earth / core to
core)
06. Twisting : Pair twisted with lay of 60 mm (max)
07. Twisting Direction : All pairs in the same direction. Lapped to
form bunch with mylar tape.
08. Screen (Pair & Overall) : Aluminium mylar tape with a thickness of
28 m (min.) for individual pair screen and

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60 m (min.) for overall screen with 100%
coverage and 25% overlapped edges.
Over the individual pair screening tape
two laps of 0.05 mm thick (min.) polyester
tape shall be applied with minimum
overlap of 25%. Metallic side of the screen
shall be in contact with drain wire.
09. Drain wire : Annealed tinned copper wire, stranded.
Size 0.5 Sq. mm. (No. of strands / size:- 7
/ 0.3mm)
10. Inner Sheath : Extruded FRLS PVC (anti rodent, anti
termite & moisture resistant properties)
HR PVC Type ST2 of IS-5831,1984
Thickness as per IS-1554Part-I 1976
11. Rip Cord : Non metallic under sheath
12. Armouring : GI wire / strip as per IS 3975
13. Outer Sheath : Extruded FRLS PVC (anti rodent, anti
termite & moisture resistant properties)
HR PVC Type ST2 of IS-5831,1984
Thickness as per IS-1554Part-I 1976
14. Filler : Non hygroscopic with FRLS property
15. Temperature Range : Up to 85 C
16. Insulation at 20
0
C : 100 MOhms/Km [Min]
17. Capacitance at 800 Hz : 120 nf/km
18. Cross talk : 60 dB
19. Attenuation : 1.2 dB/Km
20. Codes & Standards : a) IEC 332-1
b) ANSI MC 96.1
c) IS-8784-1987
21. Tests : a) Oxygen Index: Min.29 at room temp.
(ASTM-D-2863)

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b) Acid Gas Gen.: Max.20% by weight
as per IEC 754 Part-I
c) Temp Index : Min 250 DEG C at
21Oxy. Ind. (ASTM-D-2863)
d) Smoke Density Rating : Max.60%
(ASTM-D-2843).
e) Flammability Test : as per IEC 332
Part-I /IEEE-383
Swedish Chimney Test - SS-424-
1475 F3
f) High voltage test
Core to core- 1.5 KV for 1 min.
Core to screen- 1.0 KV for 1 min.
g) Insulation Resistance 100 M Ohm /
Km Min
h) Rodent & Termite repulsion test
(Presence of lead shall be confirmed)
22. Conductor material & sheath color for thermocouple cable as per ANSI MC
96.1

CABLETYPE
OVERALL
SHEATH
COLOR
WIRE SHEATHCOLOR CONDUCTORMATERIAL
KX Yellow
Positive Yellow Nickel / Chromium
Negative Red Nickel / Aluminum
JX Black
Positive White Iron
Negative Red Constantan
RX Green
Positive Black Copper
Negative Red
Copper Nickel
Alloy


23. Durable printed or embossed numbering at regular interval of 50mm shall be
provided for identification of pairs.

12.01.01 INSTRUMENTATIONMULTIPAIREDSIGNALCABLE

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01. Conductor type : Stranded (7) annealed tinned copper
02. Conductor size : 0.5 / 1.0 / 1.5 Sq.mm (as required)
03. Conductor resistance : 39 /Km/18 /Km/12 /Km
04. Conductor Insulation : HR PVC Type-C (IS-5831,1984) 0.6 mm
thick
05. Operating Voltage : 300 / 500V RMS (Core to earth / core to core)
06. Twisting : Twin twisted with lay of 60 mm
07. Twisting Direction : All pairs in the same direction. Lapped to form
bunch with mylar tape.
08. Screen (Pair & Overall) : Aluminium mylar tape with a thickness of 28
m (min.) for individual pair screen and 60 m
(min.) for overall screen with 100% coverage
and 25% overlapped edges. Over the
individual pair screening tape two laps of 0.05
mm thick (min.) polyester tape shall be
applied with minimum overlap of 25%.
Metallic side of the screen shall be in contact
with drain wire.
Analog signals- Individual pair & overall
shield to be considered.
Binary signals- overall shield to be
considered.
09. Drain wire : Annealed tinned copper wire, stranded. Size
0.5 Sq. mm. (No. of strands / size:- 7 /
0.3mm)
10. Inner Sheath : Extruded FRLS PVC (anti rodent, anti termite
& moisture resistant properties)
HR PVC Type ST2 of IS-5831,1984
Thickness as per IS-1554, Part-I 1976
11. Rip Cord : Non metallic under sheath
12. Armouring : GI wire / strip as per IS 3975
13. Outer Sheath : Extruded FRLS PVC (anti rodent, anti termite
& moisture resistant properties)

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HR PVC Type ST2 of IS-5831,1984
Thickness as per IS-1554, Part-I 1976
14. Filler : Non hygroscopic with FRLS property.
15. Temperature Range : 85
O
C
16. Insulation at 20 Deg.C : 100 MOhms/Km [Min]
17. Capacitance at 800 Hz : 120 nf/km
18. Cross talk : 60 dB
19. Attenuation : 1.2 dB/Km
20. Codes & Standards : a) IPCEA-S-61-402
b) BS 5308
c) IEC 332-1
d) ASTM-B-33
e) IS-8130-1984
f) IS 1554 Part-1
g) IS 10810
21. Sheath colour : Inner- Black and Outer- Gray
22. Tests : a) Oxygen Index: Min.29 at room temp.
(ASTM-D-2863)
b) Acid Gas Gen.: Max.20% by weight as
per IEC 754 Part-I
c) Temp Index : Min 250
O
C at 21Oxy. Ind.
(ASTM-D-2863)
d) Smoke Density Rating : Max.60%
(ASTM-D-2843).
e) Flammability Test : as per IEC 332 Part-I
f) Swedish Chimney Test-SS-424-1475 F3
g) Insulation Resistance 100 M Ohm / Km
Min
h) High voltage test

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Core to core- 1.5 KV for 1 min.
Core to screen- 1.0 KV for 1 min.
i) Rodent & Termite repulsion test
(Presence of lead shall be confirmed)

23. Colour of core for Instrumentation Cable (As per IS-9938)

PAIR CORE COLOR
1st 1st Blue
1st 2nd Red
2nd 1st Gray
2nd 2nd Yellow
3rd 1st Green
3rd 2nd Brown
4th 1st White
4th 2nd Black

Above 4 Pairs, 4 Pairs making a unit shall have indelible printed colour coded
bands like Pink for 1st unit, Orange for 2nd unit and Violet for 3rd unit and so on. In
addition band marking, for example single band for 1
st
. unit, double band for 2
nd
.
unit and so on, shall be provided on each conductor for identification of unit. Band
marking on individual core shall be provided at regular intervals not exceeding 50
mm.

12.02.0 Cables near high temperature zone shall be capable of withstanding high
temperature and terminated in junction box / panel in normal temperature zone.
Teflon insulated and sheathed thermocouple extension cables and copper
conductor cables shall be used in high temperature zone. Conductor and sheath
shall be extruded FEP (Teflon) as per VDE 0207 Part 6 and ASTMD 2116. These
cables shall be pair, multipair, triad, multitriad and twisted & shielded.

12.03.0 CONTROL&POWERCABLE

Bidder shall refer to Volume IIF of the electrical specification for detail.


13.00.0 ERECTIONHARDWARE

This section provides the general technical guidelines for the erection materials for
instruments. All erection materials shall be of good quality and conform to the
operating environment of the corresponding instrument.

13.01.0 ELECTRICALACCESSORIES


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Electrical conduit and associated materials shall conform to the requirements of the
articles which follow :

a) RigidSteelConduit

i) Conduits up to and including 25 mm shall be of 16 SWG and conduits
above 25 mm shall be of 14 SWG. Minimum size of conduits shall be
19 mm.

ii) Each piece of conduit shall be straight, free from blister and other
defects and covered with capped bushing at both ends.

iii) All rigid conduit couplings and elbows shall be hot dip galvanized rigid
mild steel in accordance with ANSI C 80.1 and UL6. The conduit
interior and exterior surfaces shall have a continuous zinc coating with
an over coat of transparent enamel or zinc chromate. Conduits shall be
furnished in standard length of 3 meters, threaded at both ends.

iv) All conduit fittings shall conform to the requirements of ANSI C 80.4 and
UL-514 where these standards apply.

b) FlexibleConduit

i) Flexible conduit shall be of three layer construction of very high quality
of lead coated steel. Outside and inside layer shall be reinforced with
heat resistant material.

ii) Lead coating outside and inside of the conduit steel surface shall
provide a non-corrosive characteristic particularly in acidic atmosphere.
Besides flexibility, this shall be strong enough to stay at the desired
profile without support and shall be durable and strong so as to offer
sufficient mechanical protection. It shall also be fully liquid dust and air
tight and shall withstand a continuous hydraulic pressure up to 2 Kg/Sq.
cm and temperature up to 200 C.

c) SpecialFittings

i) Conduit sealing and fittings shall be provided as required and shall be
consistent with the area and equipment with which they are installed.

ii) Double locknuts shall be provided on all conduit terminations not
provided with threaded lugs and couplings. Locknuts shall be designed
to securely bond the conduit to the enclosure when tightened. Locknuts
shall not loosen due to vibration.

13.02.0 ElectricalJunctionBox

01. Type of Enclosure : Dust tight & weatherproof conforming to IP 65
02. Material : 3 mm sheet steel

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03. Type of Cover : Solid unhinged with retention chain
04. Paint : 631 IS 5 Epoxy Powder Coated
05. Mounting : Surface
06. Cable Entry : 3 mm (min) Gland plate
07. Gasket : Neoprene
08. Grounding : Brass earth lug with green screw head
External-2 nos , Internal-1no.M6.
09. Number of Drain Holes : Two at bottom capped.
10. Identification : Label for JB and Tags for cable
11. Accessories : a) Rail mounted cage clamp type screwless
terminals with markers
b) Cable gland
c) Ferrules
d) Canopy at top

13.03.0 CableGland

01. Type : Double compression
02. Entry Thread : NPT
03. Material : Brass
04. Finish : Cadmium Plated.
05. Protection : IP 54 or better
06. Accessories : Neoprene gasket, locknuts, reducers etc.

13.04.0 CableTray

01. Material : Mild steel, slotted

02. Thickness : not less than 2.0 mm

03. Finish : Hot dip galvanized

04. Perforation : As per MFR standard.

05. Cover : Suitable for tray

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13.05.0 PROCESSHOOKUPACCESSORIES&SPECIFICATION

Material and rating of the hook up items shall suit the piping and fluid condition.
Hook up materials shall be IBR certified for applicable cases. Bidder shall furnish
hook up drawings and the drawings for open racks & closed racks for owners
approval.


13.06.0 SeamlessStainlessSteelPipe

01. Reference : ASTM A-312 TP 316

02. Material Grade : TP 316

03. Type : Seamless /Plain end

04. Size : NB

05. Schedule : 40

06. Standard Length : 5 meter

13.07.0 StainlessSteelPipeFittings

01. Reference : ASTM A-182 F 316 / ANSI B16.11
02. Type : Forged
03. Rating : 3000 lbs / 6000 lbs / 9000 lbs
04. Size : NB
05. End connection : Generally socket weld
06. Type of Fittings : Reducing coupling, male-female reducer,
straight coupling, equal tee, three piece union,
elbow, cap etc.

13.08.0 SeamlessStainlessSteelTube

01. Reference : ASTM A-213 TP 316

02. Material Grade : TP 316

03. Size : OD X 2.1 MM Thick

04. Type : Cold drawn annealed, pickled, passivated, de-
scaled, ,hydraulically cleaned seamless tube.

05. Properties : The tube shall be free from scratches and
suitable for bending and capable of being flared
by hardened and tapered steel pin. The

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expanded tube shall show no crack or rupture.
Hardness shall be RB 80.

06. Test Pressure : 400 Kg/Sq. cm (minimum)

07. Tolerance : 0.13 mm for outside diameter
15 % for wall thickness

08. Standard Length : 5 meter

09. Test : Flare, Hardness, Ball and Bubble Test

13.09.0 StainlessSteelTubeFittings

01. Reference : ASTM-A-182

02. Type : Double ferrule double compression

03. Material : 316 Stainless steel forged

04. Ferrule : 316 Stainless Steel

05. Type of Fittings : Male / female connector, elbow, cross /equal
tee, straight connector, bulkhead union, ferrule
etc. as required to suit installation.

06. Size : To suit SS tubing and NPT end connection

13.10.0 C.S.Pipe

01. Reference : ASTM-A 106 Gr. C

02. Material : Cold drawn seamless black C.S.

03. Type : Seamless / Plain ends

04. Size : NB

05. Schedule : 80, 160, XXS as required

06. Standard Length : 5 meter

13.11.0 C.S.PipeFittings

01. Reference : ASTM-A 105 / ANSI B16.11

02. Type : Forged

03. Rating : 3000 lbs / 6000 lbs / 9000 lbs

04. Size : NB

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VOL-II-E-SEC-VI - 146 DCPL-11Z02


05. End connection : Generally socket weld

06. Type of Fittings : Reducing coupling, male-female reducer,
straight coupling, equal tee, three piece union,
elbow, cap etc.

13.12.0 A.S.Pipe

01. Reference : ASTM-A 335 P22 AS PER ANSI B 36.10

02. Material : Cold drawn seamless A.S.

03. Type : Seamless / Plain ends

04. Size : NB

05. Schedule : XXS

06. Standard Length : 5 meter

13.13.0 A.S.PipeFittings

01. Reference : ASTM-A 182 F22 AS PER ANSI B 16.11

02. Type : Forged

03. Rating : 9000 lbs

04. Size : NB

05. End connection : Generally socket weld

06. Type of Fittings : Reducing coupling, male-female reducer,
straight coupling, equal tee, three piece union,
elbow, cap etc.

13.14.0 CarbonSteelGlobeValve

01. Reference : ASTM A-105

02. Type : Globe

03. Construction : Forged Body Cadmium Plated

04. End Connection : Socket Weld

05. Rating : Cl. 800 / CL. 2500


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06. Material : Body - Carbon steel
Stem - Hardened Steel
Plug - AISI 316 SS
Seat- Stainless steel stellited

07. Packing : Teflon / Grafoil as required

08. Yoke : ASTM A105

09. Handwheel : Carbon steel

10. Design standard : As per ANSI B 16.34

13.15.0 StainlessSteelGlobeValve

01. Reference : ASTM A-182 F316

02. Type : Globe

03. Construction : Forged Body

04. End Connection : Socket Weld

05. Proof Pressure : 400 Kg/Cm2

06. Material : Body - Stainless steel
Stem - Hardened Steel
Plug - AISI 316 SS
Seat- Stainless steel stellited

07. Packing : Teflon as required

08. Yoke : ASTM A182 F316

09. Handwheel : Carbon steel

10. Design standard : As per ANSI B 16.34
13.16.0 AlloySteelGlobeValve

01. Reference : ASTM A-182 F22

02. Type : Globe

03. Construction : Forged Body

04. End Connection : Socket Weld


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05. Rating : CL. 2500

06. Material : Body - Alloy steel
Stem - Hardened Steel
Plug - AISI 316 SS
Seat- Stainless steel stellited

07. Packing : Grafoil as required

08. Yoke : ASTM A182 F22

09. Handwheel : Carbon steel

10. Design standard : As per ANSI B 16.34
13.17.00CondensatePot

01. Reference : ASTM A182 F22 /ASTM A105

02. Material : Alloy steel / carbon steel as per application

03. Construction : Drilled from barstock

04. End connection : 3 nos. socket weld end

05. Accessories : Vent valves

13.18.0 InstrumentValveManifold

01. Type : a) Two valve manifold
b) Five valve manifold

02 Mounting : Remote 2 Pipe Mounting

03. Construction : Single block (bar stock)

04. Material : Forged body and bonnet AISI 316 stainless
steel

05. Ports : 1/2 " NPT (F)

06. Rating : 420 Kg/Sq. cm at ambient

07. Operating
Temperature : (-)30 to (+)170 Deg C

08. Packing : PTFE Wafer


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09. Seat & Stem : AISI 316 SS

10. Plug : AISI 316 SS free to turn on stem / 17-4 PH

11. Handle Bar : AISI 316 SS

12. Connection : Straight

13. Accessories : i) Plugs for all ports
ii) Mounting Bracket , bolts , nuts

13.19.0 PNEUMATICHOOKUPACCESSORIES

13.19.01 AirHeader

TechnicalParticulars
ForPanel ForField
01. Material of
Construction : Stainless steel Stainless steel

02. Inlet Connection : 2" NPT (M) 1" NPT (M)

03. Header Take-off : Stainless steel Stainless steel

04. Take off connection : 1 / 2 NPT (M) 1/ 2 NPT (M)

05. Take-off Valves : stainless steel stainless steel

ForPanel ForField

06. Tube Take-off : Tube adapter Tube adapter
on valve on valve

07. Drain : SS drain valve at SS drain valves at lowest
lowest point point

13.19.02 SeamlessStainlessSteelTube

01. Reference : ASTM A-269 TP 316

02. Material Grade : TP 316

03. Size : OD X 0.049 wall thickness

04. Type : Cold drawn annealed, pickled, passivated, de-
scaled, ,hydraulically cleaned seamless tube.

05. Properties : The tube shall be free from scratches and
suitable for bending and capable of being flared
by hardened and tapered steel pin. The

CPCPL-Super Critical TPP-Tharangambadi
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expanded tube shall show no crack or rupture.
Hardness shall be RB 80.

06. Test Pressure : 400 Kg/Sq. cm

07. Tolerance : 0.13 mm for outside diameter
15 % for wall thickness

08. Standard Length : 5 meter

09. Test : Flare, Hardness, Ball and Bubble Test


14.00.00 SPECIAL TOOLS & TACKLE AND TEST EQUIPMENT FOR DDCMIS AND OTHER SYSTEMS
(Common foe all Units)

14.00.01 Bidder shall supply a complete set of new, unused and reliable type of special tools
and tackle and test equipment which are necessary or convenient for erection,
commissioning, maintenance and overhaul of the plant and equipment provided
under this specification.

14.00.02 The tools & tackle and Test Equipment shall be shipped in separate container,
clearly marked with names of the equipment for which they are intended.

14.00.03 Bidder shall furnish list of tools & tackle and test equipment proposed to be
supplied along with the bid.





VOLUME : II-E

SECTIONVII

STEAM AND WATER ANALYSIS SYSTEM (SWAS)


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
CONTENT DCPL-11Z02




CONTENT



CLAUSE NO. DESCRIPTION PAGE NO.

1.00.00 INTENT OF SPECIFICATION V.II-E/S-VII : 1

2.00.00 GENERAL PERFORMANCE REQUIREMENTS V.II-E/S-VII : 1

3.00.00 SWAS PANEL AND ACCESSORIES V.II-E/S-VII : 3

4.00.00 ALARM ANNUNCIATION SYSTEM V.II-E/S-VII : 4

5.00.00 ANALYZERS V.II-E/S-VII : 4

6.00.00 DOZING CONTROL V.II-E/S-VII : 15



CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-VII - 1 DCPL-11Z02


VOLUME : II-E

SECTIONVII

STEAM AND WATER ANALYSIS SYSTEM (SWAS)



1.00.00 INTENT OF SPECIFICATION

This specification is intended to cover scope of design, engineering, supply,
erection, testing and commissioning of the Steam and Water Analysis System
(SWAS) for the Power Generating Units. Two separate systems (one for each
unit) shall be supplied.


2.00.00 GENERAL PERFORMANCE REQUIREMENTS

2.00.01 The typical monitoring and analysis requirement for plant steam and water
system is furnished below. Bidder shall however determine the analysis
requirement based on the criticality of major equipment.

2.00.02 Steam and Water Analysis System shall be furnished for continuous monitoring of
water and steam purity in the plant cycle and at other important points The
system shall enable the plant chemist and operators to make adjustments in the
water and steam conditioning system or to modify the plant operating procedure
to minimize equipment damage due to corrosion, scaling etc..

2.00.03 The SWAS system shall be unitized and preferably be located at the ground floor
level of the powerhouse in air-conditioned environment.

STEAM AND WATER ANALYZERS

TYPE

LOCATION
Specific Conductivity : Main Steam
Cat. Conductivity : Main Steam
Specific Conductivity : Condenser (Both & for BFP, if separate)
Cation Conductivity : Condensate at CEP O/L
Specific Conductivity : CEP Discharge
Specific Conductivity : Stator water
Cation Conductivity : Reheat Steam
Specific Conductivity : FW at Economizer I/L
Cation Conductivity : FW at Economizer I/L
Specific Conductivity : Separator water
Specific Conductivity : DM make-up to condenser
Cation Conductivity : DM make-up to condenser
Specific Conductivity : Condenser cooling water
Specific Conductivity : Condenser Polishing Unit (CPU) outlet
Cation Conductivity : CPU outlet
pH : Condensate at CEP O/L

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
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TYPE

LOCATION
pH : FW at Economizer I/L
pH : Separator water
pH : DM make-up water
pH : DMCW pump (TG)
pH : DMCW pump (Boiler)
pH : Main steam
pH : Condenser cooling water
pH : CPU outlet
Chloride : Separator water
Chloride : CPU outlet
Chloride : CEP Discharge
Sodium : DM make-up water
Sodium : Separator water
Sodium : CPU outlet
Sodium CEP Discharge
Residual Hydrazine : Feed water to Economizer
Silica : Main steam
Silica : CEP Discharge
Silica : Feed Water at Economiser Inlet
Silica : Separator water
Silica : DM make-up water
Silica : CPU outlet
Dissolved oxygen : CEP discharge
Dissolved oxygen : Deaerator outlet
Dissolved oxygen : Feed Water at Economizer
Residual Chlorine : Condenser Cooling Water
Any other paramentrs as recommended by BTG and other system Vendors.

2.00.04 The sampling system shall obtain samples from steam and water lines, which
shall be adequately conditioned and led to Analyzers for continuous analysis and
also to provide facility for grab (manual) sampling.

2.00.05 The system shall include complete Sample Conditioning system, Analyzers,
Converters / Transmitters, Indicators, alarm initiating devices, Annunciators,
interlocks for sample protection, hardware interface with DDCMIS, interface with
dozing system for remote closed loop control, all necessary pipes, tubes, fittings
and valves etc. and other conditioning and protective devices to integrate into a
completely assembled system.

2.00.06 Bidder shall be responsible for proper engineering, selection of hardware,
manufacture, testing, commissioning and satisfactory functioning of complete and
fully operational steam and water analysis system, meeting the intent of the
specification.

2.00.07 System components shall be assembled, piped, wired and tested at the factory
as a complete unit and shall be ready for installation at the project site.

2.00.08 Parts subject to high pressure or temperature or severe duty shall be of materials
suitable for the service.


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
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2.00.09 Pipings, tubing, fittings and other wetted parts in the sampling and analyzing
system shall be of 316 stainless steel or better. No plastic or rubber hoses or
tubes shall be used except within Analyzers as furnished by the Manufacturer.

2.00.10 The grab sample valves shall allow grab sample feed to be directed to grab
sample nozzles to the sample trough.

2.00.11 SWAS System components and accessories shall be from the latest proven
product range of qualified manufacturers. Components and accessories shall be
proven for SWAS application in power plant of comparable size.

2.00.12 Analysers shall be microprocessor based, drift free, auto compensating.

2.00.13 Sample coolers shall be designed for the maximum allowable water pressure
drop, from inlet connection to outlet connection of 0.7 Kg/Sq. cm with an inlet
pressure of 6 Kg/Sq. cm.

2.00.14 Self-regulating type devices shall be provided to maintain constant sample flow
through analyzers at a preset sample pressure. Variations in sample flow to
individual analyzer shall not exceed 5%.

2.00.15 Bidder shall provide necessary isolated 4-20 mA DC outputs from analyzers at
separate terminal block for DDCMIS.

2.00.16 A microprocessor based system with PC, 22 colour LCD monitor and printer
shall be provided in the SWAS dry room for display of parameters and alarm
condition of SWAS analyzers / systems.

2.00.17 Analyzers shall be powered from the unit UPS system.

2.00.18 The system shall be designed in line with the recommendation in ASME.

2.00.19 Furniture

a) Bidder shall include a complete set of furniture for the SWAS Room of
ergonomic design suitable for industrial application. Furniture shall include
but shall not be limited to Operators chairs, work benches for calibration and
testing purpose, cabinets for storage of manuals / booklets, storage racks for
special tools / chemicals / reagents etc.

b) Table top surfaces and other surfaces which are likely to come into contact
of chemicals and reagents shall be suitably coated / treated.


3.00.00 SWAS PANEL AND ACCESSORIES

3.00.01 SWAS panels shall be of modular construction and comprising of :

(i) a wet section consisting of a sample conditioning panel housing
components for processing samples and grab sample.
(ii) a dry sections housing all the converters / transmitters and corresponding
annunciators and monitors. The dry section shall be physically separate
from the sample conditioning panel, so that the electrical equipment are

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-VII - 4 DCPL-11Z02

kept dry and away from process fluids. Dry panel shall be kept in air
condition environment.

3.00.02 The wet section shall be a vertical panel housing various sample lines, primary
coolers, instruments such as sight flow indicators, Pressure / Temperature
Gauges, Pressure Control Valves, Rotameter, Pressure / Temperature Switch,
Solenoid Valves, NRVs, Secondary heat exchangers, Strainers, Isolation Valves,
Drain Headers, Grab Sampling Pans etc. The panel shall be provided with
bulkhead connection to connect sample pipes drawn from tapping points.

3.00.03 The Chiller Unit shall be kept near the Wet Panel to supply chilling water to the
Isothermal Bath or secondary heat exchangers in Wet Panel. Capacity of chiller
unit shall not be less than 5 TR (Tonnage refrigeration capacity) & refrigerant
shall be eco friendly type.

3.00.04 Sample conditioning components shall be mounted on the front of the wet section
with easily accessible operating handles, levers and dials etc.. All components
shall be suitably supported to the panel and shall be clearly labeled.
The physical arrangement of the tubing and wiring shall permit easy access for
maintenance.

3.00.05 Bidder shall keep provision of 25% spare capacity in coolers for future addition of
analyzers. Sample coolers shall have removable SS coil. Coolers shall be
designed to achieve the required sample temperature at the specified maximum
flow rate of the Analyzers with an assumed fouling factor of 0.2 and at maximum
cooling water temperature.

3.00.06 Piping and tubing shall be neatly installed and securely braced to ensure
mechanical rigidity. The complete SWAS panel and accessories shall be suitable
for continuous operation under ambient temperature condition of 8
O
C to 50
O
C
and relative humidity of 100%.

4.00.00 ALARM ANNUNCIATION SYSTEM

4.00.01 Alarms shall be available in the local monitor in the dry room for each unit
covering the entire SWAS system, with repeat facility in DDCMIS.


5.00.00 ANALYZERS

All Analyzers shall be of microprocessor based design. The general technical
specification of the analyzers is provided in this section. Bidder in his offer shall
indicate the sample flow requirement of each analyzer and the total quantity of
cooling water required for the system.

