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SPECIFICATION FOR EPC CUM DEBT FINANCING CONTRACT VOLUME V INSTRUMENTATION & CONTROL WORKS CHAPTER-1 GENERAL INFORMATION 1.01.00 Information to Be Furnished With the Offer The bidder shall furnish the following documents/drawings along with the Bid: Complete Specification/data sheets, bill of material of instruments, equipment and accessories with their particulars. The proposed control schemes/logic diagrams with detailed functional write ups to meet the specification stipulations. System architecture/Configuration Drawing for DDCMIS, DCS, PLC & any other Microprocessor based control system, MIS, PADO, ERP, HMS, Simulator, Station LAN, CCTV & Plant Intruder detection System & OCAMMMS etc. Supervisory Mosaic Grid Control Panel/Desk layout/local control panel GA drawings and OWS layout drawings. Steam & Water sampling system schematic and typical general arrangement. Technical literature of all offered instruments & Equipments whether procured or manufactured. Performance report for instruments/Equipments/control system procured from other suppliers. Dimensional drawings of each type of the panels/cubicles and number of each type of the panels offered for each system. Load burden of each system/subsystem furnished by bidder to be fed by UPS and DC sources with inrush current details and heat load for each cubicle/system cabinet/panel section. Connection scheme diagrams of all instruments offered with recommended number of cores/pairs indicating separately power and signal cables wherever applicable. Grounding scheme to be adopted for the entire system and sub system.

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Complete power distribution scheme both for AC and DC system. Schedule of Design, Manufacture, Erection, Testing and Commissioning to project schedule along with PERT network/chart. All other data, drawings and documents specifically called for in various sections of the specification. 1.02.00 Documentation The bidder shall furnish the following documentation as mentioned in chapter 2 at the time of design and engineering for review & approval. Complete set of technical catalogs shall also be submitted for review & record. The number of copies will be in accordance with the enclosed Distribution Schedule. 1.02.01 ABBREVIATIONS APRDS: Aux. Pressure Reducing and Desuperheating Station AMC: Annual Maintenance Contract ATT: Automatic Turbine Tester ATRS : Automatic Turbine Runup System ACW: Auxiliary Cooling Water ACDB: Alternating Current Distribution Board APH: Air Pre Heater AAQMS : Ambient Air Quality Monitoring System AHP: Ash Handling Plant BUP: Back Up Panel BFP : Boiler Feed Pump BMS : Burner Management System BOP : Balance of Plant BTG : Boiler Turbine Generator BTLD : Boiler Tubes leak Detection System CAAQMS : Continuous Ambient Air Quality Monitoring System CCR: Central Control Room CER: Central Equipment Room CW: Circulating Water CCTV: Close Circuit Television CPU: Condensate Polishing Unit CEMS: Continuous Emission Monitoring System

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CMIMS: Computerized Maintenance and Inventory Management System COLTCS: Condenser On-Line Tube Cleaning System CRH: Cold Reheat CHP : Coal Handling Plant DMP: Dot Matrix Printer DDCMIS: Distributed Digital Control and Management Information System DCS : Distributed Control System DCDB : Direct Current Distribution Board DAS: Data Acquisition System DEHGC: Digital Electro Hydraulic Governing Control DMPS : DM Plant System EOP : Emergency Oil Pump EDMS : Electrical Distribution & Management System EHGC : Electro Hydraulic Governing Control ESP : Electrostatic Precipitator ERP : Enterprise Resource Planning EWS : Engineering Work Station EWLI : Electronic Water Level Indicator ES : Ethernet Switch FSSS: Furnace Safeguard Supervisory System FS : Fire Survival FRLS : Fire Retardant Low Smoke FG : Flue Gas GPS : Geostationary Positioning System HRH: Hot Reheat HFO: Heavy Fuel Oil HPBP: High Pressure Bypass HART : Highway Addressable Remote Transducer HSR : Historical Storage & Retrieval HEA Igniters : High Energy Arc Igniters HMI : Human Machine Interface HMS : Hart Management System IEC : International Electro-Technical Commission

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DESEIN IJP: Ink Jet Printer IPR : Interposing Relay JOP : Jacking Oil Pump LAN : Local Area Network LVS: Large Video Screen LJP : Laserjet Printer LIE : Local Instruments Enclosure LIR : Local Instruments Rack LCP : Local Control Panel LDO: Light Diesel Oil LPBP: Low Pressure Bypass LCR: Local Control Room MIS : Management Information System MFT : Master Fuel Trip MGP: Mosaic Grid Panel MIS : Management Information System

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OCAMMMS: Online Computer Aided Microprocessor Based Machinery Maintenance Management System OWS: Operator Work Station OEWS: Operating & Engineering Work Station OPC : OLE (Object Linking & Embedding) for Process Control O&M : Operation & Maintenance PADO : Performance Analysis, Diagnostic & Optimisation PLC: Programmable logic Controller POS: Plant Optimization System PTZ : PAN, Tilt & Zoom RAM : Random Access Memory ROM : Read Only Memory RO : Reverse Osmosis SCADA: Supervisory Control and Data Acquisition SG: Steam Generator STG: Steam Turbine Generator SWAS: Steam and Water Analysis System

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DESEIN 1.03.00 SPM: Suspended Particulate Matter SPM : Suspended Particulate Monitor SADC : Secondary Air Damper Control SBC : Soot Blower Control SOE : Sequence of Event

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TCP/IP : Transmission Control Protocol/Internet Protocol TDBFP : Turbine Driven Boiler Feed Pump TNEB: Tamilnadu Electricity Board TANGEDCO : Tamilnadu Generation & Distribution Corporation. TSC : Turbine Stress Evaluation Control System TBC: Turbine Bypass Control TMR : Triple Modular Redundancy TSI: Turbo supervisory Instrumentation UPS : Uninterrupted Power Supply UCP : Unit Control Panel UCD : Unit Control Desk VAS : Visual Alarm Annunciation System VMS : Vibration Monitoring System WAN : Wide Area Network

Operation & Maintenance Instruction Manual The bidder shall furnish operation & maintenance instruction manual for all the instruments/equipment supplied by them. These shall be sent along with the instruments/equipment. Instruction regarding installation, testing, calibration, repair, maintenance and commissioning of the instruments/equipment six months in advance before the commissioning date of the unit. In addition the bidder shall furnish instruction manual on operation & maintenance of their overall system. This shall be furnished to the Owner Six (6) months before the commissioning date of the unit as per the enclosed distribution schedule.

1.04.00

Drawings/Document Distribution Schedule The successful bidder will be required to furnish all the necessary Design basis reports (DBR),drawings, data sheets etc. of the Plant/Equipment with appropriate Status stamp in adequate number of copies as indicated below:S.No. "Status" of the Drawing, Data etc. Number of Copies

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1. 2. 3. 4.

"Preliminary" "Reference" "For Approval" "Final & Certified" duly signed Test Certificates Operation & Maintenance Manual Test Procedures "For Erection Purposes"

5. 6. 7. 8.

Six (6) prints Six (6) prints Eight (8) prints Ten (10) prints & one (1) Reproducible tracing Six (6) copies

9. 10. 11. 12. 13.

Ten (10) copies Six (6) copies One (1) Reproducible & ten (10) prints Erection Procedure/Manual Six (6) copies Performance & Acceptance Twelve (12) Test Procedure copies All Other Documents Six (6) copies Two additional sets of DVDs of all final control programs as implemented. Soft copies of all the drawings, Six (6) Nos. Documents, catalogues etc. with navigation facility

1.05.00

INTENT OF SPECIFICATIONS & SCOPE OF SUPPLY, DESIGN, ENGINEERING, ERECTION, TESTING & COMMISSIONING The scope of work for the equipment, materials and systems to be furnished in accordance with this specification and specified elsewhere shall include design, engineering, manufacturing, fabrication, assembly, preshipment testing at manufacturer's works, proper packing for transportation, delivery at plant site, unloading, storage, erection, interconnection with related plant and equipment, calibration, testing, commissioning and putting the instrumentation and control system together with all accessories, auxiliaries, and associated equipment as specified here in after, in a fully operational condition acceptable to the owner. The Control & Instrumentation shall be furnished, erected and commissioned and all other services shall be performed by the bidder as covered under this specification and this work shall be fully in compliance with the requirements stated herein in the tender specification for following equipments/systems/subsystems and shall not be limited to the following:a) Boiler & its Auxiliaries 1. 2. 3. 4. 5. 6. 7. 8. 9. Boiler integral controls Burner Management System/ FSSS SADC System Soot Blowing System Auxiliary P.R.D.S. System etc. Mills Control H.P. Bypass System BFP Controls & TSI Other controls as required.

1.05.01

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DESEIN b)

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Electrostatic Precipitator (Requirement of controls have been defined in ESP specifications elsewhere). Turbine and Generator set & its auxiliaries. 1. 2. 3. 4. 5. 6. 7. TG set integral control Automatic Turbine Run Up Control System Turbine Stress Evaluator control system Turbine Governing System (DEHC) & TSI Automatic Turbine Tester L.P.Bypass System Other controls as required.

c)

d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s) t)

HP/LP Heater & Deaerator. Power Cycle pumps. Turbine Driven & Motorised BFP Power cycle piping and valves Circulating Water Pumps Auxiliary Cooling Water, DMCW System & DM Makeup system Condensate Polishing Unit Chemical dozing system On line condenser cleaning System. Control valves and dampers with actuators Venturi pipes / Flow elements Field instrumentation for Compete plant. Complete Instrumentation & Control cables including all data cables, special cable, fiber optical cables required for power plant & cable trays, raceway. Plant wide area Network including complete MIS system, PC, hardware & Software and ERP system. Complete control panels & instruments in Central & Local control room. Complete C&I for off-site packages including PLC/Relay based control system, UPS, 24 V DC System, Field instruments, Cables, cable trays etc. All details, SOE, status etc for all type of electrical systems as mentioned below shall be in DDCMIS, Requirement of control & operation have been defined in specification elsewhere. i. ii. iii iv. v. Generator Transformer, Station Transformer and Unit Auxiliary Transformer 3.3 & 11 KV Switchgear & Bus duct, LT switchgear, LT Transformer. Generator Bus duct Bus Transfer Scheme Protection System for Generator, Generator Transformer, Unit Auxiliary Transformer, Station, Transformers and motors and Generator synchronizing scheme. Any other electrical system as per requirements.

vi. u)

v)

Providing Engineering Drawings, documents, licensed copy of Softwares and development tools, data, instructions, operation and maintenance manual etc for Owners review/approval/record. Arranging for Owners Inspection and testing of manufactured as well as bought out items at the respective works.

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DESEIN w)

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x) y) z)

aa) bb) cc) dd) ee) ff)

Packing and Transportation of Instruments, equipments, accessories and erection hardwares, tools from the Manufacturers works to the site, including transit insurance. Receipt, storage, preservation and conservation of instruments, equipments and erection hardware at the site. Fabrication of Site-Constructed Items. Pre-assembly (if any), erection, testing and commissioning of all the equipments and instruments in totality (including erection hardware, accessories/devices etc.). Performing availability tests and Performance and Guarantee tests on the completion of Commissioning. Furnishing of spares, tools and tackles, test and Laboratory Instruments. Fulfilling post commission liabilities. Arranging training of Owners personnel of different categories at Equipments manufacturer works. Other Activities detailed in the subsequent sections of the technical specification. Prepare and submit all approved and as built drawings both in hard and soft copies.

Any other item not mentioned above, but required for completion of Project. It is not the intent or purpose of this specification to specify all individual system/components since the bidder has full responsibility for engineering and furnishing of total system. The requirement of instrumentation and controls for the above are indicated in respective packages specification wherever required. The bidder shall be responsible for providing all materials, equipment and services, specified or otherwise which are required to fulfill the intent of ensuring operability, maintainability, and reliability of the total work covered under this specification within his quoted price. This work shall be consistent with modern power plant practice and shall be in compliance with all applicable codes, standards, guides, statutory regulations and safety requirements in force on the date of award of this contract. 1.05.02 The requirements specified herein are based on certain typical configuration of the main plant. It shall be the responsibility of the Bidder to co-ordinate with Owner and offer Instrumentation and control System to meet the actual requirements of the plant and furnish a complete system as per Section 1.05.01 above. The bidder shall also be responsible for coordination with other units in operation for proper interfacing of Instrumentation and Control System with all other related equipment and systems. In the event of conflict between requirements of any two clauses or specification documents, the more stringent requirements shall apply unless confirmed otherwise by the Owner in writing before the award of this contract based on a written request from the Bidder for such clarification. Any deviation or variation from the scope, requirement, and/or intent of this specification shall be clearly brought out under Schedule of Technical Deviations, irrespective of the fact that such deviation/variation may be the standard practice or a possible interpretation

1.05.03

1.05.04

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of the specification by the Bidder. Except for those deviations covered under Schedule, which are accepted by the Owner before contract award, it shall be the responsibility of the Bidder to fully meet the intent and requirements of this specification within the quoted price. No other departure from this specification, except for the declared deviations submitted by the Bidder with his proposal under Schedule of Technical Deviations shall be considered and bids not complying with this requirement are likely to be treated as non-responsive. The interpretation of the Owner in respect of the scope, details and services to be performed by the Bidder shall be binding, unless specifically clarified otherwise by the Owner in writing during the bidding period. 1.05.05 All equipments, systems and accessories furnished under this specifications shall be from the latest proven product range at the time of supply and of a qualified/reputed manufacturer (as per approved vendor list by the owner) whose successful performance has been established by a considerable record of satisfactory operation in coal fired power stations of capacity as specified in BQR based on the best modern engineering practice. The equipment/ devices offered shall be suitable for satisfactory performance for their respective application. The owner reserves the right to reject any work or material in which in his judgment is not in full accordance therewith. The Bidder shall furnish as per Data Requirements Schedules and other applicable sections full details regarding all equipment and systems including complete Bill of Materials, Design basis reports (DBR), drawings, data, information, technical literature and other details required to fully establish the capability and performance of the equipment and systems offered by him. Any bid not containing sufficient details to fully describe the equipment and systems offered or sufficient details regarding past experience for meeting the qualifying requirements may be treated as non responsive and hence rejected. The drawings enclosed with the specification are indicating the minimum requirement, which shall be complied by bidders. Any further improvement required during detailed engineering and execution shall also be implemented by bidder. Bidder shall confirm that the type, make, model of all bought out items supplied by the bidder under the specification shall be subject to the approval of the Owner during detailed engineering stage. Scope of Work, Exclusions and Terminal Points Scope of Work The Bidder's scope of work for this Control and Instrumentation package includes furnishing the required Control and Instrumentation equipment and materials including system design, engineering, manufacturing, supply, assembly, packing, transportation, warehousing, field construction, erection, connecting piping and wiring, cabling, shop and site tests, putting them into successful commissioning as per instructions of Owner's personnel and all other services as specified in relevant sections in accordance with the intent and requirements of this specification. The Bidder shall include in his proposal and shall furnish all equipment and services which may not be specifically stated herein but are needed for completeness of the equipment/systems furnished by the Bidder and for meeting the intent and

1.05.06

1.05.07

1.05.08

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requirements of this specification. The only exception to this requirement shall be the equipment and services which are specifically excluded from Bidder's scope. 1.05.09 Scope of Supply, Erection, Testing & Commissioning This clause describes the Control and Instrumentation equipment, materials and field construction, supply, warehousing, erection, testing, commissioning & training services to be provided for two units of Ennore SEZ, NCTPP stage IV, 2 x 660 MW Coal Based Thermal Power Plant. The scope includes the following on per unit basis except any item, equipments etc specified common for both units:1. 2. Measuring and Field instruments Distributed Digital Control Monitoring & Information System including operation, monitoring, modulating controls, interlocks & protection sequential controls, data acquisition including all auxiliaries, UCP, ECP, LVS, TSI, TSC, HMS, OCAMMMS, VMS, TG integral instrumentation, SG integral Instrumentation, Performance & optimization package (PADO), ERP package and all other control system/sub system. PLC/relay based control system including all auxiliaries, backup control desk, LVS for Offsite/BOP packages. Steam and Water Analysis System, Water analyzers, Flue Gas Monitoring and Boiler continous Emission monitoring System, Environment Monitoring System. Supervisory Mosaic Grid Control Panels/desk, OWS Consoles, printer tables, large video screens panels, Marshalling/termination panels, Interposing relay panels, control panels, System panels and other panels. Parallel Redundant Uninterruptible Power Supply System - 150 KVA UPS (min.) (or as per system requirement in case capacity is higher than 150 KVA) and its Battery separate for each 660 MW units Station C&I DDCMIS panels, BTG Panels, DCS panels, LVS, Annunciation system, SWAS, CEMS, HMS, TSI, VMS, PADO, BUP instruments, C&I Lab, Operator Training Simulator system & other microprocessor based system for BTG etc and separate parallel redundant UPS & and with its Battery (package wise) for ERP system, CAAQMS, PLC/Microprocessor based BOP system as per chapter 4 & 7. Parallel Redundant 24 V DC system and its Battery separate for each 660 MW units for MFT control panels, Turbine protection control panels and Solenid valves shall be provided by bidder. All the microprocessor based system shall be provided with UPS and 24 V DC system as per requirements specified in technical specification. Separate industrial grade UPS system shall also be provided by bidder for other system like Station LAN, MIS, and Plant Security & Surveillance system etc. specified elsewhere in specification.

3.

4.

5.

6.

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7.

H W Visual alarm/Annunciation system for BOP/off site Packages. H/W annunciation system is not required at 660 MW Central control room and LVS shall take care of Annunciation. Mandatory Spares Supply, erection, laying & commissioning of Erection Hardware & cables Control valves and flow elements, actuators, process connection and piping etc. Vibration Monitoring & Analysis System (VMS & OCAMMS) Maintenance and C&I Lab Instruments Complete Furniture including chairs, tables, almirahs etc. in CCR, computer rooms, Local control rooms, SWAS room, Lab Room, conference room, meeting room, documentation rooms, simulator room, C&I staff room, etc. as required being located in different building in bidder scope Quality Assurance, Testing and Guarantees. Material supply, ware-housing, erection, testing & commissioning. All prefab cables and connectors. Electronic earthing and panel grounding with earthing material and cables. Plant Security and Surveillance System Public Address system All OEM software & software licenses with life time validity. Station LAN, MIS system, WAN and ERP based system Special tools & tackles and test equipments Operator Training Simulator for DDCMIS & DCS Training of Plant O&M personnels. Any other item not listed, but required and mentioned elsewhere in the specification for completition of project.

8. 9. 10. 11. 12. 13.

14. 15. 16. 17. 18. 19 20. 21. 22. 23. 24. 25.

All above equipment and systems shall be furnished in accordance with the above referred sections and all other applicable sections/documents and drawings forming a part of this specification. Bidders proposal shall be based on types and quantities of instrumentation and control equipment as specified hereinafter. However, the Bidder shall furnish all equipment and

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services as per actual requirements finalised during detailed engineering stage, in accordance with drawings and documents approved by the Owner and Technical Specialist. 1.05.10 Scope of Erection, Testing and Commissioning Bidder's scope for erection, installation and commissioning work under this specification shall include: Installation, interconnection, testing and commissioning of all field instruments, equipment, cables and systems furnished by the Bidder as per this specification. This will include all required erection, testing and commissioning work for ensuring satisfactory operation of control and instrumentation equipment as per intent and requirements of this specification. Supply of all necessary tools, tackles, test instruments and experienced personnel for completion of the above erection, testing and commissioning works. Services of collaborators specialist if necessary or felt necessary by owner for successful commissioning of the system(s) shall be provided by bidder within overall Package price. 1.05.11 Other Services The Bidder shall provide all other services necessary for meeting the intent and requirements of this specification. These shall include, but shall not be limited to, the following services for all equipment/ systems furnished as per this specification: 1. System engineering and design for all equipment/systems specified on system basis to ensure that the intent and requirements of this specification are fully met. Preparation and furnishing of all drawings, data sheets, cable schedules, information as stated hereinafter in multiple copies to the Owner and other equipment bidders. This will include all drawings/documents, technical literature identified under this specification and shall be adequate for:a) Ensuring proper review by Owner to ensure full compliance with specification requirements and proper interface with other related system. Quality assurance checks during various stages of design, manufacture, installation, testing, system integration and commissioning; performance guarantee tests. Post commissioning operation and maintenance of the equipment and systems. The above drawings/documents shall be prepared by the Bidder and furnished to the Owner generally as per Distribution Schedule. As commissioned/built drawings and documents.

2.

b)

c) d) e) 3.

Participation of Bidder's senior personnel and experts in discussions with Owners and other equipment bidders during various stages of contract implementation as required by the Owner.

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DESEIN 4.

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Facilities for detailed engineering, system integration, inspection and witnessing of shop and site tests by representative of Owner and carry out performance guarantee test. The Bidder shall conduct all shop and site tests as per the requirements of this specification and Owner approved 'Quality Assurance Programme. All approval/Inspection are to be carried out by Owner or owner appointed agency only.

5.