5.01.00 Conductivity Analyzer

A. Sensor

01. Type of Cell : Flow thru

02. Conductivity Range : As per instrument schedule

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
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03. Cell Constant : 0.01 / 0.1 / 1.0 depeding upon range

04. Temp. Compensation : Manual and Automatic (Integral) 0-100C

05. Process Connection : Screwed

06. Wetted Parts : Electrodes-SS 316L/ Insulators KYNAR/ Viton

07. Pressure Rating : 10 kg/cm
2


08. Accessories : Vessel (SS 316) with NPT connection

09. Cable : Upto transmitter in flexible conduct

B. Transmitter

01. Type : Microprocessor based, Single stream

02. Mounting : Flush Panel

03. Protection Class : IP-55 or better

04. Output : 4-20 mA DC (isolated)

05. Display : Digital Display in Engineering Unit, Alarm Status.

06. Zero/Span Adjustment: Front Panel Membrane type Keyboard

07. Temp. Compensation : Manual or Automatic

08. Diagnostic : Self diagnostic for electronics, electrode etc

09. Alarm : Dual set point, hysterisis and time delay adjustable

10. Enclosure : Die cast aluminum, epoxy coated

11. Cable Termination : Internal (cable entry through conduit)

12. Accuracy : 1.0 % of measured range

13. Response time : Less than 5 sec

14. Stability : 1.0 % of output range / month non-cumulative

15. Accessories : For cation conductivity- Dual Ion-Exchange column,
resin, etc. (minimum 12 months requirements).

5.02.00 pH Ananyer

A. Sensor


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-VII - 6 DCPL-11Z02

01. Type of Cell : Flow thru

02. Range : 0-14 pH

03. Type of measurement : Combination electrode

04. Temp. Compensation : Manual and Automatic (Integral) 0-100C

05. Process Connection : Screwed

06. Measuring Electrode : Glass

07. Pressure Rating : 10 kg/cm
2


08. Accessories : Vessel (SS 316) with NPT connection

09. Cable : Upto transmitter in flexible conduct

10. Preamplifier : Integral or separate

11. Liquid J unction : Ceramic / Kyner or equivalent

B. Transmitter

01. Type : Microprocessor based, Single stream

02. Mounting : Flush Panel

03. Protection Class : IP-55 or better

04. Output : 4-20 mA DC (isolated)

05. Display : Digital Display in Engineering Unit, Alarm Status.

06. Repeatability : 1% or better

07. Temp. Compensation : Manual or Automatic

08. Diagnostic : Self diagnostic for Calibration requried /
Calibration O.K. , electrode checking etc.

09. Alarm : Dual set point, hysterisis and time delay adjustable

10. Enclosure : Die cast aluminum, epoxy coated

11. Cable Termination : Internal (cable entry through conduit)

12. Accuracy : 0.2% of FSD or better

13. Response time : Less than 5 sec

14. Stability : 0.001 pH /week

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-VII - 7 DCPL-11Z02


15. Accessories : Ultrasonic Electrode Cleaner, Buffer solution tablets

5.03.00 Silica Analyzer

01. Type : Colorimetric monitor, gravity / pumped feed
Microprocessor based

02. Output : 4-20 mA DC (isolated) into 600 ohms

03. Readout : Digital Indicating meter for direct readout

04. Accuracy : 1% of F.S.D or better

05. Reproducibility : 2% of F.S.D. or better

06. Calibration : Manual & automatic

07. Cycle time : Less than 10 min or better

08. Operating temperature : 0-45
O
C

09. Mounting : Flush panel

10. Life of light source : 9,000 hours (approx.)

11. Alarm Facility : 2 HI & 2 LO independently adj. over span.

12. Alarm for : a) Monitor mal-function
b) Monitor on standby
c) Monitor auto-zeroing
d) Concentration high
e) Loss of sample
f) Concentration low
g) Loss of reagent

13. Accessories : a) Reagent cabinet
b) Sample strainer
c) Reagent Reservoir etc.
d) Phenolic name plate
e) Reagents & consumables
f) Special cables




5.04.00 Sodium Analyzer Assembly

01. Type of Cell : Flow Through ion-selection electrode

02. Flow Chamber : Plexi Glass Body or equivalent


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-VII - 8 DCPL-11Z02

03. Measuring Electrode : Sodium Selective Glass Electrode

04. Output : 4-20 mA DC (isolated) into 600 ohms

05. Temp. Compensation : Automatic upto 45 deg.C

05. Read Out : Digital Indicating meter

07. Accuracy : <5% of reading

08. Response Time : 2 minutes or better

09. Mounting : Flush Panel

10. Calibration : Automatic

11. Alarm Facility : 2 HI and 2 LO independently adj. over span.

12. Accessories : i) Phenolic tag plate etc.
(Preassembled, pre- ii) Sample filter.
wired and pre-tubed iii) Pressure regulator & flow meter
in enclosure) iv) Automatic calibration kit
v) Reagents and consumables
vi) Special cables

5.05.00 Hydrazine Analyzer

01. Type : Electrochemical

03. Output : 4-20 mA DC linear

04. Readout : Digital Indicating Meter, linear read-out

05. Accuracy : 2% of FSD or better

06. Reproducibility : 2% of FSD or better

07. Drift : 2 ppb/month or better

08. Temp. Compensation : Automatic up to 45
O
C

10. Response Time : 1 minutes or better

11. Mounting : Flush Panel

14. Alarm Facility : 2 HI and 2 LO independently adj. over span.

15. Preferred Feature : i) 2 Hi and LO alarm LED visible from front
ii) Power supply on/failure LED

16. Accessories : Chemical reagents for 12 months.

5.06.00 Dissolved Oxygen Analyzer

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-VII - 9 DCPL-11Z02


01. T y p e : Electro-chemical, Microprocessor based.

02. Range : As per approved instrument schedule

03. Type of Cell : Flow through sampling type (continuous)

04. Enclosure : IP-55 or better

05. Output : 4-20 mA DC isolated to a load of 600 Ohms
(minimum)

06. Temp.Compensation : Automatic up to 45
o
C

07. Readout : Digital Indicating meter

08. Accuracy : Better than 4% of full scale for Transmitter

09. Sensor Response Time : 90% in 30 seconds or better

10. Mounting : Flush panel

11. Alarm Facility : 2 HI & 2 LO independently adj. over span.

12. Preferred Feature : a) HI & LO Alarm LED visible from front.
b) Power supply on/failure LED.
c) In-built calibration facility.

13. Accessories : a) Reagent Cabinet (if applicable)
b) Reagent Reservoir (if applicable)



5.07.00 Chloride Analyzer

01. T y p e : Electro-chemical, Microprocessor based.

02. Type of Cell : Chloride Ion Selective Electrode

03. Enclosure : IP-55 or better

04. Output : 4-20 mA DC isolated to a load of 600 Ohms

05. Temp.Compensation : Automatic with Pt 100

06. Ambient Temp. : 45
o
C

07. Readout : Digital Indicating meter

08. Accuracy : 2% or better

09. Reproducibility : <3%


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-VII - 10 DCPL-11Z02

10. Detection Limit : 0.5 mg/l or better

11. Analysis Time : 5 minutes (max)

12. Cycle time : Adjustable

13. Calibration : Manual and automatic

14. Mounting : Flush panel

15. Alarms : 1 HI, 1 LO and 1 system alarm

16. Control accessories : a) Sample level detector
b) Reagent level detecor
c) Calibration solution level detector
d) Automatic sample, rinse and drain valve
e) Pump for calibration solution
f) Pump for reagent solution

17. Accessories : a) Reagent solution tank
d) Calibration solution tank

5.08.00 Sample Conditioning System

The objective of the water and steam sample conditioning is to modify and
correct sample temperature, pressure and flow rate from the sample source to
delivery point for grab sampling or online analysis. The conditioning must be
done safely and so as to ensure that the sample is truly representative of the
system condition at the point of sampling.

The sampling system and the equipments shall generally in compliance with the
section 5 of ASME PTC 19.11 2008.

5.08.01 Sample conditioning system shall be designed and constructed to receive and
condition all samples as required by the respective analyzers. This shall include
all conditioning equipment mentioned herein:

Sample filtering
Primary and final sample cooling and temperature control
Pressure reduction and control, as required
Flow rate control
Pressure and Temperature Protection
Other treatment as required by individual analyzers or mentioned herein.

5.08.02 Sample line to analyzers shall incorporate an anti-siphon design to prevent
possibility of running dry because of a broken or plugged sample line.

5.08.03 Sample Filter / Strainer

Sample particulate removal shall be accomplished by passing samples through
cartridge type filters with 316 stainless steel body or Y-Strainer. The filter

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-VII - 11 DCPL-11Z02

elements shall be capable of retaining particulates of 40 microns and larger. The
filter elements shall be installed immediately after the sample shut off valve.

5.08.04 Primary Sample Cooler

a) Primary cooling of samples having temperature in excess of 45 C shall be
accomplished by passing each sample through one or more individual
sample coolers of shell and tube heat exchanger type.

b) The primary coolers shall use plant auxiliary cooling water.

c) The overall capacity (flow rate and heat transfer capacity) of cooler / coolers
in cascade shall be adequate to cool all samples to within 5 C of the
cooling water inlet temperature for the combined flows of each required
analyzer sample plus a manual grab sample flow rate of 500 cc/min.

d) Sample coolers shall be of submerged helical coil type of shell and tube
design with removable coil meeting the intent of ASTM D1192-64
(Equipment for Sampling Industrial Water and Steam). Sample tubing shall
be seamless type with no welded or other joints inside the cooling jacket.
Unions shall be provided to facilitate removal of coils.

e) All sample tubing, fittings and other components wetted by the samples
shall be constructed of type 316 stainless steel.

f) Primary cooler shall be protected on the cooling water side by relief valve
on the water header. The cooling water header is provided with pressure
gauge and isolating valves.

g) Provision shall be made for draining the heat exchanger shell. The drain
line shall be valved and piped to waste drain header.

5.08.05 Isothermal Bath / Secondary Heat Exchangers

a) Each sample stream shall be finally cooled to 25
o
C 1
o
C, in an isothermal
bath by counter current or in secondary shell and tube heat exchanger
similar to the primary coolers with chilled water at about 20
o
C.

b) Chilled water shall be produced in a packaged refrigeration unit (chiller).

c) Sufficient heat exchange capacity (flow rate and heat transfer capacity)
shall be provided to obtain 25 C 1 C sample outlet temperature at the
maximum flow rate required by all analyzers and grab sample requirements
of all sample streams. Additionally, 25% spare coils / capacty shall be
provided for samples/analyzers added infuture.

d) Provision shall be made for adjusting each sample temperature
individually.

e) The isothermal bath and heat exchanger coils shall be of stainless steel
(SS 316). Heat exchanger coils shall be provided with unions to facilitate
easy removal. A removable cover shall be provided for the isothermal bath.

CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-VII - 12 DCPL-11Z02


f) Adequate space shall be provided for maintenance.

5.08.06 Temperature Control System of Isothermal Bath

a) A local Temperature Controller modulating a three way-mixing valve shall
maintain the isothermal bath temperature at 20 C 1 C by mixing the
chilled water from the chiller with the re-circulated water from the
isothermal bath.

b) The chilled water isothermal bath shall include the following:-

Automatic water make-up.
Bath temperature indicator.
Level gauge to indicate bath water level.
Drain and over-flow connection for bath.
Chilled Water Re-circulation System.

c) Temperature Switch shall be provided to annunciate high chilled water
temperature.
5.08.07 Chiller

a) A pair of 100% capacity redundant water-cooled chillers each with
sufficient refrigeration capacity to ensure desired isothermal bath
temperature under all operating conditions shall be provided.

b) The compressor shall be readily accessible for service and shall include
low noise, hermetically sealed motors. Compressors assembly shall also
include crank case heater, suction and discharge valves, oil sight glasses,
forced feed lubrication system and an integrated motor protection system.

c) The condenser shall be water cooled and of the cleanable shell and tube
design and constructed in accordance with the ASME code for Unfired
Pressure Vessels. A condenser water-regulating valve shall be included.

d) Chiller shall be of the direct expansion type with refrigerant tubes inside a
shell. The chiller is to be completely insulated and to be constructed in
accordance with the ASME code for Unfired Pressure Vessels.

e) Refrigerant circuit shall be complete with thermostatic expansion valve,
liquid line solenoid valve, sight glass, filter-dryer, refrigerant shut-off and
charging valves.

f) Chilled water pumps with suction and discharge gauges and the
thermometers shall be provided, mounted with the packaged chiller on the
channel base. Chiller water tank shall have level indication and auto level
control.

g) The chiller water pump shall be of the centrifugal type, close coupled,
bronze fitted construction, complete with motor. Pump & motor shall be
designed for continuous operation.


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h) Vibration dampeners, mounted between the chiller and the base channel
shall be provided.

i) Cooling water and chilled water piping shall be provided with block valves.


5.08.08 Sample Pressure Conditioning

a) Pressure reduction of samples shall be accomplished by using high
pressure reducing element as detailed below.

b) For samples less than 500psig the pressure reducer should be needle
valve.

c) Each sample line shall have Pressure Indicator and Temperature Indicator
upstream of pressure reducer. The gauge shall be 100 mm dial with
suitable stainless steel wetted parts. Casing shall be stainless steel
construction.

d) Each sample line shall include a safety relief valve set at about 3 kg/cm
2
g,
upstream of the rate set valve, having stainless steel wetted parts.

5.08.09 High Pressure Reducing Elements (HPRE)

a) For samples greater than 500 psig the pressure reduction shall be
accomplished by means of a variable rod-in-tube orifice (variable or fixed).

b) The device shall be designed for inlet pressure of 350 kg/cm
2
g,
temperatures of 65
o
C and flow rate of not less than 2000 milliliters per
minute. The device shall be sized for maximum required sample flow rate.

c) The pressure-reducing elements shall be conveniently located for removal
and periodic cleaning.

5.08.10 Pressure Regualtors:

The back pressure regulators to be provided to achieve the constant pressure
zone. This provides the pressure and flow regulation of the sample to ensure
proper instrument performance and repeatability.

5.08.11 Flow Restricting Element (FRE)

Flow Restricting Element for grab sample line shall be provided for all samples to
maintain constant sample flow at a preset sample inlet pressure.

5.08.12 Thermal Protection Device

To ensure operator safety and prevent analysers failure due to overheating, the
thermal protection device to interrupt sample flow if an overtemperature condition
occurs is to be provided. Self contained temperature control valve or temperature
controller with an appropriately rated automatic shut off valve need to be
provided. The remote indication in DDCMIS with alarm in local panel is required.

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5.08.13 Blow Down Valves

The blowdown valves are used be to purge sample lines. These are to be located
in the downstream of the pressure reducer after sample cooler. The regulating
type valves rated for sample source pressure and temperature should be
selected for application before the sample cooler. High pressure service ball
valve shall be used for blowdown / flushing after sample cooler. Ball valve are
used for low pressure blow down.

5.08.14 Sample Relief Valves

The sample line shall be provided with suitable relief valve at the downstream of
the pressure reducer and primary sample cooler. The relief valve is to be
positioned such that there is no dead leg present which will contaminate the
samble.

5.08.15 Temperature Gauges

Temperature gauges shall be of 100 mm size gas filled type with stainless steel
armored capillary tubing. Gauges shall be provided after primary coolers and
outlet sample lines. Each gauge shall have a dial engraving or separate phenolic
nameplate to identify the service. All wetted parts, internal and casing shall be
stainless steel.

5.08.16 Pressure Gauges

Pressure gauges shall be 100 mm size, stainless steel movements and bourdon
tubes and nylon bearings. Gauges shall be provided after primary cooler and
outlet sample lines. Each gauge shall have a dial engraving or separate phenolic
nameplate to identify the service. All wetted parts, internal and casing shall be
stainless steel.

5.08.17 Flow Indicators

Rotameters shall be provided for sample flow rate indication (to be located in
individual branch line to Analyzer Cell) with 75 mm scale length, panel mounting
bezel, and stainless steel float and body.


5.08.18 Flow Switches

Flow switch shall be provided on the primary cooler cooling water outlet. The
switch shall be equipped with alarm contacts for annunciation and interlocking.
Wetted parts shall be stainless steel.

5.08.19 Fittings

The bends to be used rather than fittings to change direction of sample tubing.
Compression fittings are to be used instead of welded fitting in the sample line.

5.08.20 Grab Samples

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Grab sample valves on the panel front shall be furnished to allow grab sample
flow to be directed grab sample nozzles to the sample trough. Approximately 300
mm of flexible tubing shall be furnished for each sample to allow grab sample
collection and prevent splashing. Valve body and trim shall be of SS-316.

5.08.21 Sample Sink

A continuous sink for Grab Sample Analysis shall be provided. The sink shall be
made of stainless steel. Sink shall have drain to a header.

Cleaning water connection shall be provided for cleaning of sample containers.

Sample Filters are not to be used as they affect sample analysis result.


6.00.00 DOZING CONTROL

The AVT panel located near the dozing stations shall be the primary control point.
However, the dozing pumps shall have provision for stroke adkustment from
DDCMIS, once the controls are transferred to remote mode. The dozing control
loops shall be synthesized in DDCMIS based on SWAS parameters received
through hardwired interface and will produce 4-20 mA signals for stroke
adjustment.

VOLUME:IIE

SECTIONVIII

ERECTIONANDCOMMISSIONING


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
CONTENT DCPL-11Z02

CONTENT

CLAUSE NO. DESCRIPTION PAGE NO.



1.00.00 ERECTION TESTING & PRE-COMMISSIONING
PRACTICES GENERAL V.II-E/S-VIII : 1

2.00.00 SPECIFIC ERECTION PRACTICES AND
GUIDELINE V.II-E/S-VIII : 2

3.00.00 CONSUMABLE, TOOLS AND TACKLE,
CALIBRATION AND TEST, INSTRUMENTS
AND ERECTION MATERIALS V.II-E/S-VIII : 31

4.00.00 INSTRUMENT CALIBRATION / CHECKING
AT SITE PRIOR TO ERECTION V.II-E/S-VIII : 32

5.00.00 EXAMINATIONS AFTER INSTALLATION V.II-E/S-VIII : 36

6.00.00 PROTECTION DURING MANUFACTURE,
TRANSPORTATION AND STORAGE BEFORE
ERECTION V.II-E/S-VIII : 38

7.00.00 QUALITY ASSURANCE SERVICES V.II-E/S-VIII : 39

8.00.00 INSPECTION AND TESTING V.II-E/S-VIII : 41

9.00.00 TRAINING OF PERSONNEL V.II-E/S-VIII : 57


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VOLUME:IIE

SECTIONVIII

ERECTIONANDCOMMISSIONING



1.00.00 ERECTIONTESTING&PRECOMMISSIONINGPRACTICESGENERAL

1.00.01 This part of the specification is intended to provide a general guideline for the
procedures to be followed for the erection, testing and commissioning of various
Control & Instrumentation systems, field instrumentation, final control elements
and accessories.

1.00.02 Omission of any specific reference to any method, parts, accessories or material
required for proper and efficient execution of the work shall not in any way relieve
Contractor from his responsibilities of providing such facilities and performing the
successful erection, testing and commissioning.

1.01.00 EQUIPMENT,MATERIALS&SERVICESTOBEPROVIDEDBYCONTRACTOR

1.01.01 Equipment, Materials & Services to be provided under this specification and shall
include but shall not be limited to the following:

a) Shop testing and Factory Acceptance Test.
b) Pre-calibration of instruments at site and maintaining record of the same.
c) Pre-assembly at site, as required.
d) Erection.
e) Cleaning / flushing (as required).
f) Pre-commissioning check to ensure correctness of erection.
g) In-situ calibration, testing, loop checking etc,. and maintaining record of the
same.
h) Cleaning up of instruments, accessories and worksite during and after
erection.
i) Powering on and Commissioning.
j) Perform site acceptance test and handing over.
k) Participating in performance guarantee and other performance tests at site.







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2.00.00 SPECIFICERECTIONPRACTICESANDGUIDELINES

The specification provides the general guidelines to be followed for the
warehousing, handling, testing, erection, pre-commissioning checks and
commissioning of instruments and accessories.

a) The guidelines provided shall not be deemed as an effort to describe the
entire work involved or to identify the steps and sequence to be adhered to
in the erection of specific work items.
b) The basic intent is to establish a sound engineering practice to be adopted
throughout.
c) Equipment manufacturers' recommendation, where available, shall prevail.
d) For special instruments viz. analyzers etc., the specification is of general
nature only and manufacturer's recommendation shall be followed as
guideline.
e) The specification shall not be treated as comprehensive. Any activity, not
specifically mentioned but felt essential or advisable from good engineering
consideration shall be included.

2.01.00 FIELDINSTRUMENTS

Guidelines provided herein shall be adhered to while erecting an instrument or
accessory in the plant.

a) Care should be taken to avoid damage to the instruments during handling
and transportation. Special care shall be taken while handling breakable,
spillable, fragile and delicate items.
b) Before erection, instruments shall be subjected to calibration and other
functional checks at Contractor's site laboratory. The instruments shall be
uncrated and unpacked with care and as per instructions furnished on the
respective packages, using appropriate tools and implements.
c) Instruments, jigs, tools and tackle for the purpose of performing the tests
shall be provided by Contractor.
d) Instruments shall be tagged with engraved aluminum / stainless steel tag
plates and shall be secured to the instrument with metallic wire fasteners,
during the test.
e) For instruments found acceptable and conforming to the declared
performance parameters, a test report shall be prepared.
f) Minor repairs and adjustments of the instruments shall be performed by
Contractor. Once a defective instrument has been successfully repaired, it
shall again be subjected to calibration and functional checks, as above.
g) A record of such repairs and adjustments shall be maintained by Contractor.

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h) For instruments where the extent of damage is such that the same cannot
be repaired at site, a failure report shall be generated by Contractor,
enumerating the nature of fault/ damage. Cases where the damages are
only superficial and does not affect the performance of the instrument/s, the
decision as to whether such instrument/s are fit for erection shall lie solely
with Owner.

i) In no case, erection work shall be taken-up in areas where heavy equipment
movement is foreseen, major welding activity is under progress, heavy
structural items are being erected or any major activity is being carried out or
is anticipated, which may damage the erected instrument or its support.
j) If any erected instrument or its accessory is found to be vulnerable to
damage or to be fouling/interfering with progress of other activities in the
area, same shall be dismantled/removed immediately. During re-erection of
such instruments, the steps indicated for erection shall be carried out afresh.
k) After erection, instruments shall be covered with transparent polyethylene
sheets to protect from unauthorized handling.
l) Colored PVC adhesive tapes shall be put on the polyethylene cover to
indicate various stages of activities. Red tape shall indicate erection under
progress. Yellow tape shall indicate completeness of erection. Blue tape
shall imply approval of erection and Green tape shall signify the
commissioning of the instrument. Adhesive paper tapes shall be fixed on the
respective tapes to inscribe the dates of completion of activities.
m) Location of field instruments shall be consistent with tapping points on pipes
and equipment.
n) No field instrument shall be installed in such a manner that it depends on
rigidity of the impulse piping or the electrical connection to it for support.
o) Handrails shall not be used, in general, for mounting or supporting
instruments.
p) The place where the instrument is to be installed must be easily accessible
from nearest floor / platform level and there must have enough-clear space
to allow maintenance work and lay-down.
q) The location shall be such as not to cause any inconvenience to repair,
removal, observation, inspection and maintenance of the installed equipment
and other items nearby.
r) Nearby high temperature equipment or piping shall not give rise to any
injurious effect to instruments.
s) There will be no safety valve or effluent drain point near the instrument
which may cause injurious effect. In general, no instrument shall be erected
in areas prone to vibration.
t) Instruments which are outside the building or shed and are not located
within transmitter rack shall be provided with protective cover or canopy to

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[2 x 660 MW] Main Plant Package
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provide effective protection against dust, rain, sun etc. The cover shall be
installed immediately after mounting the instrument.
u) Clamps, supports, stands etc. required for installation and erection of
instruments and their accessories, shall be painted.
v) No field instrument shall be installed without simultaneously taking up the
connected impulse line work.
w) Proper precaution is to be taken to protect installations, instruments,
accessories, devices etc. from possible damages during steam blowing,
flushing, hydrostatic testing.
x) Wherever practicable, the height of the instrument from its working floor/
platform shall be between 1000-1400 mm. The illumination at the locations
where instruments are erected shall be adequate so that the scales can be
read unassisted.
y) Sub-trays, where required, shall be erected for proper routing of the cables
and tubes and no cable shall be laid unsupported.
z) The indicating meters shall be oriented properly so that the scale can be
read unassisted and unobstructed from the approach floor / platform.


2.01.01 Pressure/DifferentialPressure(D.P)Transmitters/LevelTransmitters

a) Manifolds, cocks and valves shall be hydraulically tested at rated test
pressure. All air line and draft / vacuum service cocks and valves shall be
leak tested.
b) Manifolds / valves shall be mounted on / connected to transmitter at
Contractor's workshop / site and the assembly shall be leak tested after
completion of the plumbing. The leak test shall be performed with
compressed air and soap solution at pressure not exceeding the maximum
overload pressure of the transmitter.
c) For transmitters located in racks, the erection activities shall normally imply
mounting with its manifold/valve assembly on appropriate support structures
in the rack with proper fasteners, viz. U-clamps, bolts etc., levelling, pipe
connections from process, piping to drain valve / vent valve, supporting/
clamping of the valve, pipe connection from to drain pot/ drain header/
nearest system drain, cabling to the junction box using flexible conduits,
termination of the cable with appropriate lugs, sleeves and markers;
mounting and connecting all settling chambers / damper pots / siphons etc.,
as applicable.
d) Stanchions, brackets etc., and such supporting structures shall be designed
properly to support all transmitter accessories.
e) For pneumatic consumers, necessary work related to signal and supply air
tubing shall be part of erection activity. Thus, supply air tubing from the
nearest instrument air take-off points with formation of additional
sub-headers, where necessary; air supply pipings / tubings with all

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associated fittings, signal air tubing up to nearest pneumatic junction box /
local controller/control room shall be part of erection.
f) For displacer type level transmitters, the blanks provided on the vessel /
stand pipe shall be removed and the transmitter shall be mounted with
proper gaskets, bolts and nuts. All nut and bolt heads shall be properly
greased before tightening.
g) For external cage type level transmitters, additional supports to the
transmitters in the form of bracings / pedestals, if felt necessary, shall be
fabricated and erected. While supporting/mounting such structures due
consideration shall be given to the movement / expansion of the vessel /
stand pipe.
h) For transmitters mounted on local structures, cabling shall be done up to the
nearest junction box through suitable flexible / rigid conduits.
i) Attention shall be paid to allow free space for the removal of transmitter
cover.
j) During installation of level instruments on vessels, if the nozzles on vessels
are found to be out of alignment or not of appropriate size, necessary
modification or addition of spool pieces as required, for proper installation,
shall be carried out.

2.01.02 TemperatureInstruments/Thermowells

a) Weldable thermowells shall be welded on pipes / vessels / equipment by
certified welders only and post-weld tests shall be performed as per main
pipeline specification. Tests and certification of the welds shall be done as
per rule.
b) Thermowells shall be thoroughly cleaned with air jet and wire brush before
insertion of temperature element.
c) The dial of temperature gauges and switches shall be oriented properly so
that the scale can be read / set point can be adjusted unassisted from the
approach floor/ platform.
d) Capillary type instruments shall be mounted on appropriate support
structure with clamps, bolts etc.
e) Contractor shall fabricate structures for routing, supporting and protecting
the capillary tubes. Capillaries shall be clamped at intervals not more than 1
meter. Capillaries shall not run unsupported.
f) Where movement of the pipelines is expected, adequate loop lengths shall
be kept in the flexible conduits/ capillaries to allow for the movement without
any strain.
g) In the phase between erection and cabling work, all cable entry points shall
be kept plugged with PVC caps.
h) All compensating cables shall be terminated with proper polarity.

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i) All cables shall cross ferruled at both the junction box and element head
end.
j) In case of thermowells with long immersion length and temperature
elements having long and rigid extension neck, as in case of air or flue path
measurements, mechanical supports shall be provided to avoid excessive
suspension weight on the boss.

2.01.03 PressureGauges/Switches,DifferentialPressureGauges/Switches

Pressure gauges / switches and differential pressure gauges / switches shall
either be directly mounted on the process pipeline or shall be mounted on local
brackets, gauge boards or open racks depending on accessibility and
maintainability. Guidelines provided above shall be generally followed for
pressure and differential gauges and switches as well.

2.01.04 LevelGauges/Switches

Level Gauges and Switches shall be mounted on the vessel or on standpipe.
a) Contractor shall verify the following in advance:
i) Necessary access platforms, ladders are provided.
ii) The center line of the tap-off valves are in plumb.
b) Necessary support structures, if required, for installation of external cages /
gauges shall be fabricated.
c) The erection activity of Level Gauges / Switches shall normally include
mounting of the instrument to vessel / stand pipe with necessary pipes,
nipples, drain / vent valve, connection of drain to nearest system drain,
cabling up to external junction box using flexible conduit, termination of
cable with proper sleeves, conductor marker/ferrules and lugs etc.
d) Necessary sub-trays shall be erected for routing of cable.
e) The indicating side of gauge glasses shall be so oriented that it can be read
unassisted and unobstructed from the approach floor / platform.
f) Illumination in the areas where level gauges are mounted shall be adequate
for the level to be visible without the help of flash light. Areas where this
requirement can not be met, gauge glasses shall be provided with internal
illumination.

2.02.00 ANALYZERS

Analyzers shall include flue gas analyzers, boiler emission monitoring system and
the steam and water analysis system with all accessories, associated pipings /
tubings and drain / purge line work/sampling system and necessary cabling.

a) Necessary measures and precautions to be exercised for field instruments
shall be adhered to for field mounted analyzers, as well.

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b) Attention shall be paid to the accessibility of probe locations and
withdrawal area for the probes. If Probe locations are found inaccessible,
Contractor shall construct necessary access platforms. Also if any
obstruction is observed to the smooth withdrawal of probes due to some
interfering structures / railings etc., necessary modification work shall be
performed by Contractor.
c) Protective covers / canopies shall be fabricated and installed to protect the
probe head / converter cabinet / calibration kit.

2.02.01 InSituAnalyzers

a) Suitable adapter plates with necessary openings on the duct or furnace wall
properly stiffened and blanked with suitable blank flanges, shall be used for
mounting analyzers/ probes.
b) Work shall include the erection of sub-trays or conduits for the cabling
between probe head to the converter cabinet and the tubings for reference
air and test gas, from calibration kit to the probe.
c) While installing the converter cabinet / unit, care shall be taken to locate
the same within the specified distance from the probe.
d) Activities shall also include the necessary sub-header work to extend
reference air supply line from the nearest instrument air header to the air
set, piping / tubing work between reference air purge meter to the reference
air set and the probe, piping/tubing work between auto calibration kit to the
probe and the necessary piping / tubing between the reference gas
cylinders to the probe.
e) All earthing continuity tests, insulation tests etc. shall be done as per
manufacturer's recommendation.

2.02.02 Extractive/DilutionAnalyzers

a) Analyzer cabinets / shelters shall be prewired and pre-tubed and shall
house fine filter, 5-way valve, diaphragm pump, electric cooler, coarse filter,
sample flow regulator, the analyzer/s, reference gas cylinders and reference
gas pressure regulators.
b) Adapter plate with the mounting flange for mounting the sampling probe
duly blanked with blank flange shall be used.

c) It is advised that after removing the blank flange on the adaptor, the
insertion path for the probes be first inspected for any fouling. The
inspection can be performed by inserting a poker rod of equivalent
dimension.
d) Any minor assembly-work on the probe or its accessories shall be carried
out as per Manufacturer's guideline.

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e) Minor adjustments on the adapter if necessary shall also be performed as a
part of erection activity.
f) The work shall include the erection of sub-trays conduits for the cabling
between probe head to the analyzer cabinet and the tubings for test gas,
from analyzer cabinet to the probe.
g) All earthing continuity tests, insulation tests etc. shall be done as per
manufacturer's recommendation.

2.02.03 EmissionMonitoringSystem

Contractor's scope of work shall include complete transportation, lifting,
mounting, calibrating, testing and commissioning of Continuous emission
monitoring system. Contractor's scope of work shall also include drawing of
instrument air line up to platforms and subsequent distribution to consumer
points. Necessary tubing, sub-tray work, cabling up to junction box on duct /
stack platform, conduiting etc. shall also be deemed to be a part of installation
activity.

a) Contractor's scope of work shall also include to arrange :

i) Inserts and cutouts on duct wall with studs blanked-off temporarily by
plates. Similar activities on the stack shall be arranged by Owner.
ii) Main cable tray/ ladder up to the platform level.
iii) Instrument air take-off point near the analyzer location.
b) Prior to installation of analyzers Contractor shall check the stack or duct for
air leakage and availability of all components.
c) Adapter plate should be removed before installation and then bolted to the
insert available on the stack or duct wall.
d) Contractors scope shall include; rigging, installation by bolting, necessary
air piping up to the cubicle, cabling up to local junction box, testing,
calibrating and commissioning of the system.
e) Cabling from probe head to analyzer cubicle, analyzer cubicle to local
junction box including laying of cable subtrays, conduits as required shall be
in Contractor's scope of work.
f) Before mounting the trans-receiver units, the alignment of ports must be
checked optically for straightness.
g) Contractor's scope of work shall also include cabling from trans-receiver
units to local junction box or electrical unit; providing air purge connection
up to trans-receiver units and routing of air lines up to the required point
with valves, air filter regulators, pneumatic lines.
h) Field mounted electronic unit (if any) shall be installed on site fabricated
stands/ stanchions/ enclosures.


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2.02.04 SteamandWaterAnalysisSystem(SWAS)

a) The scope of work shall include installation of panels and the skid mounted
equipment; connecting incoming sample lines / cooling water lines to the
sample conditioning panel bulkhead, laying of cooling water lines up to and
inside SWAS room; connecting drain headers to the nearest system drain,
installation of the chilled water compressor system with associated cooling
water and chilled water connection to the bath/ heat exchangers, insulation
of chilled water lines; laying of all special / prefab cables, mounting of
instruments / equipment in position.
b) Contractor shall take care in handling the pre-tubed and pre-wired panel
sections during transportation and installation.
c) The general guidelines for installation of SWAS panels shall be as per panel
erection specification.

2.03.00 LOCALPANELS,RACKS,CUBICLES,GAUGEBOARDSANDENCLOSURES

Local racks, panels, gauge boards, cubicles shall be installed at specified
locations as indicated in layout drawings. Work shall also include fabrication and
installation of gauge boards, stands, mounting brackets and frames, drain
headers etc. with associated painting and civil work.

a) Contractor shall erect panels / cubicles / enclosures etc. only after ensuring
availability of work front.
b) The panels shall be issued from warehouse or storage yard on the same
day when the actual erection is performed.
c) Panel, once uncrated, must be installed on the same day.
d) Panels supplied in packed condition, will be properly silinged for lifting.
When lifting unpacked panels eye-bolts shall be used. Unpacking should be
done at store or installation site only.
e) During slinging or lifting of the panel, care shall be taken not to damage the
structure or any instrument/equipment mounted on the panel.
f) Panels shall be slowly lowered on its foundations and shall not be subjected
on unnecessary jerk or bounce.
g) Prior to the installation of panels, the foundation shall be inspected for
presence of foreign matters and existence of possible defects or damage.
Positions, shape and dimensions of the foundation shall be verified against
corresponding drawing. Pockets for grouting shall normally be on the
concrete base. Contractor shall arrange anchor bolts or grouting spikes and
grout the same in the pocket.
h) Accurate center lines and auxiliary lines shall be marked-off with due
consideration of proper alignment and level. Base channel of panel shall be
dismantled from the panel and shall be positioned and set by grouted
anchor bolts. Before fixing the bolts, the panels must be properly aligned

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and plumbed. Only brass shims may be used for leveling of the panels.
Leveling of panel should be done by the help of spirit level or similar device.
i) Contractor shall arrange to provide suitable protective coverings for the
panels since unpacking and after erection to avoid any damage due to
movement of men and materials in the vicinity.
j) Retouching work of painted surface of panels shall be carried out wherever
required.
k) During installation of panels and panel instruments the panels must be kept
in perfectly clean condition.
l) All panels shall be suitably earthed as per guidelines furnished in the
specification.
m) Only construction power shall be utilized during erection of panels. Under
no circumstances power lines shall be tapped-off from the panels.

2.03.01 JunctionBoxesandPullBoxes

Contractor's scope of erection of junction boxes shall include mounting in
appropriate locations indicated in the drawings, fabrication of necessary supports,
pedestals, brackets, frameworks etc., for erection and final painting of the
structures.

a) Before installation, gland plates shall be drilled / knock-outs shall be
removed.
b) As required, pedestals may be fabricated and grouted / bolted to structure.
c) Unused knock-outs in the junction boxes shall be left plugged to prevent
dust and moisture entry.
d) Necessary nuts, bolts, screws, fixtures etc. for mounting and supporting
shall be supplied by Contractor.
e) Identification tags for the cables shall be provided both inside and outside
the junction boxes close to the glanding point.
f) Wherever required, Contractor shall arrange to perform retouching of paint
on the junction boxes. Proper identification numbers shall be labeled on the
junction boxes for ease of identification.
g) After erection, junction boxes shall be covered with polyethylene sheets.
h) Ideally the height of junction boxes shall be 1000-1400 mm from the
approach floor level.

2.03.02 TransmitterRacks

a) The location of transmitter racks shall normally be pre-assigned. However,
depending on site conditions, some may have to be relocated at site.

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b) Guidelines provided for erection of local panels shall apply for erection of
transmitter racks, as well.
c) Impulse lines shall normally terminate at the bulk head union plates..
d) Contractor shall avoid hot bending of impulse pipes inside the enclosures.
All bending and forming activity should be performed outside before fixing
in position.
e) Contractor shall suitably support the drain/vent valves, manifolds etc. with
the necessary clamps, bolts, washers etc.
f) Contractor's scope of work shall also include terminating transmitters with
cables in flexible conduits up to the terminal blocks with necessary conduit
supports, clamps, glands, sleeves, conductor markers / ferrules, lugs etc.


2.03.03 Stanchions,SiteStructuresandMountingFrames

Contractor's scope of work shall include fabrication and installation of mounting
frames, pedestals, canopies, protective enclosures and local gauge boards for
mounting local instruments, analyzers and junction boxes. Contractor's scope
shall also include mounting of the instruments in these local stanchions /
pedestals / gauge boards with all necessary mounting fixtures; piping, painting,
cabling up to local junction box and any other associated civil work like chipping,
grouting etc.

a) Floor/ platform mounted structures shall be self-supporting and free
standing type. These should not depend on supports derived from nearby
columns/ structures/ pipelines etc. for their rigidity and mounting.
b) Before installation, accurate center lines and other auxiliary lines are to be
marked for proper leveling and alignment.
c) Necessary grouting pockets are to be chipped and anchor bolts/ studs shall
be fixed on floor, column or wall.
d) Necessary precaution should be taken during locating site mounted
structures so as not to interfere with erection activity in the area or block
passage for movement of personnel / equipment during normal operation
and maintenance.
e) Contractor shall arrange to provide suitable protective covers for site
fabricated structures to avoid damage due to movement of men and
materials in the vicinity.
f) After erection, all site fabricated structures shall be painted as per
specification.
g) Contractor shall fabricate 3 mm MS / Aluminum canopies for shielding
instrument from direct exposure to rain or sun.




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2.04.00 CABLINGANDINTERCONNECTION

Cabling and interconnection shall include cabling work between local switches,
temperature elements, transmitters, positioners, converters, limit switches,
position transmitters, solenoid valves etc. to local junction boxes, from local
junction boxes / local panels / transmitter racks / instruments to termination
cabinets / panels / electronic cabinets in control room / control equipment room ;
command and feedback signals from M.C.C / Switch Gear room to termination
cabinets / panels / electronic cabinets in control room / control equipment room;
inter-cabling between various cabinets in control room / control equipment room;
earthing of all panels / racks / cabinets / junction boxes etc, with appropriate
cable; special cabling between sensing devices to converter cabinets and cabling
work of prefabricated and data hiway cables. Cabling work shall normally imply
pulling, laying, marking, splicing, glanding, dressing, ferruling, crimping and
termination of cables at both ends with associated conduit and sub-tray work;
followed by testing of cables.

a) Cable shall be neatly laid with proper dressing and shall be adequately
fixed and supported.
b) Cable shall enter in the enclosures via cable glands.
c) Cable runs shall be properly identified with permanent tag plate fastened
with steel wires both at field end and panel end and at a maximum of 20
meter intervals in straight length. Tags shall be provided at bends and both
sides of barrier walls as well as at both terminal ends.
d) In the cable spreader room, cables shall be clamped rigidly below the panel
before entry. If required, vertical cable tray shall be provided in case where
the horizontal cable tray is more than 1 Meter below the panel bottom.
e) Cables laid near high temperature pipings shall be protected against
damage due to continuous exposure to high temperature.
f) Bend trays with suitable roller shall be used for cross over of cables from
one section to other.
g) Spare cable runs shall be kept coiled inside the enclosures with the ends
suitably protected and cables properly identified.
h) In case of a single straight multicore cable run, no joint in the cable shall be
provided in between.
i) Cables shall be laid maximum upto 2 layers for horizontal cable trays and
in single layer for vertical trays.
j) Cable glands and other openings in the junction boxes shall be properly
sealed by means of sealing compound to make them thoroughly dust and
moisture proof.
k) Cables shall not be subjected to excessive tension so as to cause damage
to the conductors.

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l) Care shall be taken to avoid any possible damage while laying the cables
at bends where excessive spatial stress may concentrate or where danger
exists of damaging the insulation.
m) Cable shall be tested for continuity and insulation resistance before and
after installation as per the latest Indian Electricity Rules. Test for continuity
shall be done by a circuit tester. Insulation resistance test shall be done
with a 500V megger. The measured insulation resistance shall be more
than 100 meg. Ohms between conductors and one conductor to ground.
n) Cables shall run through conduits up to local junction box / sub-tray.
o) Cable shields shall be individually terminated and jumpered together at the
terminal blocks. Earthing of the shields shall, however, be performed at the
control room end only.
p) Cable shall be laid only along the route specified in the cable schedule.
q) If at any time during progress of work, trays are found inadequate to
accommodate the assigned cable, Contractor shall discontinue laying of
the cable until the problem is rectified.
r) Cable conducting AC and DC signals shall be spatially segregated.
Compensating cables shall not be mixed with cables carrying milliampere
signals. The signal cables and power cables shall not be in the same
conduit, tray or junction box. In general, a minimum clearance of 1500 mm
shall be maintained between noise generating equipment like large motors,
generators, transformers etc. and signal / control cables. The minimum
distances to be maintained between the instrumentation signal cables and
any AC power cables running in parallel are as follows :

MAXIMUMCIRCUITVOLTAGE SEPARATION(MM)
240 V AC 250
415 V AC 300
6.6 KV / 11 KV 600 / 900

s) Cables shall be laid or pulled in trays so that neither cable nor the trays are
damaged. Cable shall be cut in sufficient lengths to conform to the contour
of the trays, especially for vertical inside bends. Excessive slack shall be
removed from the cable so that the cables lie parallel to the sides of the
trays.
t) Cables shall be tied to the trays with G.I./Aluminum or self-locking grip
strips at not more than 2 meter intervals for horizontal runs and at not more
than 1 meter intervals for vertical runs. All cable shall be strapped
individually.
u) Pulling of cable shall be done with manila rope or nylon rope.
v) Only the type of lubricants recommended by manufacturer shall be used.

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w) Before pulling cable, the drum shall be visually inspected for protruding
nails, fastenings or other objects which may damage the cable. Such
articles shall be removed before pulling of the cable.
x) Contractor shall perform a thorough visual inspection for flaws, breaks,
cracks and abrasions in the cable sheath during pulling.
y) Cable damaged in any way during installation shall be replaced.
z) The pulling tension of any cable shall not exceed the maximum tension
recommended by the manufacturer.
aa) To avoid insulation damage from excessive sidewall pressure at bends in
conduit runs, the pulling tension in Kilograms shall not exceed 1.5 times the
radius of bend in centimeters.
bb) For cable without metallic shielding or armor and cable with metallic tape
shielding, the cable bend radius shall be in accordance with the
requirements of IPCEA standards. For cable with metallic wire shielding or
metallic armor the bend radius shall not be less than 8 times the overall
diameter of the cable.
cc) Spare conductors of a multicore cable shall be left at their maximum
lengths for possible future replacements of any other conductors in the
cable. Each spare conductor shall be identified and neatly coiled separately
and then taped to the conductors being used.
dd) Exposed conductor surfaces shall be taped with all-weather vinyl plastic
electrical tape.

ee) Printed ferrules are to be used and necessary ferrule printing machine to
be made available at site to improve the quality of job, save time and
manpower.

ff) For all networks cable, before charging, Network cable analysis test shall
be carried out through certified agency.

2.04.01 Extenion&CompensatingCables
a) Single pair compensating cables shall be drawn through conduit. Lubricants
like French chalk, soap stone etc., shall be used liberally so as to facilitate
pulling the wires in the conduit, but in no case shall it be greased or coated
with oil or any substance injurious to the insulation of the cables.
b) While connecting to thermocouples, care shall be taken to connect with
proper polarity.
c) Sufficient length of multipair cable will be left extra in the form of loop at
either end.

2.04.02 PrefabricatedCables

Cabling work shall include laying and terminating prefabricated cables between
different equipment.

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a) Necessary special glands, grommets etc. shall be supplied and erected.
b) Prefab cables shall run through cable spreader room on trays. Vertical riser
trays, to support the vertical run of cables from the main trays in cable
spreader room to the panel glanding areas shall be supplied and erected.
c) Cable runs shall be properly identified by engraved aluminum tag plates
fastened to the cable at not more than 10 meter intervals.
d) Cables laid shall not be subjected to tension so as to cause damage to the
conductors or plugs.
e) In cases where the connecting heads/ plugs are supplied loose, Contractor,
after laying the cable, shall solder cable cores and screen ends to
connector pins/ plug-in crimped ends of the cable to the connector plug
socket/crimp-in special connectors for coupling the cable to the plug socket
/ wire wrap the ends to connector pins, as the case may be. Contractor shall
ensure properness of end connection before embarking upon the
termination.
f) Necessary modifications, rework, splitting etc. of the gland plates to
accommodate prefab cables, their glands / grommets shall be performed.
g) Prefab cables shall be routed through special glands/ grommets as
recommended by the manufacturer.

2.04.03 SpecialCables

Category of special cables shall include the cabling work related to the data
highways, ignitor cables, flame scanner cables, proximeter cables, flue gas
analyzer system cables etc. where proprietary cables are supplied as part of
instrument for transmission of low level voltage signals or other signals
susceptible to noise interference.

a) Special cables shall not be laid through trays carrying signals having
voltage level of more than 60 volts AC/DC. As far as practicable special
cables shall be laid through conduits.
b) Minimum separation to be maintained between special cables and other
cables shall be as indicated in the specification, unless specified otherwise
by the supplier of the cable/ instrument.
c) Necessary connectors, lugs, sleeves, conductor markers/ferrules etc. for
termination of special cables shall be supplied by Contractor .
d) Special cables shall not run unsupported for more than 1 meter.
e) Special cables shall run un-spliced for each individual run. J unctions, loops,
bends and long vertical falls shall be avoided to the extent possible.
f) Tools recommended by the cable/instrument supplier shall only be used for
splicing, connecting and terminating special cables.

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g) Where teeing, tapping, looping or branching are required for special or
co-axial cables; only the equipment, tools and tackle recommended by the
manufacturer shall be used.




2.04.04 Conduits

Flexible and rigid conduits shall be used for connecting instruments to the
junction boxes or nearest trays/ sub-trays. The activities shall include threading,
plumbing, routing, supporting, connecting to cabinets; cleaning, sealing
grounding painting and other related activities, as required.

a) Threads shall be cut and cleaned before reaming.
b) Ends of all conduits shall be reamed to remove all burrs and rough edges.
c) Cutting oil shall be used for threading and dies shall be kept sharp.
d) Rigid conduits shall be installed in exposed runs either parallel or
perpendicular to dominating surface, with right angle turns made of
symmetrical bends only.
e) Conduit shall not be installed on the outside face of exposed columns but
shall be routed on the web or on the inside of the flange of column.
f) Metal conduits shall be joined by threaded conduit couplings.
g) A run shall not contain more than the equivalent of four quarter bends
including those immediately at the outlets or fittings of cabinets.
h) Precautions shall be taken to prevent accumulation of water, dirt, concrete,
foreign material etc. in the conduit.
i) Bending radius of the rigid conduits shall not be less than six times the
internal diameter of the conduits.
j) Rigid conduits shall be regularly clamped at intervals of not more than 600
mm.
k) Flexible conduits shall be installed in conduit runs across expansion joints.
l) Screwed joints shall be properly sealed with sealing compound to make
thoroughly water proof.
m) Loop shall be provided in the flexible conduit while joining with rigid conduit,
enclosure or detector. Flexible conduit shall not be kept under tension.
n) Flexible conduits used for connecting instruments or equipment subjected
to vibration, expansion or thermal movement shall be provided with loops
to allow free movement.
o) Not more than 40% of conduit area shall be taken up by cables.

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2.04.05 Subtrays/Supports

Erection of sub-trays / supports shall include sub-tray sections up to the main
trays. In areas where main trays are not available, tray sections shall be laid up to
the master junction boxes/ local panels/ cable spreader areas. Contractor's scope
of work shall include laying and supporting of trays, fabrication of trays wherever
required, painting of trays and supports and associated minor civil work wherever
required.

a) Normally slotted G.I. trays or aluminum trays shall be used.
b) Trays shall be used to run pneumatic tubes and electrical cables and shall
be mounted on steel structures and along the pipe racks wherever
convenient. Stands/supports shall be fabricated wherever required.
c) Erection of trays shall include fabrication, welding and installation of
supports from structurals and installation of tray in position. Trays shall be
bolted to the supports and grounded.
d) Supports shall be welded to the main structures, grouted in the walls/ roof
or welded to the plate inserts. Welding of supports to main equipment/
piping shall not be allowed. Welding or gas cutting of trays shall not be
allowed.
e) The scope of work shall also include the supply, fabrication and fixing of
supports, bends, offsets, corners, tees, crossings etc. as per requirement.
f) Civil / masonry works like grouting, providing inserts, chipping the concrete,
bricks etc. for providing supports etc. shall be included.
g) Contractor shall arrange to provide hangers, jigs, inserts and other fixtures
on walls, ceilings, structures and permanent scaffolding etc., for fixing
racks. Fabrication and fixing of necessary jigs, hangers, inserts and other
fixtures, as required, shall be considered a part of erection of structural steel
work.
h) The trays shall be properly finished and laid to give neat appearance.
i) All supports, clamps and other fixtures shall be painted.
j) All trays carrying SS tubes shall, in general, be vertical type.
k) In dust laden areas, Contractor shall provide covers for trays. The covers
shall be strapped with G.I. strips, nuts and bolts.
l) If any erected tray or its supporting structures are found to be vulnerable to
damage or to be fouling / interfering with other activities in the area, the
same shall be dismantled and re-erected.
m) The decision, whether to use rigid conduit or sub-tray shall be judiciously
decided.

2.04.06 Earthing

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Contractor's scope of work shall include the earthing of all instruments /
equipment, enclosures and other metallic parts and objects. Necessary wires,
lugs, sleeves, markers / ferrules etc. shall be supplied. In addition to the general
guidelines given below, Contractor shall remain responsible to follow the
instrument/equipment manufacturer's grounding recommendation.

a) Screens of cables between instruments to local junction box shall be
terminated to terminal blocks/ copper strips. The instrument end of the
screen shall be left disconnected and taped with adhesive vinyl tape.
Screen terminal blocks at J B end shall be shorted with shorting links. The
screens of cables to cabinets shall be connected to the screen terminal
block in J B and the other end to be grounded at panel end only.
b) Compensating cable screens shall be terminated at independent terminal
blocks in control panel end only. This terminal block shall, however, be
wired up to insulated screen bus bar integral to the panel.
c) J unction boxes, stands, stanchions, local panels, cubicles etc., must be
connected to the nearest riser of electrical earth mat by SWG 10 MS
galvanized steel wire.
d) Control panels, desks, consoles, cubicles, cabinets etc. must be physically
earthed with the electrical ground mat in the control room area.
e) Electrical ground terminals of local instruments shall be individually
terminated up to local junction box by one core of the signal cable and
these terminal blocks shall be shorted by links. The common earth point
then may be led to local earth point by SWG 10 galvanized steel wire.
f) Local panel and central panel instruments shall be grounded to the common
ground bus inside the panel.
g) For terminating grounding wires only ring-tongue type lugs shall be used.
h) Regarding the earthing requirement of power supplies and electronic
equipment, manufacturers recommendation shall be strictly adhered to.
The earthing cables shall be carefully sized not to exceed the specified
earth impedance. Separate salt pit earth and earth risers shall be created
as required.

2.05.00 PIPINGANDTUBING

Instrument piping and tubing work shall include the plumbing work between
take-off valves / nozzles (for air and flue gas connections) and the instrument; the
drain pipings to the drain point; sample pipings from take-off valves to coolers
and coolers to analyzer system either in SWAS panel or in the field with
associated cooling water pipings and drain pipings; instrument air sub-header
installation and testing and tubings between air header/sub-header to different
instruments / consumers.

2.05.01 ImpulsePiping/TubingandAccessories


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a) This section enumerates the basic guidelines for erection of primary
impulse pipings, all associated fittings on primary impulse pipings, pipings
for all instrument drain and vent lines with all associated valves and fittings,
impulse line support and routing with accessories, all impulse line
accessories viz condensing pots, temperature equalizing columns, seal
chambers, settling columns, drain headers etc. connections between
instruments and valves / manifolds and their testing.
b) For impulse piping / tubing routing Contractor shall develop a field routing
sketch.
c) The pipes shall be cut with a hacksaw or high speed cutting emery wheel;
squarely and burrs shall be removed. Roller type tube cutters shall not be
used.
d) Cold bending of the pipes shall be performed with proper pipe bender
forming radius of bends greater than five times the outside diameter of the
pipe/tube. Allowable deformation shall be within 4%.
e) Impulse piping shall be installed with a slope greater than 10% in proper
direction and shall never be installed in level horizontally.
f) Piping shall run with the minimum of changes in direction consistent with
good practice and neat appearance.
g) The bends/ offsets must be smooth and regular. Bending shall not exceed
90 Deg. in any case. Necessary couplings, unions, fittings etc. shall be
provided on impulse lines to facilitate removal and maintenance of
instruments conveniently.
h) No pipe shall be left with strain on it.
i) Drain lines shall be terminated at approved drains only.
j) The total length of impulse piping / tubing between tapping point and
instrument shall, in general, be within 10 meters.
k) Pipes/ tubes and accessories shall be adequately supported and fixed.
Distance between the supports shall not exceed 1.5 meters in any case.
Process piping shall not be used for supporting instrument piping. If
additional structures and scaffoldings etc. are required for proper supporting
of instrument pipes or accessories the same shall be arranged.
l) Contractor shall follow the welding specifications of the main piping for the
instrument piping, as well, wherever applicable. While welding, full care
shall be taken to provide sufficient grounding so as not to damage any part
of the instrument by arc current.
m) Welding of steam piping and high pressure piping shall be carried out by
certified welders only.
n) Pipes installed but not connected, shall have ends closed with caps or plugs
to prevent the entry of foreign material. Reasonable precautions shall be
taken to prevent the entry of foreign materials in pipelines before and during
erection. Drain points, after installation shall be sealed with caps/plugs.

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o) Pipes shall be thoroughly cleaned to remove all foreign materials, scales,
oil, grease etc., before installation after disconnecting the instruments.
p) After testing of steel impulse piping, the same shall be painted.
q) The color coding to be followed for impulse pipes shall be as follows :

Steam (Main and Auxiliary) : Red (IS-5 : 537)
Condensate : Azure Blue (IS-5 : 104)
Feed Water : Sea Green (IS-5 : 247)
Air : Sky Blue (IS-5 : 101)
Flue Gas : Yellow (IS-5 : 356)
Fuel Oil : Brown (IS-5 : 439)
Hot Reheat/Cold Reheat : Orange (IS-5 : 591)

r) Instrument impulse pipe fittings and accessories which shall include but not
limited to brackets, supports, clamps, angle irons/flats shall also be painted
as per the color code above.
s) SS pipes, tubes and fittings need not be painted. Similarly G.I. pipes and
fittings need not be painted.
t) Clamps shall be first painted and then fitted.
u) Surfaces and impulse pipe to be painted shall first be cleaned by wire
brushing and then with emery cloth to remove all rust / dust / grease etc.
After proper cleaning two coats of red-oxide zinc chromate primer
(conforming to IS-2074) / followed by two coats of paint with a D.F.T. of 1
mil shall be applied.
v) For differential pressure instruments, wherever applicable, both the seal
pots / condensate pots shall be brought to the same level.
w) Thread lubricants shall be dry film type. Any of the following compounds
shall be used as pipe thread sealer :

i] Permatex
ii] Molycote
iii] Neolube
iv] Teflon tapes shall not be used as pipe thread sealer.

x) Preferred path for all instrument piping shall be along concrete walls,
ceilings and building steel. Instrument piping may be routed in open areas,
if necessary, provided that the lines are adequately supported and
protected from damage. Instrument piping and piping supports shall not be
supported from electrical raceways or electrical raceway supports, or
process piping.

Piping/Tubing shall not be routed :

i] Across equipment removal areas.
ii] Below monorails or cranes.
iii] Above or below removable gratings.
iv] Above, below, or across cable trays.