Training/Familiarisation / Acquaintance of Owner's engineers in all aspects including system design, engineering, installation, system integration, testing, commissioning, operation and maintenance at Bidder's manufacturing works either in India or abroad. Recommendations and proposal covering spare parts required trouble-free operation. for 3 years

6.

7. 8.

Guarantee for all equipment and system furnished under this specification. Provision of post commissioning support on as required basis beyond Guarantee period on terms to be discussed and finalised later. Provision of spare parts for at least 15 (Fifteen) years after commissioning of the plant. Training of Plant O&M peronnels.

9.

10. 1.05.12 1.05.13 1.05.14

Terminal Points Nil Exclusion Nil. THOUGH GENERAL SPECIFICATION FOR INSTRUMENTS AND PLC of BOP PACKAGES ETC. HAVE BEEN INCLUDED IN VARIOUS VOLUMES OF RESPECTIVE PACKAGES, BUT THE DETAILED SPECIFICATION DESCRIBED IN THIS VOLUME- V SHALL BE FINAL AND IN CASE OF ANY DISCREPANCY OR DEVIATION BETWEEN THIS VOLUME AND RESPECTIVE PACKAGE VOLUME, SPECIFICATION DESCRIBED HERE IN VOLUME- V SHALL BE FINAL. INTERFACE WITH OWNER FURNISHED EQUIPMENT/SYSTEMS The Bidder shall furnish necessary interface equipments required for satisfactory operation of equipment furnished by the Bidder with own system and Owner furnished equipment/Systems (minimum five nos details shall be furnished during detailed engneering). This will include the following:Interfacing requirements including cables / co-axial cables / gate ways/all type of hardwares/interposing relays/ softwares for exchange of signals for information & controls are in bidder scope.

1.06.00

1.07.00

SYSTEM PARTICULARS

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DESEIN System particulars are as follows: Tropicalisation: 1.

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All equipment supplied against this specification shall be given tropical & fungicidal treatment in view of the severe climatic conditions prevailing at site as described under project data. Tropical protection shall conform to IS:3202 entitled "Climate Proofing of Electrical Equipment" or BI:CP-1014:1963 entitled "Protection of Electrical Power Equipment Against Climatic condition". Sulphur dioxide and/or trioxide fumes mildly present. Climate is tropical conductive to fungus growth. Heavily dusty with abrasive dust and coal particles of size 5 to 100 microns present in the atmosphere in large quantity.

2.

Gases and fumes

Dust particles 1.08.00 1.08.01

CODES AND STANDARDS All equipments, system and service covered under this specification shall comply with the requirements of the latest statutes regulations and safety codes as applicable in the locality where the equipments/systems will be installed. The Bidder shall fully acquaint himself with these requirements and shall ensure compliance with them. The equipments, systems and services furnished as per this specification shall conform to the codes and standards mentioned in Cl. no. 1.08.02 of this Section. However in the event of any conflict between the requirements of two standards or between the requirements of any standard and this specification, the more stringent requirements shall apply unless confirmed otherwise by the Owner in writing. The decision of the Owner shall be final and binding in all such cases. The Bidder's scope of supply shall include some items such as thermowells, and other in-line devices for main steam, hot reheat, cold reheat, feed water system falling under the purview of Indian Boiler Regulation (IBR) Act. It shall be the responsibility of the Bidder to obtain the necessary approval of the concerned Inspecting Authority/Chief Inspector of Boilers for the design and design calculations and manufacturing and erection procedures as called for under the IBR act for all items requiring such certifications. The requirements of statutory authorities (e.g. MOEF, Inspectors of factories, IBR, TAC, BEE, CPCB/TNPCB etc) with regards to various plants areas like Main plant, Fuel oil plant/system, Chlorination Plant, Fire Fighting system, Emission Measurement, Ambient Air Monitoring system etc. shall be complied, even if not actually spelt out.

1.08.02

Reference Codes and Standards The design, manufacture, inspection, testing, site calibration and installation of all equipment and systems covered under this specification shall conform to the latest editions of codes and standards mentioned below and all other applicable ANSI,

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ASME, IEEE, NEC, NEMA, ISA, DIN, VDE, NFPA, IEC, EIA, TIA and Indian Standards and their equivalents. Bidder to note that in no case, OEM/manufacturers own standards shall be accepted. 1.08.02.01 Temperature Measurement 1. 2. 3. 4. 5. 6. 1.08.02.02 Performance Test Code for temperature measurement ASME PTC 19.3 (1974 R 1998) Temperature measurement - Thermocouples ANSI-MC 96.1 1982, IEC 584 Temperature measurement by electrical resistance thermometers - IS-2806. Thermometer-element-platinum resistance-IS-2848, IEC 751/DIN 43760 RTD Design Code DIN EN 60751:1996, BS EN 60751 : 2008 Thermowell Design Code ASME PTC 19.3 TW 2010

Pressure Measurement 1. 2. Performance Test Code for pressure measurement - ASME PTC 19.2 (2010) Bourdon tube pressure and vacuum gauges - IS 3624, IS 3602, ASME B 40.1

1.08.02.03

Electronic measuring Instruments & Control hardware 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Automatic null balancing electrical measuring instruments - ANSI C 39.4 (Rev. 1973), IS 9319 Safety requirements for electrical and electronic measuring and controlling instrumentation - ANSI C 39.5 - 1974. Compatibility of analog signals for electronic industrial process instruments ISA-S 50.1:ANSI MC 12.1 - 1975. Dynamic response testing of process control instrumentation - ANSI MC 4.1 (1975): ISA-S26 (1968). Surge withstand capability (SWC) tests - ANSI C 37.90A (1974) IEEE Std. 472 (1974). IEC 255.4. Printed circuit boards - IPC TM-650, IEC 326 C General requirements and tests for printed wiring boards - IS 7405 (Part-I) - 1973 Edge socket connectors - IEC 130-11. Requirements and methods of testing of wire wrap terminations DIN 41611 Part-2. Dimensions of attachment plugs & receptacles ANSI C73-1973. Direct acting Electrical Indicating Instruments: IS-1248-1968.

1.08.02.04

Instrument Switches and Contacts 1. 2. Contact rating - AC services NEMA ICS Part-2 125, A600 Contact rating - DC services NEMA ICS Part-2-125, N600.

1.08.02.05

DDCMIS & other Control System 1. 2. Application of Safety Instrumented System ANSI/ISA 84.01 1996 Functional Safety - Safety Instrumented System for Process Sector IEC 61151

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DESEIN 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17

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IEEE Application Guide for Distributed Digital Control Monitoring for Power Plant IEEE 1046 Fossil Fuel Power Plant Steam Turbine Bypass System ANSI/ISA 77.13.01 Human System Interface Design Review Guide lines NUREG 700 Annunciation Sequence and Specification ANSI/ISA 18.1 IEEE 1050, IEEE guide for Instrumentation & control system grounding in generating station, ANSI/ISA-77.44.01-2007 - Fossil Fuel Power Plant - Steam Temperature Controls ANSI/ISA-RP77.60.05-2001 (R2007) - Fossil Fuel Power Plant Human-Machine Interface: Task Analysis ANSI/ISA-77.42.01-1999 (R2006) - Fossil Fuel Power Plant Feedwater Control System Drum-Type ANSI/ISA-77.20-1993 (R2005) - Fossil Fuel Power Plant Simulators - Functional Requirements ANSI/ISA-77.41.01-2005 - Fossil Fuel Power Plant Boiler Combustion Controls ANSI/ISA-RP77.60.02-2000 (R2005) - Fossil Fuel Power Plant Human-Machine Interface: Alarms ANSI/ISA-77.70-1994 (R2005) - Fossil Fuel Power Plant Instrument Piping Installation ANSI/ISA-TR77.60.04-1996 (R2004) - Fossil Fuel Power Plant Human-Machine Interface-Electronic Screen Displays ANSI/ISA-77.43.01-1994 (R2002) - Fossil Fuel Power Plant Unit/Plant Demand Development-Drum Type ANSI/ISA-77.13.01-1999 - Fossil Fuel Power Plant Steam Turbine Bypass System

1.08.02.06

Electronic Cards, Subassemblies and Componets a) Unpackaged i) ii) iii) b) Vibration : Shock : Drop & Topple : IEC-68.2.6 IEC-68.2.27 IEC-68.2.31

Packaged Vibration, Drop & Static Compression - NSTA

C)

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

1.08.02.07

UPS System/DC control power supply system: 1. Practices and C34.2-1973. requirements for semi-conductor power rectifiers - ANSI

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DESEIN 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Vol-V : Instrumentation & Control Works

12. 1.08.02.08

Relays and relay systems associated with electrical power apparatus - IEEE Std. 3.13, ANSI C 3790-1983. Surge withstand capability tests - ANSI C37.90a-1974. IEEE Std. 472 - 1974 Recommended practice for sizing large lead storage batteries for generating stations & substations - IEEE-485. Performance testing of UPS - IEC 146. IEC 62040 General & Safety requirement of UPS. IEC 62040-2 UPS EMC Requirement. IEC 62040-3 UPS Method of specifying the performance and test requirement. IEC 60269-2 Main Supply Fuse. IEC 60947 MCCB. IEC/EN 60623 BATTERIES. IEEE485/IEEE1115 IS : 10918, IS : 1069 IEC 60146 For DC system.

Control Valves 1. 2. 3. 1) 2) 3) 4) 5) 6) 7) 8) Control Valve sizing - Incompressible fluids - ISA S39.2 - 1972. Control valve sizing - Compressible fluids - ISA S39.3 - 1973, ISA S39.4 1974. Face to face dimensions of control valves - ANSI B16.10 ISA Hand book of control valves - ISBN B1047-087664-234-2. Valves - flanged, threaded and welding end : ANSI B 16.34(2009) Casting : ASTM A 216 / A 351 (2008) Welded end connection : As per ASME boiler and pressure vessel code / ANSI.B 16.34(2009), B16.25 (2009), B 16.11(2009). Defect removal: ANSI B 16.34 2009. Cleaning : ASTM A 380 2006. CV test : As per ISA procedure S 75.02 (2008). Control Valve seat leakage : ANSI/FCI 70.2

1.08.02.09

Enclosures 1. 2. 3. Types of enclosures - NEMA Std. ICS-6-110.15 through 110.22 (Type 4 to 13). Racks, panels, and associated equipment - EIA: RS-310-B (ANSI C83.9 - 1972) Protection Class for Enclosure, Cabinets, Control Panels and Desks - IS-139471962.

1.08.02.10

Apparatus, enclosures and installation practices in hazardous areas 1. 2. 3. 4. Classification of hazardous area - NFPA Art. 500, Vol.70-1984. Electrical Instruments in hazardous dust locations - ISA-RP 12.11 Intrinsically safe apparatus - NFPA Art.493 Vol.4.1978 Purged and pressurized enclosure for electrical equipment in hazardous location - NFPA Art. 496 1982.