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y) Instrument piping shall be installed to permit thermal expansion without
placing excessive stress on the piping and without affecting the slope. Long
continuous straight runs of piping shall be avoided. Where required,
expansion loops shall be provided to take care of thermal expansion.
z) For differential pressure instrument both impulse lines shall run in parallel
and as close as possible.
aa) Impulse pipes shall be subjected to hydraulic test / leakage test at site after
erection.
bb) When carrying out hydraulic test, hydraulic pressure of 1.5 times the
maximum working pressure shall generally be applied. In order to prevent
the instruments from being subjected to testing pressure for long durations,
inlet valves to the instruments shall be kept closed. In case of differential
pressure instruments equalizing valve shall be kept open.
cc) Before using pipes, fittings, isolation valves and manifolds etc. for impulse
line work, the same shall be thoroughly tested. Contractor shall not use any
defective or untested material for impulse line work.
dd) After hydraulic testing of impulse lines, the same shall be completely
drained out and service quality air shall be blown through the pipes to dry
the pipes completely.
ee) For furnace non-pressure parts, wehere root valves may not be provided at
the take-off points, the take-off nozzle shall be sealed with threaded plug.
Contractor's scope of work shall include, removal of the plug, threading of
the impulse pipe to match the take-off with suitable adapters, if necessary.
A vertical rise of not less than 300 mm shall be allowed from the take-off
point to act as a settling column.
ff) Bends on boiler air and flue gas path shall be performed with screwed tees/
crosses with free ends plugged.

Contractor's scope of work shall include the erection of air purging system
for the impulse tubes with all necessary valves and fittings, wherever
required.

2.05.02 SamplePipingsandAccessories

2.05.02.1 Contractors scope of erection of sample and associated piping shall be from the
take-off valves on pipes/vessels to the local sample coolers, where provided by
equipment suppliers and to the sample line bulk head of SWAS panel or
between the sample take-off valves to the locally mounted analyzers; erection of
cooling water piping from nearby cooling water header take-off valves to primary
coolers/ SWAS system drains with the supply and erection of all necessary
mounting plates, fittings, connectors, flanges, adapters, cooling water
sub-headers, drain headers and other accessories.

2.05.02.2 Guidelines above regarding the erection of impulse pipes and tubes shall apply
for sample tubes as well.

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a) Sample piping shall always be installed with a slope of greater than 10% for
proper draining and shall never be installed horizontally.
b) Weldings on stainless steel lines and fittings shall be TIG welding only.
c) Sample piping shall be installed to permit thermal expansion without placing
excessive stress on the piping and without affecting the slope. Long straight
runs of piping shall be avoided. Where required, expansion loops shall be
provided to break up the continuity.
d) Cooling water and drain lines and headers shall be painted Azure blue (IS-5
: 247)

2.05.03 InstrumentAirSubDistributionPiping

Erection of instrument air sub-distribution piping include taking connection from
neareby main air header take-off valves in the vicinity of air consumers viz.
control valves, pneumatic transmitters / controllers, I/P. converters, impulse line
purge connections, power cylinders, purge rotameters etc.

a) Supply and installation of intermediate pipe fittings, isolation valves etc.
including supply and installation of necessary clamps and supports shall be
an integral part of the work.
b) For instrument air sub-header work, carbon steel hot-dipped, inside and
outside galvanized pipes shall be used. Only threaded galvanized fittings of
carbon steel shall be used.
c) Outlets of air headers shall be provided with 1/2" isolation valves, for upto 7
consumers. Contractor shall install air sub-headers up to vicinity of the
consumer and thereafter 6 / 10 mm O.D. tube shall be laid.
d) Sub-headers shall be thoroughly cleaned before installation with
compressed air.
e) Sub-headers, shall be supported properly. The distance between any two
supports shall not exceed one meter unless otherwise required to suit site
condition.
f) Air supply piping shall be installed always with a slope of not less than
1/100 in suitable direction to prevent accumulation of condensed water
within the pipe.
g) J oints in the instrument air header shall be screwed. For size of 1/2" and
below, Teflon sealing tape and for other sizes, good quality sealing
compound shall be used to ensure leak- proofness.
h) Gas cutting and gas or arc welding on all GI pipes shall not be allowed.
i) After completion of air supply piping and prior to connection to the
instruments, the piping shall be blown with oil free and dry compressed air
at 5 to 7 Kg./Sq. cm to clean out dust or foreign matter.

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j) After applying the air pressure, all connections shall be checked for possible
leaks with soap solution and all leaks shall be rectified.
k) Instrument air tubes shall be disconnected from instruments, tube ends
shall be blocked, air at pressure equal to 1.5 times the working pressure
shall be applied and the tubes shall be isolated from the source of pressure.
The pressure shall not fall by more than 0.1 Kg./Sq. cm in ten minutes.

2.05.04 PneumaticTubingsandFittings

Contractor's scope shall include stainless steel or PVC coated copper pneumatic
tubing for the signal and supply air lines with all necessary fittings and air filter
regulators, wherever required.

a) The tubes shall be thoroughly cleaned and flushed with air before
installation and defective tubes detected during checking, if any, shall be
removed.
b) Single tube runs shall be joined together by means of straight connector
(double compression fitting).
c) Individual runs of pneumatic signal tubing shall be routed mostly on tray
work or on steel angles.
d) Tubes shall be run with the minimum changes in direction consistent with
good practice and neat appearances.
e) Tube runs shall be properly dressed, neatly laid and adequately clamped /
supported. Distance between any two supports shall not exceed one meter.
f) Tubes installed but not connected shall have ends suitably capped to
prevent ingress of foreign materials.
g) Tube runs shall be provided with suitable identification tags.
h) Fittings shall be of brass for copper tubes and SS for stainless tubes of
flareless, double compression type.
i) When tightening up the nuts of the compression type fittings, spanner of
suitable size shall be used. To avoid any deformation to the compression
ring, adjustable wrench shall never be used.
j) The bending radius for single tubes shall be more than five times the
outside diameter of the tubes. The tubes shall be bent with proper benders
and care shall be taken not to cause an flattening of the bend.
k) The tubes shall be properly dressed on the trays to remove bends, dents
etc. Tubes shall not be directly hit by steel hammers.
l) Aluminum clamps or self-locking straps shall be used for clamping the tubes
on trays / angles.

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m) When connecting tubings on servo-drives / valves having thermal
movement, sufficient expansion loops shall be formed at the ends to allow
for equipment movement without developing stress.
n) Tubing shall be checked for proper connection and pressure tested by
Contractor in the following manner :

i] All tubes connected to field instruments and control valves shall be
disconnected at the consumer end.
ii] From end fittings, dry dust free air at 5-7 Kg/sq. cm pressure shall be
blown into tubings to check continuity and to blow out dust or foreign
matters from the tubes. Subsequently, connection to the consumer
end shall be made and with 1.5 Kg/sq. cm air pressure, leak test shall
be performed with Soap solution at all joints. If any leak is found, nuts
of compression fittings shall be tightened and soap solution check
shall be repeated. If the leak can not still be remedied, ring of the
fittings shall be replaced and the soap solution test be repeated till the
leak is stopped.
iii] Final testing shall be done by Contractor in the following manner :

The tubes shall be blanked of from one end and pressurized from
the other end pneumatically to 1.5 Kg/sq. cm using bubble bottle.
The bubble rate after pressurizing shall be less than one bubble
per ten minutes.

2.06.00 CONTROLVALVESANDACCESSORIES

Contractor's scope of work shall include erection of control valves along with all
related accessories. Contractor's scope of work shall also include all related
interconnecting tubing work and terminating all electrical connections up to local
junction box. Any supporting structures, pedestals etc. required to make the
installation complete shall be considered part of erection work.

a) The general conditions laid down for erection of field instruments shall also
be valid for control valves (wherever applicable).
b) Slight reorientation of flanges, if necessary, shall be considered a part of
erection activity.
c) Before installation, Contractor shall verify the adequacy and check the
make/model etc. of each item with respect to the data sheet.
d) Control valve should be identified with regard to their tag number, control
action, Cv value, flow direction etc. as inscribed on the tag plate vis-a-vis
the data sheet.
e) The orientation and position of the control valve shall be such that
difficulties shall not arise while removing, repairing or servicing the valve
after installation.
f) Contractor shall install valves only after ensuring proper flow direction.

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g) The preferred position of a control valve is diaphragm up.
h) Air supply line shall be drawn from neareby air header.
i) Tubing work shall generally comprise of tubing between I/P converter to
valve positioner/solenoid valve/actuator, air supply to filter regulator from
nearest G.I. sub-header, filter regulator to positioner/actuator.
j) Contractor's scope of cabling pertaining to control valve erection shall
include cabling from solenoid valves, limit switches and electronic position
transmitter up to local junction box if not wired up to integral junction box.
k) Contractor shall include gaskets, nuts, bolts, site fabricated clamps and
other erection items required to complete the installation.
l) Air pipings/tubings shall be blown clean with compressed air at 3.5 Kg/sq.
cm and complete lines along with fittings must be tested for leakage with
soap bubbles.
m) After installation, the control valves shall be greased at greasing nipples
wherever applicable.
n) After completing the installation satisfactorily in all respect, Contractor shall
perform the following tests.

i] Linearity of stem movement shall be checked at four points (inputs
25%, 50%, 75%, 100% of spring range) while rising and while falling.
ii] Hysteresis shall be checked.
iii] Response time shall be noted.
iv] Operation of airlock relay shall be checked.
v] Operation of stay put conditions (under electrical signal failure shall be
checked).
o) After testing, the valve shall be boxed up with blind gaskets at both ends to
prevent entry of foreign materials and clogging of plug and seat.
p) During steam blowing/acid cleaning it may be necessary to remove the
valve as a hole or in part breaking a part of top-work and reconnect the
spool piece. The removal, reinstallation, dismantling and reconnection of
tubing and cabling shall be under Contractor's scope of work.

2.07.00 FLOWELEMEMTS

2.07.01 OrificePlates

For orifice plates with flange taps Contractor's scope shall include fixing of nipple
and first take-off valve, fixing and supporting condensation pot (wherever
applicable) and insertion of orifice plate with suitable gaskets, nuts and bolts. For
orifice plates with D, D/2 tapping, pipe welded stubs shall be available.


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The general guidelines for installation of orifice plates are given below.

a) The length of the take-off nipples shall be sufficient so that the first take-off
valve protrudes beyond the thermal insulation.
b) The take-off nipples shall be screwed/welded according to the design
requirement.
c) The hand wheel of the take-off valves shall be so oriented that they can be
operated conveniently from approach platform, ladder etc.
d) For steam services, condensation pots shall be connected to the tapping
point before or after first take-off valves. Utmost care shall be taken to
ensure that both the condensation pots are at the same level. All necessary
bracing, saddle etc. shall be fabricated and used to support the
condensation pots with the main pipe.
e) Orifice plates shall be inserted with proper orientation with respect to fluid
flow in line.
f) Orifice plate should only be inserted in position for checking the alignment.
Thereafter, it will be withdrawn and preserved till pre-commissioning
activities are over.
g) Contractor shall supply suitable gaskets while fixing the orifice plates in
position.
h) The orifice bar handle, shall be so oriented that the imprints are readable
unassisted from the access floor of platform.
i) Contractor shall ensure proper orientation of drain or vent holes.

2.07.02 FlowNozzles

Flow Nozzles shall normally be shop assembled in branch pipe and welded in
position with main pipe. The flow nozzles shall generally have D - D/2 tappings
and shall be shop assembled with take-off nipples and root valves. Contractors
scope of work shall include connecting the condensation pots (for steam
services) before installation of the differential pressure instrument.

2.08.00 CONTROLROOMCONTROLPANELS/DESKS,CONSOLES&CUBICLES/CABINETS

This section provides guidelines for the erection of desks, panels, consoles,
cabinets etc, in the Control Room, Control equipment room, Local Control Room
and other such locations.

Clauses above for the installation of Local Panels shall apply.

a) After Inter-sectional bolting with necessary nuts and bolts, inter-sectional
wiring shall be terminated at both ends

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b) Contractor shall arrange anchor bolts or grouting spikes and grout the same
in the pocket. Any civil job concerned with the proper installation of the
panel shall be considered as part of the panel installation work.
c) After installation, the main incoming fuse of each panel section shall be
removed and preserved till commissioning.
d) For panels, desks, consoles etc. supplied without instruments and
accessories mounted on them, Contractor shall mount and terminate all
instruments & desk accessories as per drawing. Contractor shall also dress
& bunch the cables properly after termination is over.
e) If Solid state panels /desks/ consoles/ cubicles are supplied without the
electronic PCB's plug-in modules etc. mounted on them, Contractor's
responsibility shall include inserting these in position as per drawings. This
activity shall be carried out only after complete installation of the
panel/cubicles.

f) After installation the following tests shall be carried out.

i] Visual inspection for proper alignment and inter- sectional crevices.
ii] Meggering shall be done between terminal blocks and ground before
terminating the panel instruments.
iii] Visual inspection of surface finish for scratches & blemishes.
iv] Tightness of nuts and bolts to be physically checked.
v] Dressing and bunching to internal wires after termination to panel
instruments.

2.08.01 Common Control Room / Computer Room Panels/ Desks and Consoles/ Local Control
Panels/consolesandDesks

Contractor's scope of work shall include the installation of Operator's Terminals,
Engineering Terminals, Servers, Network cabinets, Performance Calculation
Terminals and other terminals, consoles and some other peripheral devices in the
Common Control Room / Computer Room/ Local Control room wherever
applicable. Associated activities shall include laying, glanding and terminating
prefabricated cables, related structural work and other completing activities viz.
modification of internal wirings, mounting and termination of instruments /
equipment supplied loose etc.

a) Erection of panels and desks in Control room area shall involve precise
alignment and matching of surfaces. Contractor shall perform related
activities to achieve an aesthetic completion of the job. Necessary
realignment, foundation work, packing and filling shall be done to
compensate for shifting, waviness, misalignment etc.
b) When bolting the panel sections, care shall be taken not to leave excessive
strain on any of the surfaces. All necessary packing and filling materials
shall be provided.

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c) Instruments and accessories supplied loose for mounting on panels shall be
installed only after installation of the panels.
d) Tools and tackle recommended by the desk/panel/console manufacturer
shall only be used.
e) No element shall be forced or hammered into its slot.
f) If matching prefab connectors are available in pig-tail form the properness
of connection shall be checked by Contractor before plugging-in. Contractor
shall be fully responsible for improper connection of the connectors.
g) Contractor's activities shall also include splitting of gland plates, if required,
to admit plug-in connector, mounting of special cable clamps on the gland
plates and dressing, routing and clamping of the prefabs within the
panel/desk/ console.

2.08.02 ControlEquipmentRoomPanels/Cubicles

Contractor's scope of work shall include installation of Control equipment room
(CER) panels, cubicles and consoles and peripherals like console, printers etc.,
laying and interconnection of prefab cables, conduits and trays as required. Floor
cutouts shall be provided for cable entry.

a) Contractor shall generally follow the guidelines for installation as laid down
in previous sections.

b) Some of the panel sections may arrive in connected and pre- wired
conditions. Contractor may have to disconnect these sections for
transportation, rigging and installation. Reassembly of such sections,
however, shall be Contractor's responsibility.


2.08.03 Steam&WaterAnalysisSystemPanels

The steam and water analysis system with all associated accessories shall be
located in the SWAS room.

a) Some of the primary coolers may be located at site and shall serve as grab
sample coolers during commissioning.
b) Reagents required for commissioning shall be supplied.
c) Contractor's scope of calibration and functional checking shall include the
adjustments for the primary coolers, calibration of the analyzer - converter
units and other associated activities.
d) Analyzers shall be tested separately, as per manufacturer's
recommendation with the help of standard solutions.
e) It is recommended that the standard solutions be fed to the analyzer
through a sample patch board by-passing all sample-line accessories.

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f) Measuring cells and other wetted parts which comes into the contact with
standard solutions shall be thoroughly rinsed before commissioning.
g) In view of large drift of most of the analyzers and limited life of the reagents,
it is recommended that calibration and functional checking activity for the
analyzers be performed immediately prior to commissioning.
h) Contractor's scope of work shall also include laying and connecting of all
drain headers (sample drain, cooling water drain, grab sample basin drain
etc.) up to nearest system drain.
i) After installation of pre-tubed panels Contractor shall check all connectors,
pipe/tube fittings and anchoring of panel mounted equipments.
j) Tubing and bulk head connectors inside the panel shall be blown clean with
air at 3.5 Kg./Sq. cm.
k) Any tubing work inside the panel shall be done, if necessary.
l) Laying of air sub-header, if required, from nearest take-off point in main
header up to SWAS room shall be as a part of Contractor's responsibility.
m) Contractor shall also be responsible for mounting all loose supply
instrument/equipment in the SWAS panels. Instruments in the panel shall
be mounted & terminated in accordance to the guidelines as specified
elsewhere in this specifications.

2.08.04 LVS,CCTV,MasterClocketc.

a) All items must be unpacked at installation site only.
b) Contractor shall follow the general guidelines for installation of the blind
panels as spelt out in previous sections.
c) All un-armored prefab cables shall run through flexible/rigid conduits and all
conduiting and tray laying shall be considered to be a part of Contractor's
scope of work.
d) Installation of Close Circuit TV Camera System at different locations of the
Plant are Contractors scope. This also includes supply of all installation
hardware as required to complete the installation.
e) Installation and commissioning of large Video Screen in the control room is
under Contractors scope of work. This includes supply laying and
termination of all interconnecting cables to complete the installation.
f) Installation of Plant master Clock and its Display devices at different
locations are under Contractors scope of work. This includes supply of all
mounting hardware and accessories, laying and termination of all
interconnecting cables and other accessories to make the installation
complete.

2.09.00 PANELMOUNTEDINSTRUMENTS(FORLOCALPANEL,WHEREVERAPPLICABLE)


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a) Before erection all instruments & accessories shall be subjected to visual
and calibration checks and other functional checks as per manufacturer's
standard at site laboratory.
b) All instruments, jigs, tools and tackle for the purpose of performing the tests
shall be provided by Contractor.
c) Minor repairs, adjustments of the instruments & accessories shall be
performed. Once the instrument has been successfully repaired it shall be
subjected to test, afresh.
d) A record of such repairs and adjustments shall be systematically
maintained.
e) For instruments & accessories where the extent of damage is such that the
same can not be repaired at site the same shall be brought to the notice of
Owner by Contractor as early as possible for appropriate action.
f) Cases where the damages are only superficial viz. cover warping or paints
peeling etc., the decision whether such instruments are fit for erection shall
solely lie with Owner.
g) If any erected instrument or its accessories are found to be vulnerable to
damage or to be fouling/interfering with progress of other activities in the
area, same shall be dismantled/removed.
h) During re-erection of such instruments, all the necessary steps as indicated
in this specification for the erection of the instrument shall be carried out
afresh.
i) Contractor shall take utmost care during removal/dismantling as not to
damage the instrument, its accessories, support or any other equipment in
the vicinity.
j) Completion of erection of any panel mounted instrument or accessory shall
be signified by its mounting, fixing, termination, power connection, earthing,
touch-up painting, tagging of the instrument and mounting of its title plate.
k) On completion of erection, a certificate signifying Owner's approval to
erection, in an agreed proforma, shall be obtained from Owner after joint
inspection of the erected instrument by Owner and Contractor.
l) After containing the completion certificate, all power line fuses of
instruments shall be removed by Contractor and shall be kept in his custody
only to be reinserted when directed by Owner.

2.10.00 INSTRUMENTLABORATORY

Contractor shall set up a site test laboratory for erection, testing, commissioning
and maintenance upto handing over of the plant to owner. All necessary work like
plumbing, tubing, wiring, grouting, leveling and other associated work shall be
done by Contractor.


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a) The shop shall be complete with all testing and calibrating equipment /kit,
special tools and tackle required for the systems supplied.
b) Laboratory shall have the complete arrangement, which shall not be limited
to the following :

i) Air header up to the laboratory from nearest instrument air header.
i) Distribution of instrument air up to pneumatic test benches.
ii) Internal wiring for distributing voltages of various levels (240V AC, 24V
DC, 220V DC etc.).
iii) Grouting, levelling and proper alignment of test benches, jigs, vacuum
pumps etc. Grouting bolts may have to be provided by Contractor.
iv) pneumatic test bench complete with air supply distribution points along
with necessary fittings and valves.
v) Erection of electrical/electronic test bench complete with power supply
distribution system with switch/fuse units.
vi) Mounting of accessories like gauge clamps, air filter regulator, test
gauges etc. on pneumatic test bench.

c) Workmanship inside the laboratory shall be in accordance with specified
engineering practices and specified standards for the type of work. Work
shall be done in approved manner, taking care of location and alignment of
various instruments/ equipment to facilitate unhindered operation.


3.00.00 CONSUMABLE, TOOLS AND TACKLE, CALIBRATION AND TEST, INSTRUMENTS AND
ERECTIONMATERIALS

Contractor shall be responsible to arrange for supply any other equipments/ tools
& tackle or consumable that may be required for satisfactory completion of the
job.

Necessary tools & tackle/equipment that may be required for erection/
installation/testing shall be provided.

Necessary tools & tackle, jig, instruments/equipments that may be required for
loop checking, calibrating and commissioning shall be arranged.

The items listed below are indicative in nature. Any other items that may be
required shall also be arranged by Contractor at his own cost

i) Precision calibration standard mercury manometers of accuracy
0.02% of full scale.
ii) Portable pneumatic calibrators of accuracy 0.1% of full scale.
iii) Sub-standard test gauges of accuracy 0.1% of full scale.
iv) Dead weight testers of accuracy 0.05% of measured pressure.

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v) Hydraulic gauge testers of accuracy of 0.1 of measured
pressure.
vi) D.C. potentiometers of accuracy 0.1%
vii) Wheatstone bridge of accuracy 0.1%
viii) Decade Resistance Boxes of accuracy 0.1%.
ix) Multimeters of accuracy 2%
x) Temperature Bath
xi) Line testers
xii) Telephone sets with battery
xiii) Oscilloscope (Dual trace, 75 Hz)
xiv) Signal generator
xv) mV generator
xvi) Bench top power supply (0-30 VDC, 10A) - 4 nos. at least
xvii) Special testing/calibration kit for electronic panel mounted receiver
instruments e.g. indicators, recorders etc.
xviii) Metal film resistor (100 Ohms, 250 Ohms, 62.5 Ohms of 0.1%
tolerance).
xix) Rules generator, logic probes and other digital test instruments
xx) Stop watch
xxi) Variac (0-260 VAC continuous output)
xxii) Solder suckers and IC extractors.
xxiii) Multifunction calibrators.
xxiv) RTD / Thermocouple Calibrator.
xxv) Electronic transmitter Calibrator.
xxvi) Continuity Tester.
xxvii) Electronic Meggar.


4.00.00 INSTRUMENTCALIBRATION/CHECKINGATSITEPRIORTOERECTION

The general guidelines for calibration and functional checking of instruments and
accessories are as given below :
a) For calibration and functional checking of different types of instruments,
check lists shall be prepared. The results and observations of checks and
tests shall be recorded in appropriate forms.
b) Qualified and experienced engineers, supervisors and skilled technicians
shall be deployed for calibration and functional checking of instruments.
c) Only precision testing instruments of certified accuracy specially made for
testing particular make/type of instruments shall be used for calibration and
functional checking of instruments.
d) Physical checking of the instruments shall be carried out to find out any
possible damage to the instruments.
e) Instruments requiring calibration shall be calibrated, in general, throughout
the instrument range at five check points viz. 0%, 25%, 50%, 75% & 100%
of span, both upscale run and downscale run. The error between
theoretical and calibration figures thus obtained at each check point shall
not exceed the instrument manufacturer's stated figures. If the error

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exceeds the limits specified by the manufacturer, the instruments shall be
adjusted to achieve calibration accuracy within the specified limits.
f) Regarding the calibration and functional checking of special instruments,
the instruction of the manufacturer shall be followed.

4.01.00 PRESSURE/DPGAUGES

4.01.01 Calibration for pressure / DP gauges shall be carried out with dead weight
testers/ hydraulic testers / vacuum pumps against manometers / precision
manometers/sub-standard gauges of certified accuracy.
4.01.02 Test results shall be presented to indicate accuracy, hysteresis and linearity.
4.01.03 Gauges shall be subjected to over-range test as per manufacturer's
recommendation. Gauges shall be recalibrated after over-range test.
4.01.04 Gauges for compressed air service shall be tested with air compressor and
sub-standard gauges.
4.01.05 Low pressure/dp gauges shall be tested with compressed air test jigs and
sub-standard gauges.

4.02.00 PRESSURE/DPSWITCHES

4.02.01 Pressure / DP switches shall be tested for adjustability and repeatability of set
point by means of dead weight tester / hydraulic testers / vacuum pumps against
manometers/precision manometers / sub-standard gauges of certified accuracy.
4.02.02 Exact operating point of the switches shall be identified by means of a multimeter
or any appropriate instrument.
4.02.03 For switches having adjustable differential, the differential shall be maintained
fixed during the test.
4.02.04 Test results shall be presented to indicate linearity and differential.
4.02.05 Switches shall be subjected to over-range and contact rating test. Switches shall
be recalibrated after over-range test.
4.02.06 Switches for compressed air service shall be tested with air compressor test jigs
and sub-standard gauges. Low pressure/dp gauges shall be tested with
compressed air and sub-standard gauges.
4.02.07 The switches shall be set at the desired set point after calibration. Where set
points are not available at the time of erection, the same shall be set in site, after
erection, by means of compressed air/hydraulic hand jack and sub- standard
gauges through the instrument drain connection after closing the instrument root
valve.

4.03.00 TEMPERATUREGAUGES


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4.03.01 Temperature gauges shall be calibrated in controlled temperature oven with the
help of standard laboratory thermometer of certified accuracy in addition to check
ambient temperature reading.
4.03.02 Zeroing of the gauges shall be done separately by means of ice bath.
4.03.03 Test results shall be presented to indicate accuracy, hysteresis and linearity.

4.04.00 TEMPERATURESWITCH

4.04.01 Temperature switches shall be calibrated in controlled temperature oven with the
help of standard laboratory thermometer of certified accuracy in addition to check
ambient temperature reading.
4.04.02 Switches shall be set at known set point after testing for repeatability and
hysteresis as mentioned above. Differential, if adjustable, shall be kept fixed.
4.04.03 Set point and differential shall be adjusted as per Engineering data.
4.04.04 Temperature switches shall be set prior to installations. However, in situ setting
may be necessary during commissioning by comparison with other gauges on the
line.

4.05.00 TEMPERATUREELEMENTS

4.05.01 Temperature elements shall be tested for continuity from their terminals at
element head.
4.05.02 Temperature elements shall be ungrounded and duplex type. Both the elements
shall be checked for continuity.
4.05.03 I.R. shall be measured between individual elements and between element and
thermowell.
4.05.04 In general, thermocouples and RTD's will be factory tested. However, in case of
any malfunction while loop testing, an element may have to be tested for linearity
and accuracy at Contractor's shop.
4.05.05 Thermocouple & RTD will be tested in temperature controlled bath at several
temperature (depending on the type of T/C or RTD) points with digital milli-
voltmeter / Thermocouple or RTD calibrator. The results thus obtained must be
compared with standard table as per ASME / DIN.

4.06.00 ELECTRONICPRESSUREANDDIFFERENTIALPRESSURETRANSMITTER

4.06.01 Calibration of electronic transmitters will be carried out with dead weight tester or
hydraulic tester with sub-standard gauges or multifunction calibrator. The output
(4-20 mA) shall be checked with standard DMM at five different points throughout
the specified range including zero and span with rising and falling input. Power
supply to the transmitter receiver 2-wire loop should be given from 24V DC
source in the Analog Input Card and the series load should be around 600 Ohms.

4.06.02 Following performance data should be calculated from observed input-output
data and should be presented in agreed proforma.

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a) Accuracy
b) Hysteresis
c) Dead band
d) Repeatability
e) Linearity

4.06.03 Transmitter shall always be calibrated in vertical position rigidly fixed to a suitable
jig.
4.06.04 It may be necessary to recalibrate the zero while commissioning by equalizing
the ports of dp transmitters or opening input port of pressure transmitters to
atmosphere.
4.06.05 Electrical tests shall include supply voltage sensitivity, short circuit proofness and
maximum loading in sample cases.

4.07.00 LEVELSWITCH

4.07.01 Level switch shall be functionally checked by operating the float mechanically and
hydraulically and testing the make and break of the switches with ohmmeter or
continuity tester.