1.08.02.11

Sampling System

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DESEIN 1. 2. 3. 4. 1.08.02.12

Vol-V : Instrumentation & Control Works

Stainless steel material of tubing and valves for sampling system - ASTM A26982 Gr TP316. Submerged helical coil heat exchangers for sample coolers ASTM D 11-98. Water and Steam in power cycle - ASME PTC 19.11(2008). Standard methods of sampling system - ASTM D 1066-69.

Annunciators 1. 2. Specifications and guides for the use of general purpose annunciators - ISA RP 18.1-1979. Surge withstand capability tests - ANSI C.37.90a - 1974 and IEEE std. 472-1974

1.08.02.13

Interlocks, Protections 1. 2. 3. 4. 5. Relays and relay system associated with electric power apparatus - IEEE std.3.13. Surge withstand capability tests - ANSI C.37.90a - 1974 and IEEE Std. 472 1974. General requirements & tests for switching devices for control and auxiliary circuits including contactor relays - IS-6875 (Part-I) 1973. Turbine water damage prevention - ASME - TDP-1980. Boiler safety interlocks - NFPA Section 85B, 85D, 85E, 85F,85G.

1.08.02.14

Process Connection and Piping: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Codes for pressure piping power piping ANSI B31.1 Seamless carbon steel pipe ASTM A-106. Forged and Rolled Alloy steel pipe flanges, forged fittings, valves and parts ASTM A-182. Material for socket welded fittings - ASTM A-105. Seamless ferrite alloy steel pipe - ASTM A-335. Pipe fittings of wrought carbon steel and alloy steel - ASTM A-234. Composition bronze or metal castings - ASTM B-62. Seamless copper tube, bright annealed ASTM B-168. Seamless copper tube - ASTM B-75. Dimensions of fittings - ANSI B-16.11 Valves flanged and butt welding ends - ANSI B16.34. Nomenclature for Instrument tube fittings ISA-RP-42.1 - 1982.

1.08.02.15

Instrument Tubing 1. 2. 3. 4. Seamless carbon steel pipe - ASTM - A106. Material for socket weld fittings - ASTM - A105. Dimensions of fittings - ANSI B16.11 Code for pressure piping, welding, hydrostatic testing - ANSI B31.1.

1.08.02.16

Cables 1. 2. Thermocouple extension wires/cables - ANSI C 96.1 - 1982. Colour coding of single or multi-pair cables VDE 0815

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DESEIN 3. 4. 5. 6. 7. 8. 9. 10. 11.

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12. 13 14 15. 16. 17 1.08.02.17

Guide for design and installation of cable systems in power generating stations (insulation, jacket materials) - IEEE Std. 422 - 1977. Requirements of vertical tray flame test - IEEE 383 - 1974. Standard specification for tinned soft or annealed copper wire for electrical purpose - ASTM B-33 - 81. Oxygen index and temperature index test - ASTM D-2863. Smoke generation test - ASTMD-2843 and ASTME-662. Acid gas generation test - IEC-754-1. Swedish chimney test - SEN - 4241475 (F3) Instrumentation cables and internal wiring IS-1554 (Part-I, 1976) and IS5831(1984). Standard for Control, Thermocouple Extension and Instrumentation cable NEMA WC57-2004 ICEA S-73-532, Rev. 2, 2004) PVC insulated (heavy duty) Electric cables for working voltages upto and including 1100V - IS:1554 (Part-I) Conductors for insulated electric cables and flexible cords. - IS:8130 PVC insulation and sheath of electric cables - IS:5831 Mild steel wires, strips and tapes top armoring cables - IS:3975 Water Immersion Test - VDE 0815 Drums for electric cables - IS : 1048

Cable Trays, Conduits 1. Guide for the design and installation of cable systems in power generating station (cable trays, support systems, conduits) - IEEE Std. 422, NEMA VE-1, NFPA-70-1984. Guide for the design and installation of cable systems in power generating station (Cable trays, support systems, conduits) Test Standards, NEMA VE-1 1979. Galvanising of Carbon steel cable trays - ASTM A-386-78.

2.

3. 1.08.02.18

Flow measurement 1. 2. 3. ASME Performance Test Code PTC-19.5 (2004), ISA RP3.2 BS 1042 ISO 5167

1.08.02.19

Surge Protection System 1. 2. 3. Surge withstand capability tests - ANSI C37.90a-1974. IEEE Std. 472 1974 IEC 61643-1:1998-02 and E DIN VDE 0675 part 6:1996-03/A2: 1996-10 IEC 61643-21:2000-09 and E VDE 0845 part 3-1:1999-07

1.08.02.20

Digital Video Recording & Management System (DVRMS) 1. 2. ISO 9001 (2000) ISO/IEC15504 Level3 or higher (SPICE 2.0 Software Process Improvement and Capability Determination)

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DESEIN 3.

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SEICMM Level3 or higher (American Software Engineering Institute - Capability Maturity Model)

Where: i) IEEE - Institute of Electrical and Electronics Engineers. ii) ISA - Instrument, Systems and Automation Society iii) NEMA - National Electrical Manufacturers Association iv) ANSI - American National Standards Institute v) NFPA - National Fire Protection Association vi) ASME - American Society of Mechanical Engineers vii) IS - Indian Standards viii) IEC - International Electro-technical Commission ix) ASTM - American Society for Testing Materials x) EIA - Electronic Industries Association xi) DIN - Deutsche Institute Normale xii) TIA Telecommunication Industries Association

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DESEIN

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CHAPTER-2
DESIGN CRITERIA 2.00.00 2.01.00 2.01.01 Design Criteria General Requirements The design criteria given in this section supplements the requirements stated in other sections of this specification and the drawings enclosed herewith. These shall be fully met by all equipment/systems and accessories furnished as per this specification. All equipment/systems and accessories furnished as per this specification shall be from the latest proven product range of a qualified manufacturer meeting the requirements given in this Specification. The Bidder shall furnish satisfactory evidence regarding successful operation and high reliability of the proposed equipment/systems in coal fired utility stations for similar applications for meeting this requirement as specified elsewhere. The equipment and systems shall be designed and constructed to meet all specification requirements, and perform accurately and safely under the environmental and operating conditions described or implied in this specification without undue heating, vibration, wear, corrosion or other operating troubles. It will be the responsibility of the Bidder to fully acquaint himself with the functional requirements and operating conditions, for equipment systems and accessories offered for this project. Additional features shall be provided where required to meet the service conditions, functional or descriptive requirements stated in individual specification for these equipment/systems. The bidders detailed design and scope of supply shall include all components and systems, whether included in the system descriptions or not, required to provide a complete and fully functional facility. These specifications are on per unit basis. 2.01.04 The equipment, systems and accessories furnished as per this specification shall be designed and constructed to meet all specification requirements and performance specifications during the continuous service life of the plant. The equipment or components that cannot meet this life expectancy or specified design and operational requirements during the entire service life shall be identified and their expected failure rate shall be indicated by the Bidder in his proposal. When no such information is furnished the equipment shall be deemed to have been certified by bidder suitable for the above service life and requirements. During execution of the project or at the time of dispatch, any latest product is launched or introduced then the same shall be supplied with out any price implication. Technical specifications specified for all type of hardwares, instruments, equipments & software are the minimum requirements to be met and confirmed by bidder. All the

2.01.02

2.01.03

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DESEIN

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hardwares and softwares shall be latest, with advanced features and field proven at the time of supply / dispatch as available in the market with out any price implication. Bidder shall offer latest system available at the time of supply / dispatch & shall also confirm that DDCMIS/PLC system/microprocessor based control system, MIS, ERP system etc. hardware / software shall be upgraded free of cost (for hardware up to commissioning of the project and software up to handing over of the project), whenever at later stage such upgradation takes place for his system offered by him or by his collaborator. In addition to above requirements, Bidder shall also undertake to upgrade the system hardware if required by owner, at par with the new version, for a period of 5 years after commissioning at a reasonable extra cost and The future updated version of any type of software shall be supplied free of cost as and when such software is upgraded, on request by owner until 5 years from the date of commissioning of the unit. 2.01.05 Even after the guarantee period, the Bidder shall be responsible for providing spare parts and other required support at reasonable cost during the service life of the plant as indicated above. Any exception to these requirements shall be clearly indicated in the Schedule of Technical Deviations. Bidder shall also guarantee supply of spares for at least 15 (Fifteen) years after commissioning of the plant. In case of future up-gradation of a product in terms of hardware, bidder shall remain committed to upgrade the supplied system at Par with the new version as per scheduled agreed with owner for a period of 5 years from the date of commissioning of the unit. Beyond this period, for up to 15 years, Bidder shall be obliged to indicate whether it will be possible to upgrade the system by replacing certain pieces/components of hardware by suitable new generation equipments. 2.01.06 All requirements of auxiliary equipment for instruments and control devices including thermocouples and wells, resistance elements and wells, transmitters, special wiring and piping accessories, air filter and pressure regulators, separation chambers, condensation pots and all other special devices required for installation in instrument piping and wiring system shall be furnished complete as required for each individual element, instrument or system unless specifically stated otherwise in this specification. Each pneumatic device requiring air supply and intended for field mounting shall include a filter regulator air set with gauge, to owners approval. Process fluids shall not be piped directly to instruments located in Control Room (CR) and Control Equipment Room (CER) unless otherwise specified herein. All 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. Components of instruments, control devices, accessories, piping etc. Which contact with steam, condensate or boiler feed water shall be manufactured from copper free materials which do not react with media at operating parameters.

2.01.07

2.01.08

2.01.09

2.01.10

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DESEIN 2.01.11

Vol-V : Instrumentation & Control Works

Temperature measurements shall have fail safe protection feature against open circuits of sensors. Apart from fail safe protection against open circuit, temperature measurement shall have protection against rate of rise of temperature more than pre-defined value. All motorised valves of 200NB or more than 200NB size shall be provided with integral motorised bypass valves on all process lines. All the LP heaters & HP Heaters shall be provided with upstream, downstream & bypass motorized valves. All the work stations, PC, OWS, Printers, Laptop, Servers as mentioned anywhere in this NIT/specification shall meet the minimum technical requirements specified in chapter 4, Vol. V. Each communication Network shall be industrial grade and shall be provided with industrial grade managed type Ethernet switches, external surge protection system/devices and industrial firewall. Industrial grade managed type Ethernet switches shall be provided with in built diagnostic features, 20% spare ports & in built redundant power supply. Bidder to note that all type of hardwares & electronic modules like controllers, I/O cards, communication modules and interface modules etc used in PLC shall be of same family and sourced/supplied from their Principals works. Valve end position (Open & Close) shall be monitored for the manual critical valves, wherever provided. Design criteria for continuous on line analytical measurements of important plant media such as water, steam and flue gas shall be based on microprocessor based instruments only. All the instruments/equipments/electrical items shall be provided & designed with maximum star rating as available in line with energy conservation policies notified by BEE, GOI at the time of supply. In Fire Protection & Detection system, Loop wiring & Panel networking shall be designed meeting the NFPA Style 7 requirements. All the instruments/equipments/electrical items shall be provided & designed with maximum star rating as available in line with energy conservation policies notified by BEE, GOI at the time of supply. All process parameters (i.e. pressure, temperature & flow) shall be indicated in the P&IDs on all important process lines. All approval/Inspection are to be carried out by Owner or owner appointed agency only. Incomer/outgoing feeders for any Distribution Boards rated upto 63A shall be with fast acting semi conductor fuse & MCB controlled, from 63A to 400A shall be MCCB

2.01.12

2.01.13

2.01.14

2.01.15

2.01.16

2.01.17

2.01.18

2.01.19

2.01.20

2.01.21

2.01.22

2.01.23 2.01.24

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DESEIN

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Controlled. Above 400A it shall be breaker controlled. Each feeder shall be provided with LED indication. 2.01.25 All tag nos. shall follow KKS numbering. For 2 x 660 MW, First units tag nos shall have prefix 10, Second units tag nos shall have prefix 20 and common system, Tag nos. shall have prefix 00. Environmental Conditions Instruments for location in outdoor/indoor/air-conditioned areas shall be designed to suit the environmental conditions indicated in specification elsewhere and shall be suitable for continuous operation in the operating environment of a coal fired utility station without any loss of function, or departure from the specification requirements covered under this specification. All equipment/systems for air conditioned areas shall also be designed and constructed to operate indefinitely without loss of function, departure from specifications or damage during periods of air conditioning failure in summers even if such temperature may rise up to 55 deg. C. The period for which the equipment/system can function satisfactorily without A/C (Air Conditioning) shall be mentioned by the bidder. Power Supply and Air Supply Power Supply A. UPS (Uninterrupted Power Supply System) 1. The parallel redundant UPS system furnished by the Bidder shall meet the power requirements of reliable 240 V AC, 50 Hz power supply for DDCMIS, DCS, microprocessor based control system, indicators, recorders, monitoring system, analytical instruments, SWAS, TSI, LVS, VMS & OWS, Printers, Sol. Valves, CCTV, Security System, PADO etc. as specified in various chapter for BTG packages. Separate parallel redundant UPS of adequate capacity shall be supplied for PLC package and microprocessor based system provided with BOP & offsite packages as specified in specification elsewhere. All major equipment/systems shall be served from UPS through redundant two 100% capacity feeders (from 2x100% ACDB) with a automatic change over at load point to ensure un-interrupted supply even on loss of one feeder as described elsewhere in the specifications.

2.02.00 2.02.01.01

2.02.01.02

2.02.01.03

2.03.00 2.03.01

2.

B.

24 V DC Power Supply system 1. For 24 V DC power supply requirments, Bidder shall furnish the separate parallel redundant 24 V DC charger system for each unit for MFT control panels, Turbine protection panels, and Solenoid valves in BTG package.

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DESEIN 2.

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Parallel redundant 240 V AC to 24 V DC convertor with 50% sharing shall be provided for 24 V DC power supply in each cubicle separately as per requirements for DDCMIS, DCS, PLC package and microprocessor based system provided with BTG & BOP packages as per chapter 4 & Annexure A.

Detailed specification of UPS & 24 V DC system are specified elsewhere in the specification. C Power Supply Monitoring Facility 1. The power supplies for all control panels are to be monitored for under voltage/over voltage. Necessary alarms are to be initiated for under voltage/over voltage. Loss of single power source in case of redundant power supplies is to be alarmed in DDCMIS/PLC for all control panels by providing voltage monitoring relays.

2.

2.03.02 2.03.02.01

Air Supply Clean, dry, oil free instrument Quality air of the following quality shall be provided by bidder for various pneumatic instruments/control drives & accessories:1. Nominal pressure 2. Range of pressure 3.Dewpoint 4.Maximum particle size : : : : 7Kg/cm2 gauge 3.5 to 8.5 Kg/cm2(g) + 2`C at the above pressure. - 40 deg.C at NTP 5 microns

2.03.02.02

Pneumatically operated equipment offered by the Bidder shall be designed to operate with the above air supply and adequately cater to their respective duty within the full range of pressure variation. Wherever required, moisture separator for vital instruments/actuator/analyzer may be provided in the airline by bidder. The Bidder shall indicate system wise requirement of instrument air along with his proposal and same shall be included in the compressor capacity as supplied. Instrument Standard Scales and Ranges Instrument Scales Instrument scales will be black graduations in white dials and where practicable 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. All scales and charts shall be calibrated and printed in Metric Units as follows:Metering bases and chart units 1. Temperature Degree centigrade (deg. C)

2.03.02.03

2.04.00 2.04.01

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DESEIN 2. 3. 4. 5. 6. 7. 8. 9. Pressure Draught Vacuum Flow (All gases) Flow (Steam) Flow (liquid) Flow base Density -

Vol-V : Instrumentation & Control Works

Kilograms per square centimeter (kg/cm2) Millimeters of water column (mm wcl.) Millimeters of mercury gauge (mm Hg) or water column (mm wcl) Tonnes/hour or Cubic meters per hour. Tonnes/ hour Tons/hr. or Litres/minute or cubic meters/hour Based - 760 mm Hg, 16 deg.C Grams per cubic centimeter 'g' to indicate absolute or

Pressure instrument shall have the unit suffixed with 'a' or gauge pressure.

Scales and charts of all instruments shall have linear graduations and the Bidder shall offer devices for square root extraction or other functional operations required for this purpose. Local indicator scales may be non-linear if approved by the Owner. 2.04.02 Instrument Ranges Instrument ranges will be selected to have the normal reading preferably at 75% of full scale. Deviation indicators shall have the null position at mid scale. Ranges of pressure gauges shall be selected to allow normal operation in the middle one third of the scale. The normal operating parameters shall be identified with a clear green mark. When compensation is required to implement the functional requirements and descriptive requirements of control systems furnished under these specifications, the following compensation ranges shall apply: -----------------------------------------------------------------------------------------------------Measurement Temperature Range Pressure range `C Kg/Sq.cm ------------------------------------------------------------------------------------------------------1. Feed water Flow 150 to 300 300 to 400 2. Secondary airflow 0 to 500 3. Primary airflow 0 to 500 4. Steam flow 200 to 650 50 to 300 Where temperature compensation networks are furnished, they shall produce corrections which are in accordance with theoretical requirements over the specified variations, 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. 2.05.00 2.05.01 Choice of Hardware General The primary objective for the design of instrumentation and control systems shall be to assist in the attainment of maximum unit availability.

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DESEIN

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Instrument sensing, transmission, measuring system shall be of latest microprocessor based/solid state electronic type with signal transmission in current mode with 4-20 mA level except for local instruments. All instruments and control devices located on control panels shall be of miniaturized design, suitable for modular flush mounting on control panels with front draw out facility and flexible plug-in connections at the rear. The interrogation voltage level for plant annunciation, interlock and protection systems shall be adequate to ensure high signal to noise ratio. but should not exceed 60V DC. The logic system shall be adequately protected from signal and power line borne noise and surge voltages and shall satisfy stipulations in specification. All instrument contacts unless otherwise specified shall be rated for interrupting 5 AMP at 240V AC, 50 Hz and 0.5 Amp at 220V DC. Potential free contacts at output of interlock and protection system for interlocking with electrical switchgear & motor control centers shall be capable of interrupting at least 10 Amps at 240V, 50Hz and 2 Amp at 220V DC. 2.05.02 Operability & Maintainability The design of the control systems and related equipment shall adhere to the principle of "fail safe" operation at all system level. "Fail Safe Operation" signifies that the loss of signal, loss of power or failure of any component will not cause a hazardous condition and at the same time prevent occurrence of false trips. The types of failure which shall be taken into account for plant shall include but not limited to:1. 2. 3. 4. 5. ensuring operability of the

Failures of sensors or transmitters producing high or low signal Failure of controller other modules during automatic operation. Loss of motive power to final control element Loss of control power. Loss of Instrument Air.

The Bidder shall ensure proper operability of all instruments and control modules and also take into account protections to minimise accidental mal operations, in the operator interfaces and configuration of panel boards offered. 2.05.03 Established Reliability All components and systems offered by the Bidder shall be of established reliability. The minimum target reliability of each component shall be established by the Bidder, considering its failure rate & meantime between failures & meantime to repair (MTTR), such that the availability of the complete system i.e DDCMIS, DCS & PLC etc is assured for 99.7%. Further the Bidder shall ensure that all equipment/parts of his system, that are not listed under recommended spares shall have the general service life for 15 years as per manufacturer standard practice.

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DESEIN

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In order to ensure the target reliability the bidder shall perform necessary availability tests and burn in tests for major systems. Surge protection for electronic control systems, annunciation system and other solid state systems conforming to SWC test per ANSI C 37.90a (IEEE standard 472) and selection of proper materials, manufacturing processes, quality controlled components and parts, adequate de-rating of electronic components and parts shall be ensured by the Bidder to meet the reliability and life expectancy goals. 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. In general, failure of equipment used for alarm purpose will cause switching to the alarm state. Mean Time between Failure (MTBF) of the instruments shall be considerably higher than the equipments/system, they shall cater to in order to avoid shutdown on account of instrumentation failure. All instruments and control equipments shall ensure high reliablility, low down time and ease of maintenance. 2.05.04 Provenness, Standardization and Uniformity of Hardware All C&I equipments furnished must have proven performance of working in the power plant, at least two sets of such equipment installed in a power plant of capacity as specified in BQR have been running successfully for at least two years. No prototype components shall be used. The Bidder shall state the application, the performance of the equipment furnished, including accuracy, repeatability, drift due to time and temperature, etc. and give the equipment list and the examples and statements for their application in his proposal. To ensure smooth and optimal maintenance easy interchangeability and efficient spare parts management of various C&I instruments/equipment like vibration monitoring systems, all 4-20mA electronic transmitters/ transducers, control hardware, control valves, actuators and other instruments/ local devices etc. being furnished by the Bidder for main plant areas (eg. boiler/turbine etc.) and other plant and station auxiliaries, Off site/BOP packages for similar applications, the Bidder shall ensure that they are of the same make, series and family of hardware. The bidder shall obtain & furnish the certification from his tieup partners (as consortium or other wise) that their design, enginnering, procurement, manufacturing, erection, commissioning and shop test facility are adequate to meet the specified technical & performance/quality requirements for execution & commissssioning of the package offered to the satisfaction of owner. 2.05.05 Redundancy Criteria for Sensors and Signals from MCC/SWGR Redundancy of components and systems shall be dictated by availability criteria described under DDCMIS/DCS/PLC to ensure the system availability target as well as safety considerations in critical applications are fully met.