4.07.02 Contractor shall also be responsible for checking the current rating of the
contacts.

4.08.00 CONTROLVALVES

4.08.01 Valves shall be lubricated (if required), stroked and checked for hysteresis.
Alignment of valve positioners shall be checked. Connection and operation of
solenoid valves and air lock relays (if provided) shall also be checked.
4.08.02 Action of actuator shall be checked by applying spring range pressure through air
filter regulator / multifunction calibrator and observing the stem travel against a
scale.
4.08.03 The position transmitter output scale shall be read with a 4-20 mA calibrator
capable of powering the transmitter with 24V DC supply. Necessary adjustment
of zero and span shall be Contractor's responsibility.
4.08.04 Contractor shall also check the function and adjustability limit switches.

4.09.00 FLUEGASOXYGENANALYZERS

4.09.01 Zirconium probe type oxygen analyzers shall be calibrated in situ with the aid of
two-point automatic calibration kit and reference gas cylinders.
4.09.02 Test procedure available in the manufacturer's catalogue shall be followed.
4.09.03 Prior to calibration all air and gas lines shall be tested for leakage and air
tightness and all electrical connections are to be checked for properness.
4.09.04 Reference gases shall approximately have 0.4 and 8 percent Oxygen.

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4.09.05 Sample and air flow regulators shall be preset to recommended settings prior to
the test.
4.09.06 Probes shall be purged for at least 30 seconds with instrument quality air
between introduction of successive test gases.
4.09.07 The action of the temperature controller shall be checked prior to the test.

4.10.00 SPECIALINSTRUMENTS

4.10.01 The category of special instruments shall include flue gas CO, SOx and NOx
analyzers, opacity monitors, conductivity type drum level indicators/ converters
etc.

4.10.02 The test procedure for such instruments shall be guided by the recommendation
of the respective manufacturers.



5.00.00 EXAMINATIONSAFTERINSTALLATION

5.00.01 On completion of erection of the equipment and before start-up, each item of the
equipment shall be thoroughly cleaned and inspected by Contractor for
correctness and completeness of installation and acceptability for start-up,
leading to initial pre-commissioning tests at Site. The list of pre-commissioning
tests to be performed shall be as mutually agreed and included in Contractor's
quality assurance program.

5.00.02 Contractor's commissioning / start-up engineers shall be responsible for carrying
out all the pre-commissioning tests. On completion of inspection, checking and
after the pre-commissioning tests are satisfactorily over, the complete equipment
shall be placed on Initial Operation during which period the complete equipment
shall be operated integral with sub-systems and supporting equipments.

5.00.03 All insulated conductors furnished and installed shall be electrically tested after
installation.

5.00.04 All circuits shall be tested complete except for connections at equipment end.

5.01.00 CONTINUITY,IDENTIFICATIONANDSHORTCIRCUITTESTS

All insulated conductors shall be tested for continuity and conductor identification.
In addition, all insulated conductors of multi-conductor cable shall be tested for
short circuit. Short circuit tests shall include all tests necessary to confirm that no
conductor of a multi-conductor cable is short circuited to another conductor in that
cable.

5.02.00 INSULATIONTESTS

All insulated conductors shall be tested with a 500 volt megger or an equivalent
testing device. Insulation resistance measurements shall be made between each
conductor and ground and between each conductor and all other conductors of
the same circuit . Minimum acceptance resistance values shall be 10,000,000
ohms.

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5.03.00 TESTING

5.03.01 Tests shall be performed as may times as necessary to assure proper quality of
materials and workmanship. If any tests reveal unsatisfactory materials or
workmanship, such materials or installation shall be repaired or replaced.

5.03.02 All hydrostatic and pneumatic testing shall conform to ANSI B 31.1 - Code for
Pressure Piping, Paragraph 137.

5.04.00 HYDROSTATICTESTING

5.04.01 All instrument piping which connects to process piping shall be hydrostatically
tested. The specified test pressure shall be applied to the instrument piping upon
completion of erection.

5.04.02 Before the leak tests are performed all instrument piping welds and screwed
connections shall be inspected and all air expelled from the piping being
hydrostatically tested. Welds shall be visually inspected for defects and screwed
connections shall be inspected for tightness.

5.04.03 Leak tests shall be performed using cold water to pressurize the systems. The
adverse effects upon test results caused by air pockets shall be avoided by
expelling all of the air from the system during filling.

Tests shall be made by one of the two following methods :

a) Isolate the instrument piping from the instrument and the process piping by
disconnecting the flexible connection from the instrument and closing the
root valve(s). Fill and pressurize the instrument piping through the flexible
connection.

b) Coordinate testing of instrument piping with the testing of associated
process piping. Isolate the instrument by closing the shut off valve and
disconnecting the flexible connection from the instrument. Test the
instrument piping by opening root valve(s) and visually inspecting the
instrument piping for leaks. Special precautions shall be exercised by
Contractor to avoid damage to instruments and conflict with others
performing the process piping hydrostatic tests.

5.05.00 AIRTESTING

5.05.01 All control air headers, branches and short tubing drops and all pneumatic signal
tubing shall be air tested as specified herein. Additionally, all boiler draft and all
vacuum instrument piping shall be air tested as specified herein.
5.05.02 All control air headers and instrument supply takeoffs shall be blown out with
clean dry air using full receiver air pressure. Larger headers shall be blown first,
using full size valves. Smaller headers and takeoffs shall be blown last. All
supply headers shall be blown before any instrument connected to the header
system is turned on. Instrument air headers and branch lines shall be tested by
the pressure decay method.

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5.05.03 Flexible hoses and short signal tubing runs between adjacent components shall
be tested at normal operating pressure by visually inspecting for leaks using a
commercial leak detection fluid. Long signal tubing runs shall be tested by
charging each tube with air at 2 Kg/Sq. cm through a bubbler sight glass. Tubing
shall be isolated from associated instruments with all open ends plugged.
5.05.04 Boiler draft and all vacuum instrument piping shall be tested by the same method
as long signal tubing runs above except that the boiler draft tap root valve shall
be closed in each case and the instrument piping shall be charged from the
flexible connection at the instrument. Close shutoff valves to any permanently
installed purge meters. Special considerations shall be given to multiple
instruments sharing the same process connection or signal source. The
Pressures applied shall not in any case exceed the allowable pressure rating of
any connected devices which cannot be isolated.



6.00.00 PROTECTION DURING MANUFACTURE, TRANSPORTATION AND STORAGE BEFORE
ERECTION

This section provides specialprecautions,protection&care to be taken for delicate
electronic items and supplements the general guidelines provided in the
specification.

6.01.00 PROTECTION

a) Coated surfaces shall be protected against abrasion, impact, discoloration
and any other damages. All exposed threaded portions shall be suitably
protected with either a metallic or non-metallic protecting device. Ends of
valves and conduit shall be sealed with suitable devices to protect them from
damage. The parts which are likely to get rusted due to exposure to
weather, should be properly treated and protected in a suitable manner.

b) Exposed metallic surfaces subject to corrosion shall be protected by shop
application of suitable coatings. The surfaces that are to be finish painted
after installation or require corrosion protection until installation, shall be
shop painted with at least two coats of primer.

c) Special high temperature primer shall be used on surfaces exposed to
temperature higher than 95C.

6.01.01 ProtectiveGuards

Suitable guards shall be provided for protection of personnel and delicate
instrument. All such guards shall be designed for easy installation and removal
for maintenance.

6.02.00 STORING

6.02.01 Stored equipment and materials shall be adequately supported and protected to
prevent damage.

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6.02.02 Stored equipment and materials shall not be allowed to contact the ground in
ware houses that do not have dry concrete or suspended floors, material and
equipment shall be stored on platforms or shoring.
6.02.03 Strip heaters and similar heating devices shall be energized immediately upon
placement of the equipment in storage.
6.02.04 Mechanical dehydrators provided in control panels shall be maintained in
operation from the date of receipt of equipment.

6.03.00 DEFECTS

6.03.01 All defects in erection shall be corrected. The dismantling and reassembly to
remove defective parts, replace parts, or make adjustments shall be included as
a part of the work.

6.03.02 The removal of control and instrument equipment in order to allow bench
calibration, if required, and the reinstallation of said equipment after calibration
shall also be included as a part of the work under these specifications.


7.00.00 QUALITYASSURANCESERVICES

This section outlines, in general terms, the inspection, testing and QA/QC
procedures to be adhered to with suitable check-points for Owner's intervention
for Control & Instrumentation items. The general conditions outlined elsewhere in
the specification over and above. The special requirements furnished below.

7.01.00 QUALITYASSURANCEPROGRAM

7.01.01 To ensure that the equipment and services of Control & Instrumentation items
under the scope of this Contract, whether manufactured or assembled within
Contractor's works or at his Sub-contractor's premises or at the site or at any
other place of work, are in accordance with the specification, Contractor shall
adapt suitable quality assurance program to ensure proper quality and
workmanship at all points. A quality assurance program of Contractor for Control
& Instrumentation items shall generally cover the following :

a) Organization structure for the management and implementation of proposed
quality assurance program.
b) Documentation control system.
c) Qualification and experience data of his key personnel.
d) The procedure for Purchase of materials, parts, components and selection
of Sub-contractor's services including vendor analysis, source inspection,
incoming raw material inspection, verification of materials purchased etc.
e) System for shop manufacturing and site erection controls including process
controls and fabrication and assembly controls.
f) Control of non-conforming items and system for corrective actions.

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g) Inspection and test procedure both for manufacture and field activities.
h) Control of calibration and testing of control, measuring and testing
instruments/systems.
i) System for indication and appraisal of inspection status.
j) System for quality audits.
k) System for handling, storage and delivery.
l) Item/System-wise QA/QC and inspection flow charts clearly identifying the
check-points of three types
Where in-house checks will be performed
Where in-house test reports will be submitted for Owner's approval
Where Owner's inspection is necessary
m) System for authorizing release of manufactured product.
n) System for maintenance of records, and
o) A quality plan detailing out the specific quality control procedure adopted for
controlling the quality characteristics relevant to each item of
equipment/component furnished.

7.02.00 QUALITYASSURANCEDOCUMENTATION

7.02.01 Contractor shall be required to submit the following Quality Assurance
Documents well ahead of dispatch of the equipment :

a) All non-destructive calibration, testing , examination procedures and repair
procedure actually used during fabrication.
b) The inspection plan with verification, inspection plan check- points,
verification sketches (if used) and methods used to verify that the inspection
were performed satisfactorily.
c) Factory test results for testing required as per applicable codes and
standards.

7.02.02 Owner shall have access to the works of Contractor and Sub-contractor at all
times for the purpose of carrying out system audits, conducting quality
surveillance, witnessing of tests and inspections etc.

7.02.03 Owner or his authorized representative may periodically check the work and
Contractor's method of operation to assure that quality control practices are being
followed. At the time of Owner's visit, all quality documentation pertaining to test,
qualifications, inspections etc., shall, upon request, be made readily available.

7.02.04 All reports of tests and inspections as per Quality Control Practices and Quality
Plans shall be made available to Owner on demand.

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7.02.05 Contractor shall prepare quality plan in two sections, one for quality control at
shop and the other for quality control at site.

7.02.06 Testing/inspection procedures as detailed herein gives a basic program to be
followed and is in no way comprehensive or complete. Any other inspection
stages not mentioned in these clauses but required as per Contractor's quality
assurance program shall included. Any tests necessary from operation, safety
and reliability point of view shall also be included.

7.02.07 These procedures shall include all checks/tests conducted at site for
preservation, pre-assembly, alignment, positioning of equipment, foundation
preparation, grouting, welding/bolting, heat treatment, non-destructive
examination, hydraulic test, performance tests, etc.


7.03.00 SHOPTEST

7.03.01 Shop tests shall include all tests to be carried out at Contractor's works, at works
of his sub-contractor and at works where material used for production of the
equipment is manufactured.

7.03.02 Individual components, instruments and devices furnished in accordance with
specification shall be shop tested by manufacturer prior to shipment. The tests
and test certificates shall be in accordance with the agreed QA program.

7.03.03 Such tests shall include electrical, mechanical, performance and hydraulic tests in
accordance with relevant standards called for in the specifications to ensure that
the plant being supplied fulfills the requirement of the specifications. Equipment
not covered by any approved standards shall be tested in accordance with
Contractor's quality control program.

7.03.04 All material shall be of tested quality, supported with duly correlated test
certificates and wherever called upon by the Indian Boilers Regulations or by the
design code, the test pieces shall be prepared and tested as per such
regulation/code.

7.04.00 SITETEST

7.04.01 Site tests shall include but not be limited to calibration, pre-commissioning trials,
start-up trials, trial operation and performance guarantee test.

7.04.02 Contractor shall provide all required test equipment and simulation devices of
reputed make, of required accuracy class and recently calibrated by some
appropriate authority.


8.00.00 INSPECTIONANDTESTING

8.00.01 GeneralRequirements

a) Equipment furnished under this specification shall be subject to test by
quality assurance personnel of Contractor and Owner during manufacture,
erection and on completion at specific agreed hold points.

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b) Contractor shall conduct all necessary shop and site tests and maintain
proper records to fully meet the following requirements.
c) Demonstrate to Owner's satisfaction that each equipment/sub-system fully
meet all functional, parametric and other requirement of this specification
and Owner's approved drawings/documents under all operating regimes.
d) All applicable requirements of latest revised edition of I.S.A. Recommended
practice MC-55.1 - 1982/ANSI MC 8.1-1975 regarding hardware testing of
Digital process computers shall be fully met.
e) All applicable tests shall be performed in accordance with the latest
revisions of pertinent codes of ANSI, ISA and other applicable codes and
standards. For equipment not covered by these codes, Bidder shall apply
his standard shop and site testing procedures subject to Owner's approval.
f) Contractor shall prepare detailed shop and site "Draft Quality Assurance
Program" to fully meet the requirements of this specification. The document
shall cover the following :

Quality assurance and testing procedures from component inspection
stage up to final acceptance test at site.
Formats for recording calibration/test results.
Formats for test reports.
Specifications of test equipment proposed to be used for shop and site
tests.

g) The above "Draft Quality Assurance Program" shall be reviewed by Owner.
The "Quality Assurance Program" as approved by Owner shall be used for
conducting all shop and site tests.

h) Additionally all standard quality assurance procedures of Contractor shall
also be followed to ensure proper quality of equipment and compliance with
specification requirements.

8.00.02 ShopTests

a) Contractor shall maintain proper records duly signed by authorized quality
assurance personnel regarding all stage inspections, tests on individual
equipment/sub-system/systems which are conducted by Contractor as per
his standard procedure as well as those conducted to meet the requirements
of his specification and Owner's approved "Quality Assurance Program".
These records shall be made available to Owner during Acceptance Test.

b) Contractor shall provide a complete factory test report of the system
hardware and software.

8.01.00 FUNCTIONALANDPREACCEPTANCETEST

The authorized quality assurance personnel of Contractor shall conduct all tests
as per the requirements of approved quality assurance program and fully satisfy
compliance with specification requirements by all equipment / sub-systems and
the system as a whole before sending notification for Acceptance test to Owner.

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Contractor shall maintain accurate records for all pre- acceptance test which shall
be properly documented and duly certified documents shall be furnished to
Owner at least one month prior to Factory Acceptance Test.


8.01.01 Inputoutputwiringcheck(forsystemcabinets,relaycabinetsetc.)

a) Contractor shall conduct a point by point wiring continuity check to every
input and output and verify that the wiring connections agree with
documentation. The test shall be performed by connecting a controlled
signal to each input point in sequence. One point at a time, the wiring of all
outputs shall be checked.

b) Upon completion of point wiring checkout, Contractor shall conduct a system
operational test employing static signals over the range of input signal.
Appropriate static signals simulating each input shall be applied, scanned,
processed, printed etc. as directed by the program. Signal strength shall be
varied in order to check alarm functions and output fidelity. Simulation shall
include testing of all specified system functions and operation. All
calculations and conversions shall be verified against pre-calculated results.

c) Calibration of outputs shall be individually tested for the quality and range
over the period of not less than ten days (i.e. 240 hours) after completion of
debugging, in order to confirm system stability and accuracy and to detect
faulty programming, operation and components.

8.01.02 SpecialTestsforSolidStateEquipment

All solid state equipment shall be subjected to Burn-in & Elevated temperature
test, surge protection test and electromagnetic interference test.

8.01.03 TestforClosedLoopControlSystem

a) Closed loop control system furnished as per this specification shall be
subject to shop and site tests as per the requirements of this specification,
applicable codes and Owner approved Quality Assurance Program so as to
demonstrate to Owner, that the equipment furnished by Contractor meets
the intent and requirements of this specification. These tests shall include
but not be limited to the tests indicated in the subsequent clauses.

b) Control systems shall be factory tested for circuit continuity and direction of
the response. The components to be tested shall include all controllers,
stations, other system modules, alarm contacts and multi-conductor
inter-connecting cables. The tests shall be performed with all of the system
components connected to form a complete system with the exception of field
instrument. The tests shall include a means of confirming the mathematical
design response of the control system by simulating changes in system
inputs. The tests shall be a qualitative functional test of each component of
the control system which simulates dynamic inputs and monitors system
outputs.

c) Control loops shall be factory tested using closed loop mathematical
simulating techniques. Control loops typically to be tested by the closed
loop methods are :

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i) Master coordinated control
ii) Firing rate control (fuel and air flow control).
iii) Furnace draft control

d) The input simulation equipment shall be designed to produce effects from
control system outputs based on mathematical model of the predicted
performance and process dynamics of the main unit equipment. The control
constants of various control loop components shall be adjusted to produce a
stable and optimum simulation equipment.

e) Simulation data, including factory adjustment of control system constants
and simulation equations shall be tabulated and shall be made available by
Contractor for Owner's use during field check and start-up.

f) Bidder shall state in his proposal, the availability of equipment for a
simulated type test for automatic control loop specified herein, with a
detailed description of testing methods utilized.

g) Bidder shall furnish details of test procedures and copies of test results
conducted for a similar fossil fired unit.

8.01.04 TestsforFieldInstrumentsandDevices

The shop test for all field instruments, control actuators and devices shall include
electrical, mechanical, performance and hydraulic tests in accordance with
relevant IS, IBR or any other relevant approved standard or any other tests called
for by Owner approved Quality Assurance Program.

8.01.05 NotificationforAcceptanceTestatShop

a) Owner, his duly authorized representative and/or an outside inspection
agency acting on behalf of Owner shall have access at all reasonable times
to inspect and examine the material and workmanship of the works during its
manufacture of erection and if part of the works is being manufactured or
assembled on other premises or works.
b) Contractor shall give Owner/Inspector written notice of any material being
ready for testing.

c) Owner or Inspector shall within fifteen (15) days from the date of
inspections, as notified by Contractor give notice in writing to Contractor of
any objection to any drawings and if any equipment and proposed
workmanship which in his opinion is not in accordance with the Contract.
Contractor's shall give due consideration to such objections and shall either
make the modifications that may be necessary to meet the said objection or
shall inform in writing to Owner/Inspector giving reasons therein, that no
modifications are necessary to comply with the Contract.
d) The completion of these tests or the issue of the certificate shall not bind
Owner to accept the equipment should it, on further tests after erection, be
found not to comply with the Contract.

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e) The inspection by Owner and issue of inspection certificate thereon shall in
no way limit the liabilities and responsibilities of Contractor in respect of the
agreed quality assurance program forming a part of the Contract.
f) Contractor shall furnish copies of the following as implemented documents
as prior to Acceptance Tests, failing which, Owner may withhold program for
Acceptance Tests :

i) System configuration drawings
ii) Copies of all as-built drawings
iii) Final approved copies of all drawings/documents.
iv) All off-line diagnostic program listings
v) Off-line diagnostic manuals
vi) Dump of individual and complete data base
vii) Detailed main and bulk memory maps
viii) Final Design Specification Volumes
ix) Test data to verify all calculations
x) All console operation manuals
xi) Procedures of generating graphic displays, data base, logs,
structuring/tuning of controllers etc.
xii) Test procedures, copies of approved data sheets and relevant pages
of approved QAP for field instruments & control actuators.
xiii) All test reports for all types of tests carried out by Contractor.

8.01.06 AcceptanceTest

8.01.06.1 The Acceptance Test shall include all reasonable exercises which the
combination of equipment and software can be expected to perform . The test
shall include but not be limited to , the following :

a) Demonstration of the proper function of all hardware.
b) Demonstration of required spare system capacity and all other parametric
requirements of this specification.
c) Demonstration of all man/machine functions.
d) Demonstration of the proper functioning of all software.
e) Demonstration of all diagnostic features.
f) Point by point exercising of each input and output.

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g) Thorough exercising of each device, including the processor/ CPUs,
Peripherals etc.

8.01.06.2 The Acceptance Tests shall also include the following Tests :

a) Simulation of Inputs - to verify conversion accuracies, scan rates, operator
functions, corrections of calculations.
b) Operational Tests - to verify that the system performs all required functions
and meets the specification requirements with respect to "free" processor
time, spare memory requirements, loop response time and other
parametric requirements.
c) Diagnostics Test - to test working and bulk memory locations, instruction
complements, functioning of outputs and peripheral devices, functioning of
system check modules, etc.
d) Power-consumption test - to verify KW consumption.
e) Power failure test - to observe the consequences of a total power failure.
f) Accuracy and Repeatability Test - accuracy and repeatability for analog
inputs shall be demonstrated by statistical analysis using the point values
read every scan cycle for a consecutive 8 hours period for a total of 10
percent of all analog inputs. The specified noise rejection capabilities shall
be demonstrated using the same test and analysis, by the application of at
least 135V RMS common mode and 25V RMS differential mode to the
same inputs. The noise rejection test shall be a second 8 hours test.
Inputs to be used will be randomly selected by Owner prior to the test.
g) Functions - All system functions shall be tested to demonstrate that they
are in accordance with the specification.
h) Format - All printouts and CRT display formats shall be checked to
demonstrate that they are in accordance with the specification.
i) Calculations - All calculations shall be tested to demonstrate that they are
in accordance with the specification and I/O schedule. Contractor shall
prepare all test cases for calculations (three for each calculation at low, mid
and upper ranges of inputs) and submit them for Owner's review in
accordance with contract schedule. Test cases shall include performance
calculations, flow and level calculations.
j) Demonstration of the manual and auto switch over from main to standby
Bus/Controllers.

8.01.06.3 The following minimum criteria shall be followed during all tests :

a) System shall meet all parametric and functional requirements of contract
specification.
b) The DDCMIS shall be able to perform specified functions without any
interruption and/or degradation.

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c) Any allowable operator inputs through keyboards shall not result in system
crash or hanging.
d) Except for bulk memory failure, the disconnection / failure of any peripheral
device while system is operating shall not lead to system crash.
e) Disconnection/Failure of any offsite DPU shall not result in loss of any
control function.
f) Pulling out or insertion of any I/O module from its slot, shall not result in any
system/sub-system failure.

8.01.06.4 The results of Acceptance Tests shall be properly documented by Contractor and
submitted to Owner.

8.01.06.5 Upon successful completion of Acceptance Test, Owner will provide Bidder with a
written authorization for shipment of the system equipment to the project site.

8.02.00 ONSITETESTS

a) On-site test shall include all tests to be carried out by Contractor at site upon
receipt of equipment. These shall include but not be limited to inspection of
equipment, preliminary on-site checks and tests, pre-commissioning trials,
start-up tests, trial operation, performance and guarantee test, availability
test etc. as per the requirements of clause 4.12.00 to 4.18.00 and other
applicable clauses of this specification.

b) Contractor shall perform the site tests in accordance with the requirements
of these specifications and Owner's approved "QualityAssuranceProgram".

c) Contractor shall maintain all test records in Owner's approved formats.
These shall be countersigned by the authorized quality assurance personnel
of Contractor supervising these works.

8.02.01 PreliminaryOnSiteInspectionAndTests

After field installation and before equipment energization and connection of field
inputs, Contractor shall inspect all equipment and shall check wiring and cable to
assure correctness of connections and power equipment installation. After these
checks, Contractor's representative shall power the system and perform standard
diagnostic tests on all system modules and equipment to assure that the system
is working. The field inputs and outputs will then be connected by Contractor.

8.02.02 Startup

a) On completion of erection of the equipment and before start-up, each item of
the equipment shall be thoroughly cleaned and inspected for correctness
and completeness of the installation and acceptability for start- up, leading to
initial pre-commissioning tests at site. The list of pre-commissioning tests to
be performed shall be as Owner's approved "QualityAssuranceProgram".

b) On completion of inspection, checking and after the pre-commissioning tests
are satisfactorily over, the complete equipment shall be operated integrally
with sub-systems and supporting equipment as a complete system.

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8.02.03 DistributedControlSystem(SiteTesting)

Site testing of DDCMIS being largely system-specific, only general guidelines
have been provided to ascertain the end-behavior of the system offered.
However, detail site test procedure shall be mutually decided between Owner and
Contractor during detail engineering stage and shall be followed at site.

a) The front end or the I/O sub-system calibration and functional check
procedure shall be as per the recommendation of the system manufacturer.
b) Cards shall be inspected visually and subjected to standard
pre-commissioning checks in standard test jigs before insertion in
sub-racks.
c) Cards requiring recalibration at site shall be calibrated before insertion.
d) Contractor's activities may include minor hardware and software
modification work at site.
e) Contractor scope of work regarding the commissioning of modulating
control sub-system shall include presetting of values of loop constants in
respective cards, setting of alarms, timers, visual checking, mechanical and
electrical testing and functional checking of all closed loop modulating
controls associated with DDCMIS. All tests shall be carried out after
isolating field inputs/outputs from the system.
f) Tests on the control system shall broadly consist of the following :

i) CheckofEquipment

Cable termination of the cubicles will be checked.

Locks, door function, lamps etc. shall be visually checked.

ii) FunctionalTest

Functionally test the system according to control diagram, wiring
diagram and functional diagram. In case of any non-conformity,
do some minor rectifications. All loops prior to functional test
shall be ensured to be in manual position.

Function test will be performed for each individual control loop
successively, related or cascaded control loops must also be
tested together. All normal as well as disturbance functions of
the control loop and the cubicle shall have to be tested.

iii) Testingofclosedloopmodulatingcontrolfunctions:

Closed loop modulating control functions shall be tested with
simulated input signals. Contractor shall check at least the
following function :

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Inputs and outputs shall be checked for polarity
MVS and 1/2 selection circuits shall be checked
Controller cards shall be adjusted to initial setting
Alarm limit shall be set to process requirement
A/M bumpless transfers/tracking
Transparent fall backs and retransfer
Release function
Loading of output of signal distributors
Memory retention time on power failure.
g) Contractor's responsibility shall also include testing of the following
performance criterion of CLCS together with control peripherals :

i) Keyboard operation of closed loop controls
ii) Mimic diagram and graphic displays
iii) Logs
iv) Current and Historical trend displays of parameter associated to
CLCS
v) Alarm displays in VDU
vi) Printer activation test
vii) Keyboard latency, control latency
viii) A/M transfer from keyboard
h) In addition, to the above functional tests, Contractor shall also check the
function of the Engineers console with respect to loop configurability,
graphic & log generation, power failure rebooting, trend generation etc at
software level and all hardwire interface requirement with other systems.
i) The tests on binary and sequential control sub-system shall be similar to
modulating control sub-systems. The functional tests shall be performed at
drive level as well as in group level.
j) Complete off-line simulation testing of the binary control sub-system shall
be carried.
k) Prior to simulation test, Contractor should ensure that all the interposing
relays are in position.
l) Contractor shall also check the reporting function system to the Information
System over the system bus.
m) Setting of all timers as per process requirement shall also be done by
Contractor during start-up.

8.03.00 LOOPCHECKINGANDPRECOMMISSIONING

a) After successful completion of erection and in situ calibration and on
completion of associated cabling and tubing, Contractor shall undertake
progressive loop checking to ensure all elements in measurement,
protection and control loops shall function in desired fashion.

b) Contractors activities shall include broadly the following :-

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i) Loop checking for supervisory instruments.
ii) Loop checking for modulating control sub-system
iii) Loop checking for binary & sequential sub-system

Loop checking shall be recorded and shall be submitted to Owner after
completion of section wise/equipment wise loop checking.

8.03.01 SupervisoryLoops

a) Supervisory loops shall include the bulk data acquisition system.

b) Loops shall be checked for electrical continuity and air leakage prior to loop
checking.

c) Associated groundings shall be checked before the electrical power is
energized.

d) Spare cores of field cables can be used for communication during
commissioning.

e) If discontinuity is noted in any field cabling, Contractor shall identify the run
of cable/junction at which the discontinuity has developed.

f) Cable identification markers shall be checked at all points of the loop.

g) Termination of all associated cable screens shall be checked for properness.

h) Instrument and power line fuses, removed after erection, shall be reinserted.

i) If any failure of any component of the loop occurs during loop checking and
commissioning the same shall be replaced by drawing from commissioning
spare and reerected.

j) Outgoing cables from temperature elements shall be disconnected at the
junction head during loop checking. Proper simulated signals shall be
inputted from field through the field cables to simulate temperature.
k) Similarly, for field transmitters, field cables shall be disconnected from
transmitter terminal box and simulated 4-20 mA current signal shall be
injected to the loop from field through a signal generator.
l) The input interface card shall be progressively adjusted to obtain proper
display at the console.
m) Simulated signals shall be inputted for at least five points at equal intervals
(including span and zero) of the span, both upscale and downscale.
n) Accessories related to the measurement loops shall be adjusted/checked as
a part of loop checking and commissioning.
o) For analytical system viz. SWAS system, the loop checking shall include the
adjustment of sample flow rate through the primary coolers, adjustment of
pressure breakdown valves, isothermal bath temperature control systems.

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p) Reagents and cation exchange filters, having limited operating life, shall be
regenerated by wash out or acid treatment if required, before
commissioning. Reagents having limited self life shall be checked for expiry
and recharging with reagent shall be performed before commissioning.

8.03.02 ModulatingControlLoops

a) Loop checking will be carried out with all the devices hooked up as per
drawings. The intent of loop checking is to establish that all wiring and tubing
are as intended and all components are in functional condition. Final tuning
of control loops will however be done only during commissioning /
pre-commissioning stage.

b) Before a modulating control loop is selected for checking, Contractor shall
carry out the following checks :

i) Final control element (control valve/damper etc.) shall be checked for
proper tagging, stroke and sealing, friction-free movement of stem and
positioner setting.
ii) Air supply to actuator shall be ensured at proper values.
iii) Contractor shall ensure that all primary sensors are properly installed,
calibrated and are functioning properly.
iv) Check proper hook-up between operator interface station (A/M
station) and control cabinets
v) Control loops shall be selected in MANUAL MODE while checking.
vi) Controllers constants are adjusted to nominal values as below :

PARAMETERCONTROLLED P.B. R.R D.T.

Flow 150 0.1 0
Pressure (Water) 50 0 0
Pressure (Steam) 100 0 0
Differential Pressure (Water) 50 0.1 0
Differential Pressure (Steam) 100 0.1 0
Temperature 100 0.3 0.5
Level 100 0 0

Final values of the above constants will however be adjusted
during tuning of the controller on-line.
vii) Power supply to position transmitters of final elements shall be
ensured.

c) Input process signals shall be given from the field terminals in terms of
current/voltage or resistance. The input signals should be variable over the
total span.




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8.03.03 BinaryandSequentialLoops

a) Binary and Sequential controls shall imply loops associated with interlock
and protection system, drives controlled from DDCMIS, input and output
signal loops from protection system to field, MCC/SWGR etc.,.
b) Loops shall be checked for electrical continuity and air leakage prior to loop
checking.
c) Associated groundings shall be checked before energizing the loop.
d) Suitability of power at final control element (air or electrical) shall be
checked.

e) Process switches, limit switches etc. shall be mechanically activated from
the field and shall be checked at the receiving end. After testing for proper
operation of the switches, these will be hooked up to the receiving system as
applicable.

Loopswillbetestedasfollows:

i) One functional loop will be energized at a time.
ii) The logical output from the binary system shall be checked at the
receiving end like MCC, SWGR, DC starter panel, etc.
iii) All timers will be set at optimum values.

8.04.00 COMMISSIONING

During plant / equipment / section trial run, start up, running etc. Contractor put
the associated instruments, loops, controls etc. in service in respective
sections/areas for smooth commissioning. The instruments/equipment are to be
put in operation/service as per sound engineering practice & manufacturers
recommendations. Any instrument problem/trouble that may arise during
commissioning and afterwards is to be attended and solved promptly by
Contractor.

8.04.01 TrialOperation

a) The plant shall then be on Trial Operation during which period all necessary
adjustments shall be made by Contractor while operating, over the full load
range enabling the system to be made ready for Performance and
Guarantee Tests.
b) The duration of Trial Operation of the complete equipment shall be 14 days
out of which at least 72 hours shall be continuous operation on full load, or
any other duration as may be agreed to, between Owner and Contractor.
The trial operation shall be considered successful, provided that each item of
equipment/ sub-system/software supplied and erected by Contractor and the
system as a whole can operate continuously at the specified operating
characteristics for the period of trial operation.
c) For the period of trial operation, the time of operation with load shall be
counted. Minor interruptions not exceeding 4 hours at a time caused during

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the continuous operation shall not affect the total duration of trial operation.
However, if in the opinion of Owner, the interruption is longer, the Trial
Operation shall be prolonged for the period equivalent to the duration of
interruption.
d) Trial Operation Report comprising of observation and recording of various
parameters to be measured in respect to the above described Trial
Operation shall be prepared by Contractor. This report, besides recording
the details of the various observations during trial run, shall also include the
dates of start and finish of the Trial Operation and shall be signed by the
representatives of both the parties. The report shall record all the details of
interruptions, adjustments made and any minor repairs done during Trial
Operation. Based on the observations, necessary modifications/repairs to
the system shall be carried out by Contractor to the full satisfaction of
Owner to enable the latter to accord permission to carry out Performance
and Guarantee Tests on the System.
e) During the preliminary on site inspection and test, start up and Trial
Operation the system shall be completely tested in the presence of Owner's
representative to fully satisfy Owner that each equipment/sub-system/
software module individually and the system as a whole fully meets the
functional, parametric and other requirements of this specification. All
diagnostic and software debug tests performed at the factory shall also be
performed in the field. These tests shall include a full demonstration of all
operating software program operating in the real time environment.
Contractor shall be responsible for documentation of all test results, records
of defects observed and adjustments / modifications made during these
tests. Contractor shall furnish certified copies of the site tests carried out
prior to date of commencement of Performance and Guarantee Test.

8.04.02 PerformanceandGuaranteeTest

a) Performance and Guarantee Test shall be conducted by Owner after the
following requirements are met.

i) Preliminary on site inspection, start up test and trial operation tests are
successfully completed.
ii) Certified copies of the results of all site tests are furnished by
Contractor.
iii) All deficiencies noticed during shop tests and site-tests including trial
operation are satisfactorily resolved.
iv) System documentation check is successfully completed.

b) Performance and Guarantee Test shall cover all test covered under
Acceptance Test using actual plant inputs and outputs. Additionally, Owner
may perform any other test which in his opinion is required for satisfying
himself regarding full compliance of equipment with the intent and
requirements of this specification.


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c) The guaranteed performance figures of all equipment as well as functional
and parametric requirements of this specification shall be provided /
demonstrated during these Performance and Guarantee Tests.

d) Should the results of these tests show any decrease from guaranteed value
or non fulfillment of specification requirements, Contractor shall provide all
necessary enhancements / replacements / modifications / additions in
hardware, software, system configuration and other technical features as
required to enable the system and parts thereof to meet the guarantees and
specification requirements. In such cases the Performance and Guarantee
Test shall be repeated for retest.

8.04.03 AvailabilityGuaranteeandStabilityTestRun

a) Contractor shall guarantee 99.7 percent system availability for a period of
180 days. An Availability Guarantee Test shall be conducted to assure this
level of availability. If the accrued down time exceeds 0.3 percent of 180
days, during availability test run, a new 180 days test run shall start at the
time when the system becomes available again. Loss of availability shall be
defined as the loss of the system's guaranteed accuracy and repeatability or
of any system function; except, however, that the loss of a function for not
more than five percent of the I/O points shall not be considered loss of
availability. Loss of a function for not more than five percent of the points
shall be treated as partial unavailability and the corresponding outage time
shall be weighted with respect to function and the percentage of the points
for which the function is unavailable. Loss of each function shall have one
weighing factor and unavailability of each equipment, peripheral device or
process I/O card etc. shall have another weighing factor. The guaranteed
accuracy and repeatability and system parametric requirements specified
elsewhere shall be maintained for the entire 180 days run without any
manual recalibration or any other changes made to the system.

b) Downtime shall start upon loss of a system function and shall end upon full
restoration of the affected system. A minimum of one hour's down time shall
be charged for each loss in determining system availability.

c) If availability is lost due to Owner's error, down time will not be charged to
Contractor.

8.04.04 AvailabilityTestDates

The availability test shall commence at a date which will occur between the
commissioning date and 5 months following commissioning.

Contractor will be notified of the test starting date at the time of Performance and
Guarantee Test. Any subsequent changes in the starting date shall require the
mutual consent of both Contractor and Owner.

8.04.05 TestDurationandDefinition

a) The availability test duration shall be 180 days of accumulated test duration
time. Such duration time shall be continuous from the start of test, except
as defined hereinafter.

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b) The availability shall be expressed by a percentage which shall be
calculated as
100 x [Test Duration Time - Accumulated System Outage Time]
Test Duration Time
c) The accumulated system outage time shall be a total of time in which all
systems and system functions are not available. A weighing factor shall be
used to determine the amount of outage time assessed due to partial
failures. System outage time shall be calculated as :

(Outage time) x (Weighing factors)

d) System outage time shall be accumulated over the test duration and shall
be the accumulated system outage time.

8.04.06 OutageTimeandWeightingFactors

a) Contractor shall submit a list of weightage factors for all system elements /
components required for conducting the availability test. A list shall be
submitted along with Bid documents.

b) Outage time will be assessed by the length of time in which all or a part of
any of the functions are either continuously available or not available when
requested by operator action. The outage time shall be weighed by each
functions associated weighing factor.

c) Weighing factors for system elements shall be defined and mutually agreed
upon before award of Contract.

8.04.07 Conditions

a) Downtime shall start at the time of notification exclusive of actual travel time
by Contractor but not in excess of 8 hours.
b) Contractor shall state in his proposal the unit price and quantity of each
spare part which will be required at site during the availability test run.
c) If the spare parts which are necessary for repair are not available with
Owner ex-site stock, the outage time necessary for obtaining the parts by
Contractor shall not be counted if the spare part is on Contractor's
recommended list and within the quantities indicated for each type of
spares.
d) If Contractor had not listed the spare parts or in case the requirement
exceeds the quantity indicated as per point (2) above the time required to
obtain the part by Contractor shall be multiplied by a weighing factor of 0.05
and counted as accumulated outage time.
e) Spare parts which are used by Contractor and not promptly replaced by
Contractor, shall accumulate outage time at the rate of time required to
obtain the spare parts multiplied by a weighing factor of 0.05 if the part is on
a subsequent outage.

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f) Contractor shall be responsible for replacing any of Owner's spare parts
which are used in the availability run.
g) Failure of peripheral output devices shall be counted as outage time if
failure of the device affects any or part of any function as per clause.
h) Any degradation of function shall accrues to outage time regardless of
system configuration.
i) During a period of system outage, Owner shall use operable functions of
the system provided that such use does not interfere with maintenance of
the inoperable functions or hardware as determined by Contractor.
j) Should Contractor determine that partial use of the system by Owner will
interfere with Contractor's maintenance procedures, system outage time
shall accumulate with a weighing factor of 1.0 since no functions are
available to Owner. This shall include off-line servicing.
k) Outage time for each function shall stop at the time Contractor returns each
of the functions as listed in clause on "outage time and weighing factors" to
full service and relinquishes full use of the system to Owner.

8.04.08 CriteriaforHandingoverofControl&InstrumentationSystem

a) Contractor shall apply in writing to Owner for handing over of the complete
Control & Instrumentation System after successful demonstration of tests as
specified up to "AvailabilityGuaranteeTest".

b) Owner shall take over charge of the C&I system subject to fulfillment of the
conditions enumerated hereunder :

i) Site check-list prepared by Owner are fruitfully attended by Contractor
and certified by Owner.
ii) Operation/ Instruction manuals are updated to incorporate changes
made up to Availability Test Run.
iii) Drawings/ sketches are submitted as per Contract, on as- built basis.
iv) Close loop controls, Binary & Sequential controls should be working
on auto and interlocks are demonstrated to be functional.
v) Equipment and system supplied by Bidder are in working condition.
vi) Short supply items, as per Contract, are refurnished by Contractor.
vii) The above conditions are in addition to fulfillment of any/all other
contractual obligations of Contractor towards Owner. Partial
handing-over of systems /equipments shall not be permissible, except
if desired so by Owner in special cases.





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9.00.00 TRAININGOFPERSONNEL

9.00.01 Bidder shall include in the proposal training of Owners personnel of different
categories for operation, maintenance and troubleshooting of the supplied
equipment. Training courses shall be conducted by experienced personnel of
Bidder. Course participants shall receive individual copies of technical manuals at
the time the course is conducted. Upon completion of each course, training
manuals shall be property of Owner. Bidder shall supply all updates and revisions
to the manuals.

9.00.02 Training shall be provided to operating, programming and maintenance
personnel. The total duration of training shall be approximately 35 man-months
at original equipment designer / manufacturers works. While the exact content
and duration of such training shall be guided by Bidders experience following
gives the basic requirement from Owners point of view.


CATEGORY NUMBER SUBJECT DURATION TYPE
Engineer 2 Software 3 Month Lecture & Hands-on
Engineer 3
Hardware
Maintenance
2 Month Lecture & Hands-on
Supervisor 4 Operation 1 Month Hands-on
Supervisor 3
Hardware
Maintenance
1 Month Hands-on
Operator 8 Operation 1 Month Hands-on
Technician 8
Hardware
Maintenance
1 Month Hands-on

9.00.03 Training for the operators shall be based on direct hands-on use of the offered
system. Bidder shall train Owner's personnel in the programming and
maintenance of the equipment to the extent that Owner's personnel can make
corrections and changes to the system and maintain the systems hardware
independently. Bidder shall include in his proposal a detailed description of the
training course proposed by him (class-room lecture, audio-visual presentation,
hands-on). If Bidder conducts Owners training on regular periodic basis, a
printed brochure of such program may be enclosed for reference.

9.00.04 Bidder shall provide all additional training deemed necessary by Owner , if there
are modifications to Bidders system and software after completion of the regular
training period.





VOLUME : II-E

SECTION-IX

LABORATORY INSTRUMENTS



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CONTENT



CLAUSE NO. DESCRIPTION PAGE NO.

1.00.00 GENERAL V.II-E/S-IX : 1

2.00.00 CODES AND STANDARDS V.II-E/S-IX : 2

3.00.00 DESIGN AND CONSTRUCTION REQUIREMENTS V.II-E/S-IX : 2




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VOLUME : II-E

SECTION-IX

LABORATORY INSTRUMENTS



1.00.00 GENERAL

1.00.01 This section provides the technical information for the design, furnishing,
construction and setup of an instrument shop, complete with instruments,
furniture, tools and test equipment required to maintain the instruments and
control devices of the plant.

1.00.02 Testing instrument / devices offered shall be proven type and shall incorporate
latest design. All instruments supplied under this package shall be in brand-new
and unused condition.

1.00.03 The workmanship and design shall be proven and in accordance with the best
engineering practice to meet the intended purpose. Bidder shall ensure
satisfactory performance of testing instruments/devices even in the worst
environmental condition. All instruments shall be supplied from reputed and
proven manufacturer.

1.00.04 Testing instruments/devices shall be furnished with all necessary accessories
and original instruction/operating and maintenance manuals.

1.00.05 The shop shall be provided with a complete set of test and calibration
equipment/test kits for electronic and pneumatic instruments and controls, falling
under the purview of this specification.

1.00.06 All instruments offered, shall conform to the relevant International Standards.

1.00.07 The various instruments/devices, small tools, accessories, etc. shall be furnished
(in applicable cases) with suitable and durable crates, kits or carry boxes of
convenient size; complete with necessary packing etc. for safe storage when not
in use.

1.00.08 Measuring/testing instruments, along with associated accessories shall be
suitable for intended operation (both indoor and outdoor installations as
applicable).



1.00.09 Bidder shall be responsible for proper functioning of supplied items and shall
make any necessary additions/modifications, as required for proper maintenance
and testing of the installed instruments and controls. Bidder shall also be
responsible for erection and commissioning of the test equipment.

1.00.10 It is obligatory to Bidder to furnish a complete list of spare parts for these
testing/calibrating, instruments/devices. Bidder shall render guarantee for easy

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availability of all the spare parts required, especially for the components, which
are prone to failure.

1.00.11 Bidder shall repair or replace the defective instruments/ devices at no extra cost
within the guaranteed period of each instrument/device.

1.00.12 Bidder shall submit with the proposal a full list of testing/laboratory instruments /
tools offered along with detailed specification of the items. Catalogues, drawings
and manuals as required shall be submitted with the proposal to provide
necessary information pertaining to the items offered. Information for the items
offered shall include (as applicable) but not limited to the following:

a) Working principle
b) Power supply and other utility details
c) Dimensional details
d) Mounting details including necessary accessories
e) Recommendations (if any) for installation, storage etc.
f) Accuracy (wherever applicable)
g) Make and Model
h) Conformance to or deviation from the specification, if any.

1.00.13 Bidder to note that the testing and laboratory instruments specified in this section
shall be in addition to the equipments required for installation, maintenance,
trouble shooting and calibration of instrumentation and control equipments of the
plant furnished under this volume of the specification. Also, any special
simulator/test stands which may be recommended and supplied by Contractor for
use in calibrating electronic components of the instrumentation and control
systems shall be considered separately in addition to the laboratory instruments
specified in this part. Contractor shall handover to Owner all equipment specified
in this part immediately after receiving the equipment at the job site. Use of this
equipment by Contractor shall not be permitted without Owner's consent.

1.00.14 Bidder shall include a complete set of furniture for the instrument laboratory from
reputed manufacturer designed for similar applications. The set of furniture shall
include but shall not be limited to chairs, tables for calibration of instruments, test
benches etc, all necessary cabinets for storage of manuals / booklets / records /
charts, storage racks for special tools etc. The design, color, layout and model of
the furniture shall be approved by Owner.

2.00.00 CODES AND STANDARDS

The design, material, construction features, manufacture, inspection and testing
of laboratory instruments shall comply with all currently applicable statutes,
regulations and safety codes in the locality where the equipment will be installed.
The equipment shall also conform to the latest applicable standards.


3.00.00 DESIGN AND CONSTRUCTION REQUIREMENTS

3.01.00 DEAD WEIGHT TESTER - (2 NOS.)

3.01.01 Dual range dead weight tester shall be furnished to cover 1- 6 Kg./Sq.cm. and 6 -
600 Kg/Sq.cm range. It shall be compact, stable, light in weight and self
contained with anodized metallic base, steel weights, twin area screw pump with

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ball thrust and axially located hand wheel. Accuracy shall be 0.02% for high
range and 0.025% for low range of the actual reading. Dead weight piston and
cylinder shall have over pressure stops preventing the piston from coming out.
These pistons shall be hardened stainless steel. Oil filter shall be furnished at
fill-up point to prevent contamination. The tester shall have 1/2" NPT(F)
connection. Adapters of different sizes to receive 1/4" NPT, 1/8" NPT & 3/4" NPT
pressure gauge shall be supplied.

3.01.02 The following accessories shall be included :

a) Angle connector for flush mounted gauges
b) Spirit level
c) Bag of seals
d) Wrenches
e) Spanners
f) Pointer remover
g) Pointer punch
h) Can of fluid

Make-Budenburg , U.K .

3.02.00 LABORATORY TEST PRESSURE GAUGES - (2 SETS OF EACH TYPE)

3.02.01 Two Sets of test pressure gauges (accuracy 0.1% including hysteresis) as listed
below shall be supplied :


ITEM NO. RANGE

01. - 1 to 0 Kg/Sq.cm

02. 0 - 1.0 Kg/Sq.cm

03. 0 - 1.6 Kg/Sq.cm

04. 0 - 2.5 Kg/Sq.cm

05. 0 - 4 Kg/Sq.cm

06. 0 - 6 Kg./Sq.cm

07. 0 - 10 Kg/Sq.cm

08. 0 - 16 Kg/Sq.cm

09. 0 - 25 Kg/Sq.cm

10. 0 - 40 Kg/Sq.cm

11. 0 - 60 Kg/Sq.cm

12. 0 - 100 Kg/Sq.cm

13. 0 - 160 Kg/Sq.cm

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14. 0 - 250 Kg/Sq.cm

15. 0 - 400 Kg/Sq.cm

3.02.02 All test pressure gauges shall have 150 mm anti-parallax white dial with black
figures and graduation lines of fineness and legibility used for high precision
instruments. The dial shall be mirror-polished stainless steel under the tip of the
pointer. Cases shall be fine wrinkle phenol or die cast aluminium, light but strong
and rigid. Mounting shall be direct or flush.

3.02.03 The material of the sensing element shall be solid drawn phosphor bronze upto
10 Kg/Sq.cm and above 10 Kg/Sq.cm. stainless steel tube.

3.02.04 The pointer shall be lightweight, stainless steel balanced design with tip turned 90
degree for easy reading to smallest sub- division.

3.02.05 Connection size of all gauges shall be 1/2" NPT (M).

3.02.06 For all test gauges point-by-point test certificate of the readings shall be provided.

Preferred make-Budenburg , U.K .

3.03.00 LABORATORY TYPE MANOMETER- (1 NOS OF EACH TYPE)

3.03.01 Enclosed type free-standing U-tube manometers of the following ranges shall be
supplied :

ITEM NO. RANGE

01. 0-2500 mm of WC (1250-0-1250)

02. 0-1000 mm of WC (500-0-500)

3.03.02 These U type manometers shall be used for measuring low pressures, differential
pressures or vacuum. Scales shall be calibrated in centimeters and sub-divided
into tenths. These shall be suitable for maximum static pressure of 7 bar. Cases
shall be of aluminium on three sides with clear acrylic front cover. Scales shall
have provision for zero adjustment.

3.03.03 All wetted parts and fittings shall be SS-304. Manometer will be mounted on M.S.
three leg stand having level adjustment arrangement and attached spirit level.
The scale graduations shall be engraved on milky white acrylic in black. Metering
tube shall be clear acrylic plastic having uniform reamed bore and thick walls,
gland-packed in end blocks. End connections shall be 1/2" NPT (F), with check
valves. The scale shall be provided with vernire arrangement. Liquid drain plug
shall be provided. Coloured liquid & storing bottle, fill-up funnel and nylon tubes
shall be included.

Make- Meriam Instruments, U.S.A .


3.04.00 INCLINED TUBE MANOMETER - (1 NOS.)


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3.04.01 Portable inclined tube manometers of free standing type of ranges 0-50 mm,
0-100 mm and 0-200 mm WCL shall be supplied for each Unit.

3.04.02 These shall be used for measurement of draft, air velocity and air pressure
around atmospheric pressure. Indicating tube and oil chambers shall be drilled
and reamed in a solid block of clear acrylic plastic material. These manometers
shall have levelling screws at the bottom and spirit level bubbles for accurate
levelling. Each manometer shall be complete with connecting tubes, mounting
box, brass range scale, tube chamber, connecting tube, 1/2" NPT process
adapters , manometer liquid and drain plug. Three valve manifold shall be
supplied along with each manometer.

Make- Meriam Instruments , U.S.A .

3.05.00 PORTABLE MULTIFUNCTION CALIBRATOR MICROPROCESSOR BASED - (3 NOS.)

3.05.01 Portable Multifunction Calibrator shall be supplied for testing and calibration of
process instruments. The calibrator shall have facility for measurement and
simulation of the following instruments and parameters :-

a) Pressure and DP transmitters
b) Electro-pneumatic converters.
c) Thermocouples and RTD
d) Electronic receivers and controllers
e) DC voltage & current generation
f) Frequency

3.05.02 The calibrator shall have large multiple digital indicator 4 to 5 digits. According to
function and menu guided set up mode. The calibrator shall have storing facility
of field calibration data together with set up information as per requirement.

3.05.03 The calibrator shall be microprocessor based with latest state of the art design
and shall have membrane type key pad with tactile sound, in built battery &
battery charger, carrying case, test probes etc.. Preferred feature - IP-65
enclosure class.

Prefered Make- Haven automation / Yokogawa

3.06.00 PRESSURE AND VACUUM AIR PUMP - (2 NOS.)

3.06.01 Portable type Combined pressure and vacuum pump shall be supplied. This air
pump is to produce pressure upto 2 bar for intermittent service, 1 bar for
continuous service and to pull a vacuum as high as 700 mm of mercury. The
actual free air delivery shall be 0.03 Cu.m per minute at 1 bar.

3.06.02 This pump shall be complete with pressure gauges (150 mm dial pressure gauge
0-2.5 bar and 150 mm dial vacuum gauge 0-760 mm mercury), lubricator, hose
nipples and other fittings & accessories.

Preferred make - Heaven automation


3.07.00 PRESSURE GAUGE COMPARATOR (2 NOS.)


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3.07.01 Pressure gauge comparator shall be supplied for testing pressure gauges and
vacuum gauges upto 250 bar and 760 mmhg vacuum with an accuracy of +/-
0.2%. This unit shall be complete with test gauges of ranges 0-50 bar, 0-300 bar
and 760 to 0 mm Hg. One slide wrench, screw driver, two gauge pointer
removers, gauge adaptors set packed in a separate box, one lever handle union,
gauge cock 1/2" NPT(F) and 1/4" NPT(F) connectors for pressure gauges to be
tested and other accessories as required. The pressure developed by the test
pump shall be continuously adjustable. Filling fluid, funnel to be supplied along
with the unit. Comparator shall have the features of LCD digital display for
pressure.

3.07.02 The comparator shall be of latest state of the art design and shall have in built
battery and battery charger.

Preferred make-Budenburg , U.K .

3.08.00 DECADE RESISTANCE BOX - (2 NOS.)

3.08.01 Decade resistance box shall be supplied as per specification stated below :

A dial type resistance box shall be supplied. Range of resistance box shall
typically be 0.10 to 100000 ohms. There shall be six dials, each dial providing
one decade of resistance value. The resistance coils should be coated with
paraffin to remove moisture. The ends of the coils should be soldered to the
terminal blocks with silver solder. The direct-reading accuracy of the resistance
box shall be better than +/- 0.05% at the smallest range. All resistors shall be
temperature compensated.

3.08.02 Resistance box shall be supplied with probes, leads, clips, connectors etc.

Preferred make-Yokogawa, J apan

3.09.00 A.C. UNIVERSAL BRIDGE- (1 NO.)

3.09.01 A.C. bridge of the following specification shall be supplied together with probes,
leads, clips, connectors, power supply cord, accessories etc.

3.09.02 R.L.C. bridge shall have a measuring frequency of 1 KHz/10 KHz. The bridge
shall be suitable for 240V, 50 Hz supply.


Ranges

Resistance : 10 Ohms to 10 M Ohms in seven full scale ranges with least
count 10 m Ohms in 10 Ohms range.

Capacitance : 1000 PF to 1000 micro F in seven full scale ranges with least
count of 1 PF in 1000 PF range.

Inductance : 1000 micro H to 1000 H in seven full scale ranges with least
count of 1 micro H in 1000 micro H range.

3.09.03 It shall also be possible to measure "D" dissipation factor for capacitors and "Q"
quality factor for inductances.

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Preferred Bridge shall be Hewlett-Packard make.

3.10.00 PC BASED SYSTEM FOR TESTING AND RECTIFICATION OF ELECTRONIC CARD (1 NO.)

3.10.01 Bidder shall provide a PC based trouble-shooting unit for testing and rectification
of electronic cards. The system shall be provided with diagnostic software for
detection of faulty IC chips. The system shall be capable to detect faulty
components with out removing it from the PCB. Different types of connectors and
ribbon cables shall be provided with the system so that IC chips of different pin
configurations can be checked on board. Bidder shall furnish details of the
offered system.

3.11.00 SIGNAL GENERATOR (1 NOS.)

3.11.01 Signal generator of the following specification shall be supplied.

Frequency range of the signal generator shall be from0.01 c/s to 200 K c/s in at least four
ranges. The signal generator shall have sine wave, square wave and saw tooth wave
outputs.