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DESEIN

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Bidder shall also introduce redundant control equipments or instruments wherever it is felt by owner that the introduction of the same shall lead to reduction of downtime of plant and equipments, in addition to the case/criteria clearly defined/identified in the specification. Triple redundancy or dual redundancy for signals from MCC/SWGR, sensors and transmitters will be used for critical control /Protection application, critical monitoring application & other control/interlock applications. Where correction/ compensation for the measured signal are involved, the computed signal shall be the one transferred for control purposes. The measured value indicated shall be the duly corrected/ compensated signal. Sensor/signals/measurements redundancy required (2 out of 3 or 1 out of 2) requirement have been specified in respective control system specifications and as specified elsewhere in the technical specification. However, sensor/signals/measurements utilization will be decided during detailed engineering. It is mandatory to use sensors/signals/measurements with 2 out of 3 logic for critical control & protection (Analog & Binary) application/service and sensors with 1 out of 2 logic for all other control & interlock (Analog & Binary) application/service as explained below 2.05.05.01 Triple measurement scheme Triple measurement scheme for analog inputs employing three independent transmitters connected to separate tapping points shall be employed for the most critical measurements. The same shall be used in analog control functions including, the following but not limited to, furnace draft, feed water flow, Feed Water Temperature, feed water pressure before Economiser, Discharge Flow of each BFP, BFP discharge Temperature, Boiler Separator level control, Steam Pressure, Main steam & RH steam temp. control, SH spray Flow, RH spray Flow, throttle pressure, PA/SA Air Flow, PA/SA Air Temperature, PA header pressure, Mill Air Flow, Mill outlet Temperature, Feeder Speed Control, Spray water flow, SH, RH & Aux. Steam Desuperheater inlet & outlet Temp at each stage, SH Platen Steam Temperature before Desuper heater, SH Platen Steam Temperature after all super heaters, RH steam Temperature at Turbine end, Main steam Temperature at turbine end, turbine first stage pressure, deaerator level, Deaerator Flow after Last LPH, Hotwell level, GS steam Pressure, condensate flow before recirculation line, turbine speed, Turbine Control Valve position, Power measuring device, HP/LP Heater level, PA header pressure, SCAPH temp. Control, HP Bypass controls, LP Bypass controls, Light Oil Pressure, Heavy Oil Pressure, Atomising Steam Pressure, Heavy Oil Temperature, Hydrogen gas pressure of generator, and all other trip & protection logics etc. For MFT/FSSS/BMS/Turbine protection/ Generator/Unit tripping, triple sensors shall be provided. For Binary and analog inputs required in major equipment (Furnace, Turbine, tripping/protection of any HT drive etc.) protection triple-sensing devices shall be provided. Binary and analog inputs, which are, required for protection of more than one equipment as well as protection signals for HT Drives (fed by a supply feeder of ratings 3.3 kV onwards)/MDBFP/TDBFP etc., triple sensing devices shall be provided. Triple sensors shall be provided for Instruments required for auto starting of HT driven pumps or pump tripping due to very low level of water/discharge pressure very low and

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Trip of any auxiliary which will lead to substantial (50%) loss of unit availability. For lube oil protection of all the HT drives, 2 out of 3 logics and necessary pressure transmitters for lube oil pressure shall be provided by bidder accordingly. Left and right side shall be treated as individual path / individual parameter, and each side/path shall have own triple redundancy accordingly. 2.05.05.02 Dual measurement scheme For binary and analog inputs required for other modulating control, protection and interlock purpose of other equipment and other critical monitoring application etc., min. dual sensors shall be provided. Dual sensors shall be provided for instruments required for auto starting of LT driven pumps or LT driven pump tripping due to very low level of water/discharge pressure very low. Dual sensors shall be provided for instruments required for Heat rate measurements & PADO calculations. Dual measurement scheme for analog inputs employing two independent transmitters/ temperature element, connected to separate tapping points shall be employed for the remaining measurements used for analog control functions. 2.05.05.03 All the instruments/ sensors/transmitters/switches meant for redundant applications shall have completely separate and independent impulse pipes/ root valves etc. No redundant instrument shall share a single process tapping. There will be separate and independent tapping for every individual instrument. Back-Up Instrumentation i. No full backup discrete hardwired based control or hardwired manual operation is envisaged in the 660 MW Unit control room for main plant. Bidder shall however perform a failure analysis to establish that the plant can be safely shutdown or can be brought to a safe operating condition without any damage to equipment and / or personnel during the unlikely event of catastrophic failure of DDCMIS/DCS. Since nowadays the reliability and availability of control system is enhanced due to the redundancy path, backup panel with mosaic and vertical type (not L type) is to be provided with as minimum as possible for safe guarding the main equipments BTG and auxiliaries. Hence in addition to the LVS and OWS, a limited operation from backup unit control vertical panel with mosaic is envisaged for emergency operation and to provide safe shut down of plant/equipments. The backup Unit control vertical panel with mosaic shall housed Conventional Push-button (ILPB) stations, Console inserts (SG & TG), Trip Push Buttons, Ammeters, CCTV for Furnace Flame, chartless recorders & digital display units for Boiler, Turbine & Generator Process/electrical parameters. Also bidder to refer details in Chapter 6.

2.05.06

ii.

iii.

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DESEIN iv.

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Back up panel system shall be designed for handling the situation in clause 2.12.00 for failure of HMI. For electrical layout, complete backup panel with mosaic shall have to be provided for complete on/off operations with necessary meters, DDUs, synchronoscope etc. as specified elsewhere in specification. Control panel cum desk with HW annunciation windows, ILPBs, Ammeters, PBs, voltmeters, indicators, mimic, recorders etc. shall be provided as per Annexure A Control System Philosophy for BOP packages. Profile/Overall GA of backup control panel cum desk for BOP packages shall be same as indicated in drawing no. 114-05-0105 attached with NIT.

v.

iv.

2.06.00

PROTECTION, CLASS OF CABINETS / PANELS, ENCL.OSURES ETC. a) All panels, desks cabinets, consoles & enclosures furnished at least comply with the requirements of protection classes as indicated below. In-door Air-conditioned (A.C.) areas In-door Non A.C. areas: (a) Ventilated enclosures (b) Non Ventilated. 3. Out-door (As per the requirement) b) Distribution boxes, junction boxes, cold junction compensation boxes, terminal boxes and all other field mounted equipment to be furnished as per this specification shall have weather protection conforming to IP 65. The design of panels, cabinets, enclosures and packaging density of components mounted therein shall be such that the temperature rise does not exceed 10 deg. C above the ambient under the worst conditions. The panels housing electronic hardware shall be provided with flame and smoke detectors by bidder. Enclosures for peripheral equipments like printers, etc. shall take care of noise and shall ensure minimum possible noise disturb to the working personnel. IP42 IP 54 IP55 / IP65 IP32/42 (min.)

1. 2.

c)

d)

e)

2.06.01

Guards, barriers and access doors, covers of plates shall be marked to indicate the hazard, which may occur upon removal of such devices. Danger or caution signs shall be used to warn of specific hazards such as voltage or current. The marking shall be permanently affixed to the equipment. System Documentation

2.07.00

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DESEIN

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Master document/drawing list along with dates within 3 months shall be submitted by bidder after award of contract for each package for approval of owner. The Bidder shall provide drawings, system overview & description, hardware/software details, Technical literature, functional & hardware schemes, bill of material, parts list, Inter connection diagrams, data sheets, erection/installation/commissioning procedures, Instruction/operating manuals, etc. for each of the C&I system/sub-systems/equipment, supplied under this package. The documentation shall include complete details of the C&I systems/sub-systems/equipment to enable review & approval by owner during detailed engineering stage and to provide information to plant personnel for Operation & Maintenance (including quick diagnostics & trouble shooting) of these C&I systems/subSystems/equipments at site. Following minimum documents shall be submitted by bidder during detailed engineering for review and approval: DATA / DETAILS TO BE FURNISHED S.no Description Category C&I System Design Basis Report incorporating Control philosophy / 1 A operation philosophy / Design philosophy / Redundancy philosophy. 2 Codes and application standard followed for the project. A Process & Instrumentation Diagrams (PID) indicating local gauges, 3 A transmitters, analysers for (alarm, control etc.) Engineering documents For DDCMIS/DCS & PLC based control systems: a. Bill of Quantity for DDCMIS/DCS/PLC based system b. I/O Assignment for DDCMIS/DCS, each PLC based control system including nest loading. c. Instrument Schedule with set points d. I/O List e. Drive List/ Solenoid Valve List f. Annunciation List 4 g. SOE list. A h. Process mimics/graphics indicating Analog and digital parameters i. List of logs with point assignment j. Time Synchronisation System k. Historical Storage and Retrieval (HSR) system details. l. List of Displays m. Plant Performance Calculation & Optimisation package Details n. Controller partitioning Diagram o. Data sheet for HART management system p. Drive Control Philosophy & MCC Interface diagrams Detailed technical catalog about the Analog / Digital input and output 5 modules, drive control modules, main control processor, operator A consoles, printers etc, shall be furnished for scrutiny. 6 Modulating Control and Sequential Control Schemes with Write ups A Logic diagrams (SAMA format) for Main Plant, Utility & Aux. Plants 7 A along with system description / functional write-up. System Architecture/System Configuration Drawing for DCS/ Each PLC 8 based Offsite Package including MMI, interface with Third party A systems, Master clock and Local Control Desks/Annunciator panel Back up panel/Unit control panel, Annunciator window layout and 9 A inscription.