3.11.02 The output frequency shall be continuously adjustable and frequency reading
shall be displayed on a digital indicator. The voltage of the output of the generator
shall be continuously controlled and shall be monitored on a built-in digital
voltmeter. The signal generator shall have high frequency stability and low
harmonic distortion. Harmonic distortion shall be less than 0.5 percent. Signal
generator shall be suitable for 240V single phase, 50 Hz, supply and shall be
complete with carrying case, probes and other accessories as required.



3.12.00 HAND TACHOMETER - (2 NOS.)

3.12.01 Bidder shall supply Hand tachometer with latest state of the art design. Electronic
type is preferred.

3.12.02 Measuring ranges shall be in 4 or 5 selectable scales such that the tachometers
shall be able to indicate speeds from 30 to 50,000 rev./min. The tachometer shall
be rugged in construction and shall be complete with all accessories and carrying
case. A built-in safety clutch shall be incorporated to protect the tachometer
against overload if the speed is higher than the selected range.





i) Necessary carriers with rubber and steel centres
ii) Measuring roller
iii) Extension Rod
iv) Carrying case


3.13.00 INSULATION TESTER OF DIFFERENT RANGE - (1 NO./UNIT)

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3.13.01 Insulation tester shall be portable and battery operated type with LCD display.
Test voltage shall be 250 V / 500 V / 1000 V / 2500 V D.C. Range of insulation
measurement shall be from 0.5 Meg Ohms to 50,000M ohms. Insulation
resistance shall be indicated on a meter.

3.13.02 Following accessories shall be included :

3.13.03 The indication shall be magnetically damped. Push button shall be provided to
hold the pointer for exact reading.

3.13.04 Insulation tester shall be Evershed Vigneless make or approved equivalent.

3.14.00 D.C. REGULATED POWER SUPPLY - (2 NOS.)

Bidder shall supply D.C. Regulated Power supply designed with latest state of the
art electronic and IC technology. D.C. Regulated Power supply shall have the
following features :

01. Voltage Range : 0 to +60V DC, 1 Amps. (floating)
(Continuously adjustable)

02. Voltage/Current Range
meters : 0-60V/0-2.5A

03. Display : LCD

04. Meter Accuracy : 2% FSD

05. Power Supply Connection : 240 V AC, 50 Hz.

06. Output Impedance : 50 m Ohm or less.

07. Load Regulation : 0.1% variation in voltage
0.2% variation in current

08. Drift in 8 Hours : 0.1% variation in voltage
0.2% variation in current

09. Ripple and Noise : Less than 1 mV

10. Setting Resolution : 20 mV / 20 mA

11. Temperature co-efficient : 0.05% per Deg.C

12. Accessories : Test cords and clips as required.

Power supply shall be short circuit proof and crowbar protected.

3.15.00 STOP WATCH (2 NOS)

3.15.01 Stop Watch shall be electronic type with LCD type display and complete with
battery set and carrying case. The stopwatch shall have start, stop and reset
button.

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3.15.02 The case shall be non-rusting, dust and damp- proof.

3.16.00 CONTINUITY TESTER -(5 NOS)

Continuity tester shall be electronic and battery operated. A hooter shall be
provided which will sound when continuity detected. Tester shall be supplied with
battery charger, lead wires and probes. The tester shall be kept in a carrying
case.

3.17.00 TONG TESTER (2 NOS.)

Electronic type Tong tester of the following specification shall be supplied.

Tong tester shall be suitable for measuring the current ranges of 0-5/10-15/30
amps AC and DC. It shall have swiveling joint between tongs and meter to
facilitate easy reading. Tong Testers shall have facility of indicating power factor,
frequency and KW.

3.18.00 STABILISED POWER SUPPLY (2 NOS.)

Bidder shall supply stabilized power supply designed with latest electronics and
IC technology. It shall have the following minimum features:

01. Voltage Range : 0-220V AC, continuously adjustable.

02. Current Range : 0-10A

03. Power Supply Connection : 240V AC, 50 Hz

04. Indication : Meters indicating voltage and current shall
be integral with power supply

05. Load Regulation : 0.25% variation in voltage

3.19.00 TEMPERATURE CONTROLLED BATH - (1 NO.)

Electronically controlled Temperature bath of following specification shall be
supplied. Range approximately (-20) to (+100) Deg.C

a) Insulated box of capacity (water / freezing liquid) around 0.02 Cu.m.

b) Provision of holes with lids on the top for inserting thermocouples / RTD /
Temperature gauge. The temperature controller shall have LED / LCD type
display for set and measuring parameter. Operating voltage shall be 240V,
50Hz, 1 Ph.

c) Unit shall be complete with Thermo element, Power supply cords, etc.

3.20.00 TEMPERATURE CALIBRATOR (2 NOS.)

Electronic type comprising of integral electric heater, thermometer, temperature
indicating controller and cooling fan with stability within +/- 0.2 Deg C. Instrument
shall have range of 0-600 Deg C. The equipment shall be complete with all

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standard and required accessories and carrying case. Instrument shall have
provision for accommodating different bulb size thermometers/temperature
elements (Thermocouples/RTD).

Preferred make- Heaven automation

3.21.00 HOT AIR BLOWER(1 NO.)

Portable hot air blower of reputed Make shall be supplied. Blower shall be
suitable for 240V A.C., 50 Hz supply.

3.22.00 STROBOSCOPE (1 NO.)

Portable stroboscope suitable for 240V AC, 50 Hz, supply from reputed Make
shall be supplied. Measuring range shall be from 0 to 6000 rpm minimum in
suitable ranges.

3.23.00 PORTABLE TREND RECORDER - (1 NO.)

Recorder shall be suitable for 240V AC, 50 Hz, supply. Recorder shall have
signal-conditioning circuits to receive 4-20 mA, DC, thermocouple, RTD and other
voltage-current signals encountered in electronic circuits. Recorder chart shall
have 6 speed selections between 2 and 700 cm per hour. the recorder shall be
3-pen type. The scales shall be graduated in 0-100%. Accuracy shall be +/ - 1%
or better. Reference junction compensation feature shall be built-in. The
minimum input impedance for voltage measurement shall be 500 K Ohms and for
current inputs the impedance shall be 950 Ohms. The following spares and
consumables shall be provided:

i) Chart rolls
ii) Ink cartridges/sacks
iii) Replacement tips
iv) Chart drive motor

3.24.00 BAROMETER (1 NO.)

Precision barometer shall be electronic type (digital display) with a range of 660
to 790 mm Hg with 0.1 mm Hg accuracy complete with battery, battery charger
and carrying case. The display shall be barometric pressure, humidity and
temperature.

Preferred make- Meriam Instruments, U.S.A . or equivalent.

3.25.00 SURFACE PYROMETER INFRARED (1 NO.)

3.25.01 Instrument shall be supplied with hand held probe and cable (5 metres)
assembly. Indication shall be by 3.1/2 digit LED display. Range shall be 0-999
Degree Celsius. Accuracy shall be 0.5 degree celsius.

3.25.02 Instrument shall have internal chargeable battery. Battery charging circuit
suitable for 240V AC, 50 Hz shall be integral with the instrument.



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VOL-II-E-SEC-IX - 11 DCPL-11Z02

3.26.00 ELECTRONIC AND PNEUMATIC TEST BENCH - (1 NO.)

3.26.01 Self contained test bench for testing and repair of electronic/ electrical /
pneumatic instruments and gadgets shall be supplied. This shall include
necessary isolating switch, power supply switch, holding brackets, power supply
sockets, signal sockets, meters, plugs, variac, air gun etc. laid aesthetically in a
bench-top unit.

3.26.02 The Electronic test bench shall be fitted with microprocessor based electronic
calibrator and shall include necessary power packs with the following sockets
mounted on the test bench:

Minimum Number of Socket

0 - 260V AC, 50 Hz (10A) : 4

24V DC (5A) : 2

48V DC (5A) : 2

12V DC (5A) : 2

5V DC (5A) : 2

220 V AC, 50 Hz (Stab) (5A) : 2

0 - 60V DC (1A) : 2

3.26.03 Voltage level is tentative and shall be matched to supply requirements of Bidders
range of products.

3.26.04 The variable A.C. supply shall have a range of 0-260V and the sub- panel shall
contain ammeter and voltmeter. The output shall be protected with circuit
breaker. The stable 220V AC supply shall maintain stability within 0.5%. The
stabilizer shall be servo-controlled. A voltmeter shall be provided in the
sub-panel to indicate input and output voltages.

3.26.05 D.C. supplies shall be externally settable, floating type, reverse polarity protected.
A metering sub-panel shall be provided for monitoring voltage, current with
necessary plug sockets.

3.26.06 Standard utility outlet sockets (4 nos.) shall be provided. A compressed air
blowing arrangements shall be included having a gauge, regulator and flexible
hose.

3.26.07 The test bench shall be fitted with microprocessor based pneumatic calibrator
and other accessories.

3.27.00 PORTABLE DIGITAL MULTIMETER - (10 NOS.)

Features / Preferred make - Fluke:

a) 4 digit LCD display

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b) 6 functions DC Volts; AC Volts; DC mA, AC mA, frequency and Ohms -
Total 25 ranges (min.)
c) Battery/Mains operation with low battery voltage indicator (9 V single
battery)
d) Battery life 150 hours (min.)
e) Automatic Polarity, auto zero, auto ranging
f) Response time less than 5 seconds
g) True r.m.s. display for A.C. ranges
h) Overload protection upto 1000 V D.C. or A.C. p to p
i) Ranges : D.C. Voltage - 0- 200 mV / 1000 V
A.C. Voltage - 0- 200 mV / 750 V
D.C. Current - 0- 200 mA / 2A
A.C. Current - 0- 200 mA / 2A
Resistance - 0- 200 Ohm/ 20 M Ohm
Frequency - 10 Hz to 100 kHz
j) Ambient Temperature - 0-50 Deg.C

3.28.00 PORTABLE VACUUM TESTER (2 NOS.)

3.28.01 It shall calibrate and test vacuum instrument ranges 760 mm Hg vacuum and
comprise of precision test gauge with swivel fitting shut off valve, pistol grip
handle, etc.

3.28.02 It shall have the following features and specification:

a) Light weight for field use

b) Needle valve for positive shut-off piston grip, handle for quick, easy pump
action.

c) Carrying Case : High impact plastic with a die cut foam insert
snap open enclosures and handle fitted slots for
the tester and two spare gauges.

d) Accuracy : 0.5% of gauge span

e) Range : 0 to 760 mm Hg
f) Test
Connection : 1/2" NPT 60 cm long nose

3.29.00 FIELD TRANSMITTER CALIBRATOR - (2 NOS.)

3.29.01 Bidder shall supply portable Field Transmitter Calibrators suitable for
configuration and calibration of smart transmitters.

3.29.02 Field Transmitter Calibrators shall have 4 and 1/2 Digit LCD display, in built
battery with battery charger, membrane type key pad with tactile sound and IP-65
enclosure.

3.29.03 Accuracy shall be better than smart type transmitters

3.30.00 FIELD PRESSURE COMPARATOR (2 NOS.)


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Features : Single volume pump with integral pressure regulator for fine
pressure adjustment.

To be supplied with four test gauges. Gauge shall be compensated for
temperature; operating pressure 300 Kg/Sq.cm maximum.

Accuracy : 0.5% of gauge span.

3.31.00 PORTABLE GAS ANALYZER (1 NO. CO & CO2 , 1 NO. O2, 1 NO.NO & NO2, 1 NO.
SO2 )

Bidder shall supply one (1) no. Portable gas analyzer for determining the
individual quantities of carbon dioxide, carbon monoxide and one (1) separate
portable gas analyzer for determining oxygen from flue gas samples. All
hardware and chemicals required for operation of these analyzers shall be
furnished.

3.32.00 SOLDERING IRON WITH SOLDER SUCKER (6 SETS)

3.32.01 Soldering iron shall be provided along with temperature controlling equipment for
precise adjustment of temperature. Different sizes of soldering tips shall be
provided with the iron.

3.32.02 Solder sucker shall be provided for removal of molten solder from terminal
connections.

3.33.00 VARIAC (1 NOS.)

Light weight variac providing voltage upto 550V, 10A, 50 Hz is envisaged.
Voltage scale around the voltage-varying knob shall have white lettering and
graduation as black back ground.

3.34.00 POWER PACK (2 NOS.)

3.34.01 Bidder shall supply power pack designed with latest state of the art electronics
technology. It shall accept 110V 1 phase / 240V 1 phase, 50 Hz signal as input.
Output voltage of the power supply pack shall be 0-60V adjustable over the entire
range. The systems shall be capable of providing both positive and negative
supply voltage with respect to a common reference point.

3.34.02 Power supply packs shall include indicating meters to indicate the output voltage
and output current. The power pack shall be capable of delivering current upto
10 Amps. Max ripple should be 5 mA at full load.

3.35.00 HAND HELD SOUND LEVEL METER - (1 NO)

Bidder shall supply one (1) no. portable sound level meter. Sound analysis
amplitude range shall be 45 140 dB. The instrument shall be electronic type
with LCD display and shall be provided with battery and battery charger. Bidder
shall supply all other standard features and accessories.

3.36.00 HAND HELD THERMOCOUPLE FIELD CALIBRATOR (2 NOS.)


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VOL-II-E-SEC-IX - 14 DCPL-11Z02

It shall have following specification:

01. Indication : Liquid Crystal Display (LCD)

02. Operating Temperature
Limits : - 20 to 55 Deg.C

03. Storage Temperature
Limits : - 30 to 60 Deg.C

04. Input Impedance : T/C and mV - 13 M Ohm

05. Output Impedance : Less than 10 Ohm upto 150 nano Amps.

06. mV Resolution : 1-0 or 0.1 mv depending on function
selected

07. Temperature Resolution : 1.0 or 0.1 Degree

08. mA resolution : 0.01 mA

With other standard features and accessories as required.

3.37.00 FURNACE (1 NO.)

Furnace shall be suitable for 240V, Phase, 50 Hz power supply, capacity of
heating chamber shall be 0.25 cubic metres and it should be insulated with glass
wool and heated by high grade wire elements distributed along the bottom and
sides, giving a uniform temperature. Furnace temperature shall be indicated by a
thermometer and controlled by a thermostat over a range of 0-1100 Deg.Celsius.
ON/OFF positions of thermostat shall be indicated by an indicating lamp.


3.38.00 PORTABLE METER CALIBRATOR (2 NOS.)

3.38.01 This instrument shall provide an accurate measure of DC, AC, Volts, amps and
ohms. It shall be able to generate milliamperes for instrument calibration. It shall
be electronic type with LCD display and shall be provided with battery and battery
charger.

3.38.02 Battery charging circuit shall be integral with the instrument and shall be suitable
for 240V, AC, 50 Hz supply.

Ranges :

D.C. Volts : 0 - 1mV - 10V
D.C. Current : 0 - 1 micro A-1A
A.C. Volts : 0 - 1mV - 10V
A.C. Current : 0 - 1 micro A - 1A
Ohms : 1 Ohm - 10 M Ohms
Accuracy : 0.1%

Model Fluke 760A or approved equivalent shall be supplied.


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VOL-II-E-SEC-IX - 15 DCPL-11Z02

3.39.00 DIGITAL CABLE IDENTIFICATION SYSTEM (1 NO.)

Features : Quick identification of shorting lines and open lines.

It shall handle upto 96 pairs at one time.

3.40.00 DUAL BEAM PORTABLE DIGITAL STORAGE OSCILLOSCOPE (1 NOS.)

01. Bandwidth (3 db) : 60 MHz

02. Deflection factor : 2 mV/div. to 5 V/div.

03. No. of Steps (Vert.) : 10 (min) (1-2-5)

04. Accuracy : 2%

05. Input impendence
(Signal) : 1 M Ohm, 20 pf

06. Maximum voltage : 400V d.c./a.c. p to p

07. CMRR : 10:1 at 50 MHz (minimum)

08. Sample rate : 10 x 106/Sec.

09. Record memory : 4K points

10. Save memory : 4K points

11. Display mode : x1, x10, storage compress

12. Time base : 0.05 s/div. to 0.5 s/div.

13. No. of steps (hr.) : 20 (min) (1-2-5)

14. Input impedance
(trigger) : 20 K Ohm

15. Time base linearity : 5%

16. Z modulation
frequency : Upto 5 MHz

17. Controls available : Intensity, focus

18. Operating voltage : 100-250V AC, 50 Hz

19. Ambient temperature : 0-50 Deg.C

20. Accessories : Probes, carry case etc., as required

21. Preferred make : Hewlett-Packard

3.41.00 HAND HELD THERMOCOUPLE AND PT-100 OHM SIMULATOR AND INDICATOR (2 NO.)

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VOL-II-E-SEC-IX - 16 DCPL-11Z02


3.41.01 Bidder shall supply hand held type T/C and RTD Pt-100 simulator and indicator.
The instrument shall be electronic type with in built battery and battery charger.

3.41.02 It shall have following specification:

01. Indication : Liquid Crystal Display (LCD)


02. Operating Temperature
Limits : - 20 to 55 Deg.C

03. Storage Temperature
Limits : - 30 to 60 Deg.C

04. Temperature Resolution : 1.0 or 0.1 Degree

3.42.00 SUPPRESSED RANGE MERCURY IN GLASS THERMOMETER (1 SET)

Bidder shall supply suppressed range Mercury in glass thermometers for
temperature baths / calibrator consists of the following gauges:

0 52 deg. C : 1 No.
48 102 deg. C : 1 No.
97 152 deg. C : 1 No.
147 202 deg. C : 1 No.
197 252 deg. C : 1 No.
247 302 deg. C : 1 No.
297 360 deg. C : 1 No.
350 402 deg. C : 1 No.
395 605 deg. C : 1 No.

3.43.00 I.C. INSERTION AND EXTRACTION TOOLS FOR VARIOUS PIN NUMBERS 14,16 AND 48 (2
NOS.)

Bidder shall supply the tool having professional quality and of reputed make.

3.44.00 RHEOSTATS (1 SET.)

Bidder shall supply Rheostats of the following ratings from reputed manufacturer:

1A : 1 No.
5A : 2 Nos.
10A : 2 Nos.
18A : 1 No.

3.45.00 DESKTOP DIGITAL MULTIMETER - (2 NOS.)

Bidder shall supply desktop type Digital Multimeter for measuring DC and AC
voltages, currents and resistances. Desk top type Digital Multimeters shall have
the following features:

Display : 5 digit LED display
Measurements : DCV, ACV, Resistance (2W, 4W),

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DCA, ACA
Maximum Measurements in
standard ranges
: DCV 1000V
ACV 700V
Resistance 200 Mohm
DCA 2A
ACA 2A

Sampling rate : Selectable
Over range information : To be displayed
Data Memory : To store upto 2000 measured data
and atleast 10 set up information
Operating Temperature : 5 40 deg C
Power Requirements : 240V AC, 50 Hz
Communication Interface : RS-232C
Special functions : Auto range mode, Auto sample mode
Accessories : Power supply cord, Measurement
lead, Remote connector,

Preferred make: Fluke

3.46.00 PHASE SEQUENCE METER - (1 NO)
Electronic type

3.47.00 FREQUENCY METER (1NO.)
Electronic type

3.48.00 MINISCOPE METER (1NO.)

BW: 100Mhz, Sampling rate: 5 Gs/s, No. of channel: 2 +ext. trigger, Rise time:
3.5 ns, Time/divn.:- 5ns-60s, Vol / div. 1mv to 100v, Record length: 512 Bytes /
30000 Bytes, Screen wave form / set up memory:- 10,20,40, Ni-cd operation and
charger for minimum 4 hour operation, Automatic set up and trend plot
Accessories: Charger set, Probe set and Carrying case etc.

3.49.00 SMD REWORK STATION (2NOS.)


3.50.00 VIBRATION PICK-UP TESTER (1NO.)

Instrument shall be suitable for testing of both non contact and seismic probes
supplied by the machine monitoring instrument supplier

3.51.00 TOOL KIT BOX (10 NOS.)

Each box shall comprise of sets of Allen keys of different sizes both in inch and
millimeter, slide wrenches of different sizes, D spanner of different sizes, electric
tester, Ring spanner of different sizes, Insulated screw drivers etc. as a minimum.

3.52.00 WORK BENCH (2 NOS.)

Heavy-duty wooden construction with drawers, racks, vice, drill machine.



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VOL-II-E-SEC-IX - 18 DCPL-11Z02

3.53.00 INSTRUMENT RACK (2 NOS.)
Heavy-duty steel rack for storing bulk quantity of transmitters, switches, RTD,
thermocouples etc during any capital maintenance of machine.

3.54.00 PORTABLE PH CALIBRATOR (1 NOS.)

To check and calibrate pH measuring equipments. Compact portable simulator
shall be offered.

Range : 0 14 pH in steps of 1 pH
Accuracy : +/- 0.01 ppm
Temperature coefficient : 0.001 pH / deg C
Power source : Built in battery along with battery
check switch and indicator.
Accessories



: Connector leads, carrying case and
others as necessary.
3.56.0 PORTABLE CONDUCTIVITY CALIBRATOR (1 NO.)


3.57.0 LABORATORY PC (1 NO.)

The Laboratory PC shall be multimedia compatible and shall be provided with P-
IV processor, 1.7 GHz, 1GB DDRAM, 3 FDD, 52x CD drive 21 TFT color
monitor with minimum resolution 1600 x 1200. The system shall have 3 serial & 2
parallel ports, 2 USB port for connecting Laser printers.

Operating system : Windows 2000/ XP professional and MSDOS 6.1 / Unix

Compiler : MS C/ C++

Application software : MS project / Office 2000 XP, Visual Basic

Networking software : Communication software for LAN / Ethernet

Power supply : 240 V AC 50 Hz, 1 ph.
Suitable voltage stabilizer of adequate rating

Accessories : All necessary add ones like MODEM, Ethernet adapter
etc.

Necessary software required for interfacing with the equipments offered having
PC interfacing facility shall be provided. All software shall be provided with
License.



3.58.0 OIL CONDITION MONITOR


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VOL-II-E-SEC-IX - 19 DCPL-11Z02

Type : Portable Particle Counter
Quantity : One (01)
Power supply : 240V AC mains and Battery operated
Indication : Front panel scrollable data
Function Key : Membrane key
Memory : Adequate for at least 2000
measurements
Channels : At least six
Printer : In built
Analysis : As per international standard
Enclosure : Stainless steel
Accessories : 1. Battery charger
2. Process attachment
3. Carrying case
Tractability : Yes
Special feature : Display of environmental data such
as humidity, temperature and air
velocity

3.59.0 PORTABLE ULTRASONIC FLOW METER

3.59.01 02 (two) nos. of clamp on type portable Ultrasonic flow measuring instruments for
measuring flow through any pipe sizes in between 10 to 2500 mm with an accuracy
of +/- 1% of reading. Sensor shall be weather & dustproof conforming to IP-65. Meter
shall be programmable with alphanumeric display (LCD) and membrane type
keyboard. Battery, Charger set and Temperature sensor shall also to be provided.

3.59.02 The necessary furniture required to set up the I&C maintenance laboratory which to
be located in the station building shall be supplied along with the laboratory
instruments.

3.59.03 Laboratory and test Instruments specified shall be common for both the units (2) of
power station


3.60.0 Wet and Dry Bulb Hydrometer (1 No.)

01 (one) no. of Wet and Dry Bulb Hydrometer with power supply from three 1.5 V
alkaline batteries of reputed make shall be supplied. Measuring range shall be
10 to 95% Relative Humidity and +/- 10 to 110
0
F with an accuracy of +/-
0.3
0
F. Wicks carrying case instruction set shall be supplied with the
instruments.

3.61.0 Aneroid Barometer (1 No.)

01 (one) no. of Aneroid Barometer for measuring atmospheric pressure of shall
be supplied reputed make.

Range : 28.3 to 31.8 Hg


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VOL-II-E-SEC-IX - 20 DCPL-11Z02

Accuracy : 0.33% full scale

Sensitivity : 0.2% full scale

Scale Length : 16 through 1 pointer revolution

Dial Diameter : 4/6

Dial calibration : Standard are mm Hg or inches Hg calibration
in other units and two sets of graduations on a
single dial.

Min. Graduation : 0.5mm or 0.02


3.62.00 Test RTD (1-No)

Six digit digital display Test RTD suitable for 115/230V AC 50/60 Hz with an
accuracy of +/- 0.01
0
C shall be supplied of reputed make . The range shall
be - 200 to 800C of resolution : 0.001C and two readings per second
sampling rate.



3.63.00 mV Calibrator (Table Mounted Calibrator & Portable Calibrator) (1 No.)

This instrument shall provide an accurate and reliable measure of Millivolt
thermocouple signals and shall generate millivolt signals for calibration of
receiver type instrumentation. The instrument will contain built in electronic
null detector and standard cell. Manual/automatic reference junction
compensation shall be provided for thermocouple measurements. The
instruments shall meet or exceed the following requirements:

Input range selectable : 0 10 mV DC
0 100 mV DC

Output range selectable : 0 10 mV DC
0 100 mV DC

Protection : 100% range

Accuracy : 0.02% of selected span

Ambient temperature : 0 50C

Ambient temperature error : 0.05% of span from 0 50C

3.64.00 mA Calibrator (Table Mounted Calibrator & Portable Calibrator) (1 No.)

This instrument shall provide an accurate and reliable measure of milliamp
signals for use in calibrating receiver type instrumentation. The instrument
shall be power by a self-contained rechargeable battery pack and shall
include a battery charging circuit which operates automatically when the
instrument is connected to a 240V AC supply. The instrument shall be

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designed to operate from a 240V AC, 50 Hz supply with the battery pack
removed. The instrument shall meet or exceed the following requirements

Input range selectable : 0 10 mA
0 100 mA

Output Range selectable :0 10 mA
0 100 mA

Protection :100% range

Accuracy :0.02% of selected span

Ambient temperature : 0 50C

Ambient temp. error : 0.05% of span



3.64.00 Air Set (1 No.)

Filter element : 5 micron sintered bronze filter element

Max. primary press. : 28 kg/cm2

Secondary pressure : 0-2.1 kg/cm2

Connection : NPT (F)

Accessory : O/P Gaug




VOLUME: II-E

SECTIONX

UNINTERRUPTIBLE POWER SUPPLY




VOLUME: II-E

SECTIONX


UNINTERRUPTIBLE POWER SUPPLY




CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
CONTENT DCPL-11Z02


CONTENT



CLAUSE NO. DESCRIPTION PAGE NO.

1.00.00 SCOPE OF WORK V.IIE/S-X : 1

2.00.00 GENERAL REQUIREMENTS V.IIE/S-X : 2

3.00.00 SPECIFIC REQUIREMENTS V.IIE/S-X : 6

4.00.00 TESTS V.IIE/S-X : 13

5.00.00 DRAWINGS DATA & MANUALS V.IIE/S-X : 13

6.00.00 SPECIAL TOOLS & TACKLE V.IIE/S-X : 15


ATTACHMENTS

ANNEXURE-A RATINGS & REQUIREMENTS V.IIE/S-X : 16

ANNEXURE-B SET OF ACCESSORIES TO BE
PROVIDED FOR EACH BATTERY BANK V.IIE/S-X : 21







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VOLUME : II-E

SECTION-X


TECHNICAL SPECIFICATION
FOR
UNI NTERRUPTI BLE POWER SUPPLY



1.00.00 SCOPE OF WORK

1.01.00 Scope of Supply

The scope of supply shall include Uninterruptible Power Supply (UPS) System
as required for BTG package. The UPS shall be rated to meet all the
requirement of DDCMIS system cabinets, MMI system, servers, computers,
communication network, other C&I systems and equipments, PLC system of
BTG package, SWAS system, electrical system and other equipments
covered in BTG package which require UPS supply. The UPS shall be rated
to meet the requirements of all these systems with a loading factor of 1.25.
The UPS system shall have adequate capacity to supply clean power to the
different systems considered for the period of two hours. .

a) Each UPS System set shall comprise the following :

i) 100% Static inverter banks : 2

ii) 100% Static switches : 2

iii) Manual bypass switch/breaker : 1

iv) 100% UPS System battery banks : 2

v) 100% Float-cum-boost charger : 2

vi) Step-down transformer with associated Switchgear : 1

vii) Voltage stabilizer and back up source static switch : 1

viii) UPS A.C. Power Distribution Board : 2

b) One (1) set of special tools and tackle.

c) All inter-connecting cables including those required for inter-
connection within UPS equipment as mentioned a) above.


d) Mandatory Spare parts.


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e) List of recommended spare parts for three (3) years satisfactory and
trouble- free operation of the equipment for Purchasers consideration.

f) All relevant drawings, data and instruction manuals.