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DESEIN 10 11 12

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13 14 15 16 17 18

19

20 21

22

23 24 25 26 27 28 29 30 31 32

LVS data sheets, GA drawings along with catalogs Field Instruments data sheets along with catalogs System Configuration Diagram with DDCMIS/DCS interfacing details for special monitoring & analysis systems like vibration analysis, PADO, Management information system, Security & Surveillance system, Flame Analysis , Tube Leak Detection etc. Vendor Data sheets for C&I system equipment including DDCMIS/DCS / PLC based control system. Sub-vendor's drawings and documents for all main & BOP packages Central Control room layout / SWAS room layout / Local Control Room & all control panel layout including Unit control panel. G.A.(General Arrangement) and Internal arrangement drawings of all control panels/ cabinets / local panels with all dimensional details, wiring diagrams and terminal details. Sampling schemes including SWAS schemes. Interconnection diagram, cable schedule, MCC Interfacing diagram. UPS/24 V DC system Single Line Diagram, UPS/24 V DC Load List, UPS Datasheets, G.A drawings of UPS/24 V DC system, Panel Specification, Operation Philosophy, Wiring Diagrams, Battery Sizing Calculations, Battery Data Sheets, Battery Stack GA Drawings and 24VDC system Heat load and power consumption data for PLCs and DCS. UPS and +24VDC JB Schedule, LIE/LIR for Transmitter Groupings (P, DP, F, L and transmitters) Data Sheets, sizing calculation, for Control valves & its Accessories, Data Sheets, sizing calculation, for Flow elements, BOQ, QAP, Internal TC, Technical catalogs, O&M Manuals Solenoid Valves Data Sheets for Solenoid valves, Control Valve noise calculation (both hydro-static & hydro-dynamic). Installation sketches (Individual Instrument Hook Up Drawing and Installation isometric drawings.) Hardware & software design manual (covering exhaustive details of compete DDCMIS/DCS / PLC based control system) QAP(Quality assurance plan) for all major equipment. Mandatory Spares and Recommended Spares List. Detailed technical literature of each type of instrumentation equipment offered shall be furnished. Detailed manufacturer's cable specification/data sheets with GA drawing for offered cable shall be furnished. Factory Acceptance Test (FAT) procedure/Site Acceptance Test (SAT) Procedure / Availability test procedure / PG test procedure for C&I equipment including DDCMIS/DCS / PLC control systems. Duly signed schedule of performance guarantees, List of softwares included. All test certificates including degree of protection certificates for all packages and Explosion proof certificates for oil services. Confirmation certificate for the latest version of software and hardware offered.

A A A A A A

A A

A A A A A A A A A A

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33 34.

Thermowell Sizing calculation. Vendor data sheets/GA drawings/Catalogue for each C&I system as specified in NIT.

A A

35.

All other documents not specifically mentioned here but required for A/I as completion of engineering work and proper coordination shall be unit finalized by wise. All other documents specifically called for in various sections of TANGEDCO specification. Data sheet/specifications of components/modules etc. in respect of each and every electronic card/module as employed on the microprocessor based control system and equipment including conventional instruments, peripherals etc. All type tests for the C&I systems/sub-systems/equipment as stipulated in QA section shall be included. Plant Process Simulator System documernts and data sheets Above A stands for Approval and I stands for Information. A

36.

37. 38.

If any documentations/ data sheets are required by the owner during evaluation stage or detailed engineering stage. Bidder is supposed to provide the complete information and satisfy the owner without any ambiguity. 2.08.00 System Expandability Modular System design shall be adopted to facilitate easy system expansion. The system shall have the capability and facility for expansion through the addition of controller modules, I/O cards, hand/auto stations, push button stations, peripherals like Large Video Screen (LVS), operator workstations (OWS), printers etc. while the existing system is fully operational. The system shall have the capability to add any new control loops, groups/subgroups, in control system while the existing system is fully operational. 2.09.00 On Line Maintenance It shall be possible to remove/replace online various modules (like I/O module, interface module etc.) from its slot for maintenance purpose without switching off power supply to the corresponding rack. System design shall ensure that while doing so, undefined signaling and releases do not occur and controller operation in any way is not affected (including any control loop trip to manual, etc) except that information related to removed module is not available to controller. Further, it shall also be possible to remove/replace any of the redundant controller module without switching off the power to the corresponding rack and this will not result in system disturbance or loss of any controller functions for the other controller. The on-line removal/insertion of controller, I/O modules etc. shall in no way jeopardise safety of plant and personnel. 2.10.00 Fault Diagnostics The DDCMIS/DCS/PLC shall include on-line self-surveillance, monitoring and diagnostic facility so that a failure/malfunction can be diagnosed automatically down to the level of individual channels of modules giving the details of the fault on the programmer station displays and printers. The faults to be reported shall include fault in main & standby

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power supplies, sensor fault, Controller fault, any channel fault in 2V3 channels, failure of links to PLCs, LAN etc. These faults and Controller faults shall be reported as colour change on system status display and messages on programmer LVS/OWS as well as through local indication on the faulty channel/ module and on respective rack/ cubicle. The diagnostic system shall ensure that the faults are detected before any significant change in any controller output has taken place. Failure of any I/O modules, Controller etc. shall be suitably grouped and annunciated to Annunciation facia on LVS/OWS/BUP. 2.11.00 2.11.01 Fault Tolerance & Controllability The DDCMIS/DCS/PLC shall provide safe operation under all plant disturbances and on component failure so that under no condition the safety of plant, personnel or equipment is jeopardised. Control System shall be designed to prevent abnormal swings due to loss of Control System power supply, failure of any Control System component, open circuits/short circuits, instrument air supply failure etc. On any of these failures the controlled equipment/parameter shall either remain in last position before failure or shall come to fully open/close or on/off state as required for the safety of plant/personnel/equipment and as finalised during detailed engineering. System shall be designed such that there will be no upset when Power is restored. The system shall be designed to permit the operator to supplement but not inhibit the protective functions. The control system furnished under this specification shall not inhibit a greater capacity output than the rated capacity of the unit, if permitted by the main plant equipment and required by the Owner. The controlled variable response rate & controllability shall be limited by the characteristics of main equipment, which is being controlled, and DDCMIS/PLC shall not impose any limitations in the response rate or controllability. Controlled process variables shall return to normal values in a stable manner and without control loop interactions or cycling of generation when generation matches with load demand. No single failure either of equipment or power source shall be capable of rendering any part/system/sub-system of DDCMIS/PLC inoperative to any degree. STATION BLACKOUT Availability of all equipments, drives, emergency power supplies, controls, logics required for the protection/safe operation/shutdown of the boiler/turbine and auxiliaries during emergency blackout shall be ensured by bidder. All the related drives, controls shall operate automatically on the occurrence of blackout. All such drives, controls required during emergency and black out shall be provided with continuous power supply source (each type of power supply depending upon requirements, sizing shall be done considering this requirements) to ensure availability and shall be designed for fail safe mode. All the required controls shall be available as the system to be powered from plant UPS. The UPS sizing shall consider this requirement. 2.13.00 ELECTRICAL NOISE CONTROL The equipment furnished by the Bidder shall incorporate necessary techniques to eliminate measurement and control problems caused by electrical noise. Areas in

2.11.02 2.11.03

2.11.04

2.11.05 2.12.00

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DESEIN Bidders equipment which are eliminate possible problems.

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vulnerable to electrical noise shall be hardened to

The Bidder shall be fully responsible for detailed recommendations on the type, size, shielding, input balancing, ripple amplitude and frequency, isolation and grounding for field inputs and for equipment furnished by the Bidder to achieve an installation with minimum noise from all sources. The Bidder shall carefully review the Electrical Field Construction and cabling specifications given in Section-9 of this volume. If the performance of the equipment furnished by the Bidder is likely to be adversely affected in any manner because of these cabling and electrical field construction practices, the Bidder shall bring this to the attention of the Owner along with his proposal. Any additional equipment, services required for effectively eliminating the noise problems shall be identified by the Bidder and shall be included in his lump sum proposal. The Bidder shall be fully responsible for satisfactory elimination of any noise problems that evidence themselves following the installation of the equipment. All expenses incurred in the elimination of noise problems shall be borne by the Bidder. 2.14.00 SURGE-PROTECTION DESIGN CRITERIA FOR SOLID STATE/MICRO PROCESSOR BASED EQUIPMENTS/DCS/DDCMIS/PLC/UPS etc. i. All solid-state equipment shall be able to withstand the noise and surges inherent in a powerhouse. The equipment shall be designed to successfully withstand without damage to components and/or wiring, application of surge withstand capability (SWC) wave whose shape and characteristics are defined in ANSI publication C37.90a - 1974 entitled "Guide for surge withstand capability (SWC) Tests". All solid state equipments, power supply to electronic cards, power supply to controllers, PLC panels, DDCMIS panels, SMPS power supply, UPS, battery chargers etc shall have external surge protection device with Plug ability and life indication as per IEC 61643-1:1998-02 and E DIN VDE 0675 part 6:1996-03/A2: 1996-10, to withstand max. 40 kA, 8/20 u Sec of Surge. The connection of the devices should be made as per TT configuration wherever applicable. Signal lines shall have surge protection devices with pluggability and testability as per IEC 61643-21:2000-09 and E VDE 0845 part 3-1:1999-07, to withstand max. 20 kA, 8/20 u Sec of surges. For data lines, communication lines, Ethernet/Can networks/LAN, Coaxial lines modular surge protection device should be used as per IEC 61643- 21:2000-09 to withstand a min of 2.5 kA, 8/20 u Sec of surges. The surge protection device should be used with the corresponding connector as being used for the lines i.e. RJ45, D-Sub, BNC, N-Type etc. "The Bus systems (like Profibus/ Modbus etc) or the Serial Port Systems (like RS232/ RS-485 etc) shall be protected with suitable surge protection devices, confirming to the latest IEC-61643-21 guidelines. The surge handling capacity of

ii.

iii.

iv.

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device shall at least be 10 KA, 8/20 Sec between core-core and 20 KA, 8/20 Sec between core-ground. The device shall be pluggable & on-site testable". v. All electronic cards/modules shall also be protected from failure against accidental/inadvertent application of high voltage upto 500V DC (common mode) even though these modules may be designed to operate at lower voltage levels such as 24V/48V. In the case of DC powered system/subsystem/instrument, the design shall ensure protection against reverse polarity. The Bidder shall provide details of production tests being carried out to fully satisfy the Owner that the proposed equipment meets the above requirements and to assure that the products furnished shall be of the desired grade.

vi.

iv.

2.15.00

General Tools and Tackles, Special Calibration Instruments: Bidder must offer general tools & tackles and special calibration instruments required during start-up, trial run, operation and maintenance of the plant.

2.16.00 2.16.01 2.16.02

PG TEST POINTS Pressure, temperature and flow test points shall be provided in line with latest performance test code requirements. In addition, pressure and temperature test points shall be provided for the following services: (a) (b) (c) (d) At the discharge of all pumps and fans At the inlet and outlet of the heat exchangers for the fluid media involved Adequate number at the Combustor at different zones At the inlet and outlet of each control valve

2.16.03

Pressure test points shall be complete with root valves and shall terminate with a nipple. Temperature test points shall be provided with thermowell with a cap and chain.