2.00.00 GENERAL REQUIREMENTS

2.01.00 Codes and Standards

a) All equipment and materials shall be designed, manufactured and
tested in accordance with the latest applicable Indian Standards (IS)
except where modified and/or supplemented by this specification.

b) Equipment and materials conforming to any other standard which
ensures equal or better quality may be accepted. In such case, copies
of the English version of the standard adopted shall be submitted
along with the bid.

c) The electrical installation shall meet the requirements of Indian
Electricity Rules as amended up to date and relevant IS Codes of
Practice. In addition, other rules or regulations applicable to the work
shall be followed. In case of any discrepancy, the more restrictive rule
shall be binding.

2.02.00 Annexures

2.02.01 All annexures appended to this specification shall form part of this
specification and supplement the requirements specified herein.

2.02.02 This specification shall be read and construed in conjunction with the
drawings and annexures to determine the scope of work and terminal points.

2.03.00 Completeness of supply

2.03.01 It is not the intent to specify completely herein all details of the equipment.
Nevertheless, the equipment shall be complete an operative in all aspects
and shall conform to the highest standard of engineering, design and
workmanship.


2.03.02 Any material or accessory which may not have been specifically mentioned
but which is necessary or usual for satisfactory and trouble free operation and
maintenance of the equipment shall be furnished.

2.03.03 The Tenderer shall supply all brand new equipment and accessories as
specified herein.

2.04.00 Guaranteed Performance

2.04.01 The proposal data sheets given in another volume of this package
specification shall be filled in without any ambiguity by typing in appropriate
place on each page.


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2.05.00 Drawing Approval


2.05.01 Before starting manufacture of any equipment, the contractor shall have to
take approval of relevant drawings and data from Owner/Consultant in writing.

2.05.02 Any manufacture done prior to the approval of drawings/data shall be rectified
in accordance with the approved drawings/data by the Tenderer at his own
cost and the equipment shall be supplied within the stipulated period.

2.06.00 Design Criteria

2.06.01 Design Basis

a) UPS System provides a regulated and uninterrupted single phase A.C.
power, within specified tolerances, to critical station loads during
normal and emergency operation.

b) The UPS system excluding its battery shall be installed indoors in A.C.
environment.

c) UPS system shall be compatible for satisfactory and well-coordinated
operation with other related equipment as well as with input and output
systems.

d) Energizing or de-energizing any portion of the system serviced by the
UPS shall not cause output changes which will affect the operation or
integrity of the remaining portions of the system in any way.

e) The equipment shall be self-protecting against all A.C. and D.C.
transients, voltage surges, and steady state abnormal voltages and
currents.

f) The circuit protection shall be coordinated with UPS short circuit
capacity and protective device characteristics so that a fault on any
circuit shall result in minimum loss of function.

g) All non-interrupting components of UPS system shall be capable of
withstanding the prevailing short circuit current without damage.

h) All circuit interrupting components shall be capable of withstanding
and interrupting the prevailing short circuit currents without damage.

i) For continuous operation at specified ratings, temperature rise of the
various components of UPS system shall be limited to the permissible
values stipulated in the relevant standards and/or this specification.

j) For selecting Battery capacity following data to be considered :

Maximum temperature : as per General Electrical
Specification.

Minimum temperature : as per General Electrical
Specification.

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Design margin : 15%

Ageing compensation factor : 1.25

Reference standard for Battery
Sizing calculation : As per IEEE Standard

k) UPS shall have automatic on line battery health checking facility as
indicated in Clause No. 3.05.00. It shall have connectivity with the
plant DDCMIS status monitoring.

l) The chargers, inverters, static switches, regulating transformers and
voltage stabilizers should be arranged in such a way that any
equipment will be fully isolated for maintenance without affecting in
any way the operation of other panels/ components.


m) In the A.C. Distribution Board, the Bidder shall provide 10% or
minimum one (1) no. spare feeder of each size and type of the
outgoing feeders.

2.06.02 System Concept

a) A D.C. power source and an A.C. power source are available to the
UPS system. The system is so designed that its load shall be served
without interruption as long as one of the above power sources is
available within specified limit of voltage and/or frequency.

The UPS will consist of two physically separate sets of equipment
streams each consisting of the following :

i) One set of converter to convert incoming 240V, 1 Ph, 50 Hz
A.C. power to suitable D.C.

ii) One set of suitable Battery Bank to get charged by the above
referred converter and to feed the inverter described below.

iii) One set of inverter to take D.C. input from above referred
converter - Battery assembly output and to produce high
quality 240V, 1Ph 50 Hz A.C. output power.

iv) One set of standby bypass stream consisting of suitable
transformer, voltage stabilizer etc. to produce regulated 240V,
1 Ph. 50 Hz A.C. power from new input 240V, 1 Ph. 50 Hz A.C.
power.



v) One set of static switch, synchronizing circuit to parallel the
above-mentioned Inverter output and bypass stabilized raw
power stream.


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vi) One UPS A.C. power distribution board with suitable no. of
output feeders.

Two sets of equipment streams as mentioned above will
constitute the UPS system.

One set of synchronizing equipment and high performance
static switch will parallel the above two streams and common
output will be taken to loads which can accept only single non-
redundant power input source.

For equipment requiring dual redundant input power source,
separate cables will be taken from the individual UPS Power
Distribution Boards of the above-mentioned two UPS streams.

The system will ensure highest system availability around
99%.

b) Each of the two UPS streams will be of 100% capacity and will
normally work, each sharing 50% load. On failure of any stream, its
load gets automatically transferred to the other inverter through static
transfer switch.

c) If one UPS stream is out of service for any reason then the second
UPS stream will be working with 100% UPS load.

d) Inside each stream on failure of its converter/battery/inverter assembly
the standby A.C. source will back up to supply the 100% UPS load
automatically through static transfer switch.

2.06.03 Layout Criteria

a) The UPS system will be located indoor in Power House operating
floor.

The inverter, static switches, chargers and distribution panels shall be
located in the UPS room. The batteries shall be located in a separate
battery room.

The charger, inverters, static switches, regulating transformers &
voltage stabilizers should be arranged in such a way that any
equipment can be fully isolated for maintenance without affecting in
any way the operation of other panels/components.


The equipment of the two UPS streams shall be physically isolated
with reasonable space between two installations.


b) Battery room ventilation shall be provided.


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c) Sufficient clear space shall be provided for comfortable attending and
removal of individual cells.

d) Sufficient clear space shall be kept in the battery room to
accommodate a battery of identical capacity in future.


3.00.00 SPECIFIC REQUIREMENTS

3.01.00 Static Inverter

a) The static inverters shall be static type consisting of IGBT PWM type
inverter, static filters, integrated control modules including necessary
oscillators, voltage regulators, current limiting and surge suppression.

b) The inverter equipment shall include all necessary circuitry and
devices to conform requirements like voltage regulation, soft start,
transient recovery, protection, automatic synchronization, wave
shaping etc. as specified herein.

c) Upon transfer of full load, the inverter output voltage shall not drop
below 80% of nominal voltage during the first half cycle after transfer
and 90% of nominal voltage in the next half cycle. The recovery to
within 2% of voltage shall be in less than 50 milli-seconds.

d) On occurrence of a fault in branch circuit, the inverter shall be capable
of clearing the highest rated branch circuit fuse in 4 milli-seconds or
less.

e) The inverter shall be protected against overload, short circuit, 100%
loss of load, as well as excursions, loss or restoration of D.C. input
voltage and synchronizing voltage. The overload capacity shall be
125% for 10 mins, 150% for 60 secs. and 300% for 4 msecs.

f) The D.C. input current shall never exceed twice the full load current
except for a short circuit within the inverter.

g) For any value of the load and load power factor drawn by the
equipment served, the inverter shall not impose on D.C. source any
voltage oscillations in excess of 5 volts (RMS total all frequencies) or
any current oscillations in excess of 3 percent (RMS total all
frequencies) of the D.C. current at full load.

h) The inverter will be self protecting against A.C. and D.C. Transients,
voltage surges and steady state abnormal voltage and currents likely
to be encountered in the plant.

3.02.00 Automatic Synchronization

a) Inverter equipment shall include stable solid-state oscillator devices
designed to automatically maintain the inverter output in phase and in
synchronism with the stand-by A.C. source.


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b) Facility shall be provided for automatic transfer to internal oscillator
operation when the stand-by source frequency is beyond specified


limits and the frequency shall be automatically controlled within 50 Hz
plus or minus 0.5 Hz when the inverter operates in this mode.

c) Retransfer to stand-by A.C. source for synchronization shall be
automatic after the stand-by source frequency is restored to
permissible limits and remains within this limit for an adjustable time
delay period (up to 5 seconds).

d) Provision shall be made for stepless adjustment of synch- disconnect
frequency range from 50 Hz 0.5 Hz to 50 Hz 2 Hz.

e) Automatic adjustment of phase relationship between inverter output
and stand-by A.C. source shall be gradual at a controlled slow rate,
which shall not exceed one hertz per second.

3.03.00 Static Transfer Switch

a) The static transfer switch shall be solid-state type using SCR for
automatic/manual transfer of load from "inverter" to "stand-by" source
and vice-versa.

b) Stand-by source can be either of the inverter or A.C. source
depending on whether both the inverters are supplying 50% load each
or one of the inverter is carrying 100% load.

c) The transfer time including sensing shall be less than 4 m.secs.
Further the transition shall be make- before-break in both directions.


d) The capacity of static transfer switch shall be equal to the continuous
full-load capacity of the inverter. The switch shall be provided with
protective devices in both normal and alternate power source.

e) Static transfer switch shall be furnished with contact to alarm failure of
the alternate source or opening of any fuse protecting the static
switch.

f) Static transfer switch shall include all necessary circuitry and devices
to meet the functional requirements of transfer initiation, transfer inhibit
and re-transfer back to normal as detailed below :

g) Transfer Initiation

i) The transfer of static switch from normal 'Inverter' position to
'stand-by' position shall be initiated by one of the following
causes.

Inverter failure and UPS system trouble.

Inverter output voltage failure.

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Manual push button operation.

ii) The UPS bus shall be monitored by two voltage detectors. One
fast acting circuit shall be used for detecting a complete


and instantaneous voltage loss while the other slower acting
averaging circuit with adjustable trip level shall be employed to
detect voltage deviation beyond selected limits. Both voltage
detector circuits shall automatically initiate operation of transfer
switch.

iii) The static switch shall automatic transfer the load from inverter
to stand-by source when the maximum I
2
t capability of the
inverter is reached and when the inverter output drops below
90%.

h) Transfer Inhibit

Automatic or manual transfer from inverter to stand-by A.C. source
vice versa shall be inhibited when the inverter frequency is not
synchronised to the alternate source.


i) Retransfer to Normal

i) The return to inverter mode shall be manual in all cases.

ii) Manual transfer shall be initiated by push button actuation.

3.04.00 Manual By-pass Switch

a) Manual by-pass switch is used to isolate any static transfer switch for
maintenance or repair without interruption to the UPS load.

b) The switch has also the facility of by-passing both the static transfer
switches during start-up at the option of the operator.

c) Switch contact shall be make-before-break type.

d) The switch shall have current rating equal to the full load inverter
current and necessary short time load carrying and interrupting
capacity to meet the requirement of UPS system.

e) Breakers may be used instead of By-pass switch maintaining the
same philosophy of operation.


3.05.00 Battery

General


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VOL-II-E-SEC-X - 9 DCPL-11Z02

The battery shall be stationary Ni-Cd Pocket Plate type and shall be suitable
for operating satisfactorily in humid and corrosive atmosphere.

For further specification requirement and details of Battery & Battery Charger
refer Volume II F /2 Section iii.

3.06.00 Float-cum-Boost Charger

3.06.01 Refer Battery & Battery Charger Specification.

3.07.00 Step-down transformer and voltage stabilizer

a) A three phase to single phase transformer along with associated
voltage stabilizer shall be furnished with the UPS system.

b) The transformer and stabilizer shall be sized for 100 per cent UPS
load and shall coordinate with the largest branch circuit protection
device for feeder short circuit current without sacrificing voltage
regulation.

c) The voltage stabilizer shall employ silicon solid state circuitry and shall
maintain the specified output voltage for 0 to 100% load with
maximum input voltage variation as indicated in the annexure. The
make and rating shall be subject to Purchaser's approval.

3.08.00 A.C. Distribution Boards

a) The distribution boards shall be fixed type, of modular design in
freestanding gasketted sheet steel enclosure conforming to IP-54.
Sheet steel thickness shall be 2 mm minimum. 100% redundant AC
distributed boards shall be provided for each UPS.

b) Each module shall be housed in a separate compartment complete
with individual front access door. Working height shall be limited to
1800 mm from floor level.

c) A full height vertical cable alley shall be provided in each panel to
facilitate module wiring. The alley shall be liberally sized and shall
have removable cover at the front. Removable back covers shall be
provided at the back of the panels.

d) Switches shall be double pole, air break, heavy duty type, capable of
safely making and breaking the full load current of associate circuit.


e) Switch handle shall have position indicator and provision of padlocking
in ON & OFF positions. Further it shall be interlocked with access
door for safety.


f) Fuses shall be HRC, preferably link type, design to permit easy & safe
replacement.

g) 20% spare feeder shall be provided.

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VOL-II-E-SEC-X - 10 DCPL-11Z02


Visible indication shall be provided for indication of fuse.

3.09.00 UPS Cabinets/Enclosures

a) The UPS system components shall be housed in a sheet steel
freestanding IP-52 enclosure with all access from the front. Sheet
steel thickness shall be 2 mm minimum.

b) The enclosure shall consist of vertical cabinets housing modules in
rack type sub-assemblies, connected mechanically and electrically to
form a rigid, self-supporting, metal enclosed structure.

c) The modular units shall be mounted in pull out and/or swing trays.
Each module shall be capable of being easily removed to provide for
the ready inspection of major solid-state devices.

d) Vertical wiring trough shall be provided for the entire height of the UPS
cabinet. Cable entry shall be from bottom only.

e) Adequate ventilating louvers and screens shall be provided. The top of
the panel shall be protected by a suitable drip cover to prevent
entrance of falling liquid and foreign material.

f) If the equipment supplied requires forced air cooling, the cooling
system furnished shall meet the following requirement :

i) Two (2) nos. 100% cooling fans shall be provided for each
vertical panel.

ii) Completely independent duplicate protection, control and
wiring systems shall be provided for the cooling fans for
redundancy.

iii) The cooling fans shall be powered from the output of the
associated inverter. Normally one fan will be running while the
other is on stand-by.

iv) Each cooling fan shall be equipped with an airflow switch
having an alarm contact that closes upon failure of airflow.

3.10.00 Alarms

a) Solid state audio-visual annunciation system shall be provided for
inverters, static transfer switch, and battery charger.

b) Alarm facia shall be provided on each charger and inverter panel,
complete with proper actuating devices, circuitry and legends.

c) The arrangement shall be such that on occurrence of a fault the
corresponding window will light up and stays lighted until the fault is
cleared and reset button pressed.


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d) Each time a window lights up a master relay will get energized to
provide group alarm signals for remote DDCMIS alarm system.

e) The requirements of indication/metering/alarms are given in the
annexure.

f) Alarm contacts shall be rated 0.5 A at 220 V DC and 5A at 240 V A.C.

g) Electrically independent, potential free alarm contacts for each of the
points mentioned in the annexure shall be wired up to the terminal
block.

3.11.00 Lamp / Space Heaters / Receptacles

a) The panels shall be provided with :

i) Internal illumination lamp with door switch.

ii) Space heater with thermostat control.

iii) 3-pin 6A receptacle with plug.

b) Lamp, heater and receptacle circuits shall have individual switch fuse
units.

3.12.00 Wiring / Cabling

a) The panels shall be completely wired up. All wiring shall be done with
flexible, 1100V grade, PVC insulated wires with stranded 2.5 Sq.mm
copper conductors and routed through wiring troughs. Each wire shall
be ferrulled by plastic tube with indelible ink print at both end having
terminal block No., terminal number as per approved wiring diagram.

b) Panels shall have removable gland plate for cable entry. All
incoming/outgoing cables shall be terminated in suitable terminal
block.

c) Control terminal blocks shall be box-clamp type, minimum 10 Sq.mm.
20% spare terminals shall be furnished.


3.13.00 Nameplate

a) Engraved nameplates shall be provided for each panel and for each
equipment/device mounted on it.

b) The material shall be anodized aluminium / lamicoid, 3 mm thick, with
white letters on black background.

c) Nameplates shall be held by self-tapping screws. The size of nameplates
shall be approximately 20 mm x 75 mm for equipment and 40 mm x 150
mm for panels.

d) Nameplates for panels shall be provided both on the front and rear.

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e) Control and meter selection switches shall have integral nameplates.
Nameplates for all other devices shall be located below the respective
devices.

f) Instruments and devices mounted on the face of the panels shall also
be identified on the rear with the instrument/device number. The number
may be painted on or adjacent to the instrument or device case.

g) Caution notice on suitable metal plate shall be affixed at the back of
each panel.


3.14.00 Grounding

a) Normal 3-phase A.C power supply will be grounded at the source. For
grounding other than this, isolation transformer shall be furnished with
the U.P.S.

b) The inverter D.C. input and A.C. output shall be electrically isolated
from each other and from cabinet ground.

c) Panels shall have fully rated ground bus with two ground terminals,
one at each end.

d) Each terminal shall comprise two-bolt drilling M10 G.I. bolts and nuts
to receive Purchaser's ground connection of 50 x 6 mm G.S. flat.

e) Separate electronic grounding shall be provided for each UPS system.

3.15.00 Tropical protection

a) All equipment accessories and wiring shall have fungus protection,
involving special treatment of insulation and metal against fungus
insects and corrosion.



b) Screens of corrosion resistant material shall be furnished on all
ventilating louvers to prevent the entrance of insects.

3.16.00 Painting

a) The panels shall be finished in light grey shade (shade 631 of IS-5) with
two coats of synthetic enamel paint. The panels shall have a matt finish
to prevent any glare from surface due to illumination.


4.00.00 TESTS

4.01.00 All equipment and components thereof shall be subject to shop tests as per
relevant IEC/BIS Standards. The tests shall include, but shall not be limited to:

4.02.00 Tests on Battery

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4.02.01 Refer Battery & Battery Charger Specification.


4.03.00 Tests on battery charger

4.03.01 Refer Battery & Battery Charger Specification.

4.04.00 Tests on UPS System

a) Type & routine test for various components.

b) Burning test on PCBS - Assembled PCBS shall be tested at 70C for 72
hours in loaded condition.

c) Rapid temperature cycling test at 70C and 0C for 30 minutes at each
temperature - 5 such cycles.

d) Functional tests to demonstrate compliance with all specified
requirements and published. Specifications such as frequency,
regulation, voltage regulation, current limiting, fuse clearing capability of
inverters, demonstration of phase and frequency control of inverter for
synchronization with range of adjustments transfer and retransfer of
static switches under influence of under voltage and over current, tests
on chargers, batteries and other system component to confirm
compliance with specification.

4.05.00 Type test certificates of any equipment shall be furnished, if so desired by the
Purchaser. Otherwise, the equipment shall have to be type tested, free of
charge, to prove the design.


5.00.00 DRAWINGS, DATA & MANUALS

5.01.00 To be submitted with the Bid


5.01.01 UPS panels, Battery Charger and Battery layout drawing with dimensions.

5.01.02 General Arrangement drawing of UPS panels.


5.01.03 Bill of Material.

5.01.04 Schematic drawing of UPS circuits.

5.01.05 Battery cell voltage characteristics and data for different discharge rates.

0.01.06 Technical leaflets on :

a) UPS System

b) Battery


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c) Battery charger

d) Inverter

e) Static Switch

f) Manual bypass Switch

5.01.07 Duty cycle diagram and battery sizing calculation in the format of IEEE
Standard.

5.01.08 Sizing calculation of UPS system, charger main equipment, viz. SCRs, rectifier
transformers etc.

5.01.09 Type test certificates for similar equipment.

5.02.00 To be submitted after Award of Contract.

5.02.01 Dimensional UPS, battery layout diagram in plan & section.

5.02.02 Connection details of take-off terminals.

5.02.03 Dimensional general arrangement drawings of UPS, battery charger, battery
clearly showing device dispositions, cable entry, space requirement, etc.

5.02.04 Sectional views of UPS System panels.

5.02.05 Panel foundation plan and loading.

5.02.06 UPS system schematics and wiring diagrams.

5.02.07 Test reports.

5.02.08 Detailed bill of materials.

5.02.09 Any other relevant drawing or data necessary for satisfactory installation,
operation, and maintenance.

5.02.10 Cable schedule & Inter-connection charts.

5.02.11 Instruction manuals of UPS system.

The manual shall clearly indicate method of installation, check-ups, and tests to
be carried out before commissioning of the equipment.

5.03.00 The Tenderers may note that the drawings, data and manuals listed above are
minimum requirement only. Tenderers shall ensure that all other necessary
write-ups, curves and information required to fully describe the equipment
offered are submitted with their bids.


6.00.00 SPECIAL TOOLS AND TACKLE


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6.01.00 The Tenderer shall quote any special tools and tackles needed for his
equipment or stated herein.



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ANNEXURE A

RATINGS & REQUIREMENTS



1.00.00 STATIC INVERTER

1.01.00 Application : UPS System for control system,
DDCMIS and other essential loads

1.02.00 Type : static IGBT PWM type

1.03.00 Duty : Continuous

1.04.00 Enclosure : Sheet steel, IP-52

1.05.00 Cooling : Natural convection or forced cooling
using redundant fans.

1.06.00 Ambient temperature : as per General Electrical Specification.

1.07.00 Inverter capacity : To be decided by the Bidder.

1.08.00 Overload capacity : 300% for 4 m secs.
150% for 60 secs
125% for 10 mins
110% for continuous

1.09.00 Voltage

a) Inverter input, Battery output : To be decided by the Bidder

b) Nominal output : 240 V, 50 Hz, 1-phase

1.10.00 Voltage Regulation:

a) Steady state (0-100% load at
all input voltages and all
power factors)
:
1.5%

b) Transient voltage
(On application or removal of
100% load)
:
10%

c) Time to recover from
transient to normal voltage
: 50 milliseconds.

1.11.00 Wave form:


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-X - 17 DCPL-11Z02

a) Nominal frequency : 50 Hz

b) Frequency range for all
conditions of input supplies,
loads and temperature
occurring simultaneous or in
any combination
(automatically controlled)
:
0.05 Hz.

c) Synchronization limits (for
maintenance of synchronism
between inverter and
standby A.C source)
: 49 Hz to 51 Hz (factory set)

d) Field adjustment range for
(c) above
: 50+_ 0.05 Hz to 50+_ 2 Hz

e) Total Harmonic Content : 5% maximum at rated load

f) Harmonic content for any
single harmonic
: 3% maximum

1.12.00 Rated output current at rated output voltage with current limit not operating :

a) Current : 200%

b) Duration : 100 milliseconds.

1.13.00 Efficiency at full load : 90% or better.
(Watt output/watt input)

1.14.00 SCR derating from peak voltage
and peak rating : 50%

2.00.00 STATIC SWITCH

2.01.00 Type : Solid-state, SCR

2.02.00 Duty : Continuous

2.03.00 Enclosure : Sheet Steel, IP-52

2.04.00 Cooling : Natural convection or forced cooling
using redundant fans.

2.05.00 Ambient Temperature : as per General Electrical Specification.

2.06.00 Capacity

a) Continuous : Equal to full load capacity of the inverter.


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-X - 18 DCPL-11Z02

b) Overload : 300% for 4 m secs.
150% for 60 secs
125% for 10 mins
110% for continuous

c) Peak : 1000% of continuous rating for 5 cycle.

2.07.00 Normal Voltage : 240V, 50 Hz, 1-phase.

2.08.00 Transient Voltage Tolerance : 340V peak above the nominal line
voltage.

2.09.00 Transfer Time : less than 4 m secs.


3.00.00 MANUAL BY-PASS SWITCH/ BREAKER

3.01.00 Type : Maintained, make before break.

3.02.00 Voltage : 600V

3.03.00 Rated Current : To meet the requirement as specified in
clause no.: 3.04.00 d)


4.00.00 BATTERY

4.01.00 Application : UPS Battery

4.02.00 Ambient Temperature :

a) Maximum : as per General Electrical Specification.

b) Minimum : as per General Electrical Specification.

4.03.00 Type : Ni-Cd Pocket Plate type.

4.04.00 Nos. of Cells per Battery : To be decided by the Bidder

4.05.00 Battery nominal voltage : 220V

4.06.00 Battery capacity in AH at 27 C
for 5 hr. discharge and end cell
voltage of 1.1 Volt/Cell : Bidder to compute considering 100%
UPS load for 30 minutes followed by
60% UPS load for 30 minutes. For 10
hrs. discharge end cell voltage will be
1.85v/cell for Lead Acid type.




CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-X - 19 DCPL-11Z02

4.07.00 Method of working

a) Float charge (Normal) : 1.4 Volt / Cell

b) Boost charge : 1.53 ~1.7 Volts/Cell
(After complete discharge)

4.08.00 Mounting : Wooden racks

4.09.00 Connection : Cables

4.10.00 Battery Size (AH Capacity) : Battery sizing calculation shall be done
in line with IEEE standard considering
temperature correction factor, design
margin and compensation for age.


5.00.00 BATTERY CHARGER

5.01.00 Charger : Float +Float-cum-Boost

5.02.00 Type : Solid-state, full wave fully controlled. 3
Phase Bridge.

5.03.00 Duty : Continuous

5.04.00 Enclosure : Sheet Steel, IP-52

5.05.00 Cooling : Natural convection or forced cooling
using redundant fans.

5.06.00 Ambient Temperature : as per General Electrical Specification.

5.07.00 A.C. input

a) Supply : 415V, 3-phase, 50 Hz, 3 wire

b) Voltage variation : 10%

c) Frequency variation : 5%

d) Combined volt frequency
Variation : 10% (absolute sum)

e) Short-circuit level : 50 KA

f) System earthing : Effectively earthed.


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-X - 20 DCPL-11Z02

5.08.00 D.C. output : 100% UPS load plus restoring fully
discharged battery to full charge
condition in 8 hours.
5.09.00 Blocking Diode, Peak inverse
voltage : 800 V (minimum)

5.10.00 Performance Requirement

a) The output voltage of the charger shall be regulated within 1% of the set
value for any load variation from 0 to 100% and A.C input voltage and
frequency variation as indicated above in 5.07.00

b) The ripple content in charger D.C. output shall be limited to less than 1%
with battery and less than 2% without battery.


6.00.00 DISTRIBUTION BOARDS

6.01.00 Type : Fixed, Modular.

6.02.00 Enclosure : Sheet Steel, IP-52

6.03.00 Mounting : Free standing
(can be attended from both front &
back)


CPCPL-Super Critical TPP-Tharangambadi
[2 x 660 MW] Main Plant Package
VOL-II-E-SEC-X - 21 DCPL-11Z02


ANNEXURE B

SET OF ACCESSORIES TO BE PROVIDED
FOR EACH BATTERY BANK

SL. NO. ACCESSORIES/DEVICES QUANTITY (Nos.)

1.0 HYDROMETER 2 NOS.

2.0 SET OF HYDROMETER SYRINGES SUITABLE FOR
THE VENT HOLES IN DIFFERENT CELLS
2 NOS.

3.0 THERMOMETER FOR MEASURING ELECTROLYTE
TEMPERATURE
5 NOS.

4.0 SPECIFIC GRAVITY CORRECTION CHARTS 2 NOS.

5.0 WALL MOUNTING TYPE HOLDER FOR
HYDROMETER AND THERMOMETER
2 NOS.

6.0 CELL TESTING VOLTMETER (3-0-3 V) 2 NOS.

7.0 ALKALI MIXING J AR 1 NO.

8.0 ACID MIXING J AR 1 NO.

9.0 RUBBER APRON 2 NOS.

10.0 PAIR OF RUBBER GLOVES 2 NOS.

11.0 SET OF SPANNERS 2 NOS.

12.0 NO SMOKING NOTICE 2 NOS.

13.0 GOGGLES (INDUSTRIAL) 2 NOS.

14.0 INSTRUCTION CARD 10 NOS.


IN ADDITION TO THE ABOVE, ONE (1) NO. MINIMUM AND MAXIMUM
TEMPERATURE INDICATOR SHALL BE SUPPLIED.