2.16.04

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DESEIN

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CHAPTER-3 FIELD AND MEASURING INSTRUMENTS 3.00.00 3.01.00 3.01.01 FIELD & MEASURING INSTRUMENTS (PRIMARY & SECONDARY INSTRUMENTS) GENERAL REQUIREMENTS Instruments, control devices and other equipment accessories covered under this specification shall be furnished in accordance with I&C specification sheets and drawings enclosed herewith and the requirements of all applicable clauses of this specification. The instrumentation and control equipment shall conform to all applicable codes and standards including those referred in Cl. no. 1.08.00 in this Volume. All equipment and systems shall also fully comply with the design criteria stated in chapter-2 of this part. The instrumentation/control equipment and accessories shall be from the latest proven design for which the performance and high availability have been demonstrated by a considerable record of successful operation in power station service for similar applications. The bidder shall furnish sufficient evidence to fully satisfy the Owner in this regard. For plug in type instruments, The plug & sockets shall be polarized to prevent wrong connections and have facility for secure coupling in plug-in position to prevent loose connections. Signal/Electrical connection shall be screwed connection with double compression type Nickel-plated brass cable glands for Explosion proof area, Flame proof area and high vibration prone area. Every instrument requiring power supply shall be provided with a pair of easily replaceable glass cartridge fuse of suitable rating. Every instrument shall be provided with a grounding terminal and shall be suitably connected to the panel grounding bus. All field instruments shall be weatherproof, drip tight, dust tight and splash proof suitable for use under outdoor ambient conditions prevalent in the subject plant. All field-mounted instruments shall be mounted in suitable locations where maximum accessibility for maintenance is achieved. The enclosures of all electronic instruments shall conform to IP-65 unless otherwise specified (Explosion proof for NEC article 500, class 1, Division 1 area & flame proof) and an anti corrosive paint shall be applied to the field mounted enclosures / instruments. All the field instruments shall also be provided with SS tag nameplate and double compression type Nickel-plated brass cable gland. Gaskets, Fasteners, Counter and mating flange shall also be included wherever required with the field instruments. Following minimum requirement of field instruments shall be fulfilled by Bidder (In addition, Redundancy criteria for field instruments shall be as specified else where in specification): i. Level switches / pressure switches / flow switches/any other process switches etc. for OLCS / Alarms / Interlocks / Protection. Pressure switches at inlet, outlet

3.01.02

3.01.03

3.01.04

3.01.05

3.01.06

3.02.00

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of individual pumps and discharge header of pumps for protection and auto start / stop & alarms. ii. iii. Level switches for sump/tank level high/normal/ low/very low interlocks. Level Transmitters (Type tank/bunker/vessel/heaters. as per Owner approval) for open sump/

iv. v.

Stand pipes on both side of tank for all level instruments (LT, LS & LG). Flow elements with flow transmitter & Flow meter for flow measurement of process medium like Steam, Water, Air, Flue Gas, Fuel oil, open channel liquid, solid fuel, ash flow, DM water, Raw water, Instrument and Service air etc. as decided by owner. Pressure gauges and temp. Gauges at inlet and outlet of each heat exchanger and cooler. DPG, DPT & DPS across the filters/strainers. Tapping points/test points shall be provided. All primary Instruments, hardwares & JBs etc used for measurement for HFO, LDO & Turbine Lube Oil system shall be flame proof (IEC-79.1, Part I). All primary Instruments, hardwares & JBs etc used for measurement for Hydrogen shall be intrinsically safe and explosion proof as per NEC article 500, class 1, Division 1 area I. All Thermocouples & RTDs shall be Duplex. All Field Instruments used in acid or alkaline atmosphere shall be with standard Anti corrosion coating i.e. the combination of Polyurethane and epoxy resin baked coating (ANSI/ISA-71.04). All primary instruments installed at Minus level or Floor shall be with protection class of IP 68. Transmitters (all type) for monitoring & controls purpose. Pull cord, belt sway, zero speed switches, emergency stop PB for conveyers, other limit switches, cable gland etc. of CHP which produce spark shall be provided with dust and flame proof enclosure conforming to IS-2148. Lockable Deinterlock switches shall be provided for CHP as per requirement. Bidder shall provide electronics weighing in motion system as per IS-11547, hermitically sealed load cell of precision strain gauge type,100% over load protection of cell and 250% overload protection for the construction; one calibrator attachment with two weighers.

vi.

vii. viii. ix.

x. xi.

xii.

xiii. xiv

xv xvi

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DESEIN xvii

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All field mounted push button, selector switch etc. shall be as per IEC or NEMA 4X protection. All limit switch shall be conform to IEC-60947-5-1. At APH, temperature measuring device of different lengths forming grid shall be provided to have average temperature for variable flow of flue gas, secondary air and primary air. These temperatures may be connected to nearest remote I/O panel. On both left and right sides of furnace, separate lines shall be laid and provided with furnace pressure transmitters having wide range than the furnace pressure transmitter. Temp. Transmitters are envisaged with RTD & Thermocouples for monitoring services/application only. However any RTD & Thermocouples are used for control, interlock & protection application, same shall be directly wired to DDCMIS/DCS/PLC using instrumentation & Extension cables respectively. As for the water flow/ steam flow measurements, necessary flow elements/ transmitters are chosen in the process line and supplied such that their algebric summation shall be mass balanced for calculating the system efficiency. Contacts less, electronic 2-wire position transmitters shall be provided for all inching type motorised valve and dampers. For CW sump level, Raw water reservoir level, Turbine oil tank, coal bunkers, Ash Silo, LDO/HFO tank, DM water tanks, CS tank, Acid and alkali applications, only non contact type level transmitters like Acoustic, Ultrasonic, Radar based shall be provided by bidders as specified in NIT and as approved by owner. Considering the type of application, wireless technology to bring signals to DDCMIS may be adopted by interfacing with OPC gateway to avoid cabling for smart level transmitters specified above at sr. no. xxiv. However Wireless technology as adopted by Bidder shall be reliable and field proven in power plants and same shall be approved by Owner. For Turbine oil, HFO/LDO applications & H2 Gas application, zener protection on power supplies shall be included. Where the process fluids are corrosive, viscous, solid bearing or slurry type, diaphragm seals shall be provided. Parts below the diaphragm shall be removable for cleaning. The entire volume above the diaphragm shall be completely filled with an inert liquid suitable for the application. For HFO, LFO Applications, SS capillary with thin wafer element with ANSI RF flanged ends are to be provided. For hazardous area, explosions proof enclosure as described in NEC article 500 shall be provided.

xviii xix

xx.

xxi.

xxii.

xxiii.

xxiv.

xxv.

xxvi.

xxvii.

FIELD INSTRUMENTS SHALL BE SUPPLIED & OFFERED AS PER DATA SHEETS SPECIFIED BELOW:

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DESEIN 3.03.00 3.03.01

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TRANSMITTERS, SWITCHES, GAUGES AND PANEL MOUNTED INSTRUMENTS Pressure, Differential Pressure, DP type Level and Flow Transmitters (PT, DPT, LT & FT) Smart Transmitters of the electronic type shall be furnished. All Transmitter shall be installed in closed LIE in the boiler area. Similarly transmitter for TG shall also be in LIE except the transmitters located in covered area on TG floor and these shall be mounted in LIR. Transmitters shall be equipped with mounting brackets suitable for a mounting in transmitter enclosures. In general, Transmitters are envisaged to be grouped at several places as to be decided during detailed engg. stage. For this purpose, suitable enclosures complete with all tubing, fittings, purge meters, loop cable trays etc. shall be provided. Type/Construction Material - Body : Sealed capacitance/ resonance type Inductance/ Silicon

- Diaphragm - Measurement element - Valves

: : :

Die cast Aluminum with epoxy coating for air & flue gas SS316 for other services 316 SS Teflon seal Carbon steel for non-corrosive Applications SS316 for corrosive applications. 4 to 20 m Amp. DC (Two wires) HART Compatible LCD indicator (5 digit) with scale of Engg. unit + 0.04% or better of Span for BTG package + 0.065% or better of Span for BOP packages + 0.2% or better of span for remote seal type transmitter. 100:1 in general + 0.15% of URL for 5 years. 150 msec. 24V DC nominal 600 Ohms nominal IP-65 (Explosion proof for NEC Class-1, Division 1 area) Locally adjustable, non-interacting

Output signal Local Indicator Overall Accuracy

: : :

Turn down ratio Stability Response time Power supply Drive capability Enclosure Class Span and Zero

: : : : : : :

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Zero suppression / elevation Connection - Process

At least 100% of Span

- Electrical

1. Half (1/2) inch NPT (F) Quarter (1/4) inch NPT with/without oval flanges Suitable for Plug in type connection (Both side of transmitter), unused entry with blind plug.

Accessories

: Two (2) valve SS316 manifold Three (3) valve SS316 manifold Five (5) valve SS316 manifold Separator diaphragm seals Mounting bracket

- For Absolute Pressure Transmitters: - For Gauge & Vacuum : pressure transmitter - For DP, level & flow : transmitter - For oil and corrosive : liquids - For all transmitters :

Manifold should not be mounted on the transmitter, Manifold shall be non integral and standalone type. Snubbers/Pulsation dampners shall be used where the process media is unstable for measurement such as the discharge of a pump. Over range protection shall be used where necessary. The coil syphons & condensate pots shall be used for steam services. Transmitters shall be provided with suitable drain & vent points. 3.03.01.01 Transmitters & other HART based instruments shall be supplied along with 3 Nos. of universal type hand held/portable pressure calibrators. Temperature transmitters shall be supplied along with 3 Nos. of hand held/portable mV source generators. PRESSURE SWITCHES (PS) & DIFFERENTIAL PRESSURE SWITCHES (DPS) Applicable Standards : IS3624 - 1966/ISA-RP-8.1 except as modified in spec. Bourdon/Sealed Diaphragm Piston Actuated preferable. Indicators with contacts are not acceptable. 316 SS 316 SS 316 SS Die-cast aluminum with stoved enamel black finish. Epoxy coating shall be provided for corrosive atmosphere. Teflon

3.03.02

Type/Construction Materials - Bellows - Bourdon tube - Movement - Enclouser

: : : :

- Protective Diaphragm

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Accuracy Repeatability Setting & Differential Contact - Number - Type - Rating Connection - instrument Electrical

: : :

+ One (1) percent or better + 0.5(half) percent or better Adjustable

: : : : :

DPDT /2 SPDT Auto reset with internal Adjustable snap action micro switch 5 Amp, 240V AC / 0.2 Amp, 220V DC Half (1/2) inch NPT Male Process Suitable for Plug in type connection. All the switches are internally connected and brought to the surface with Amphenol male/female connection. Cabling need not terminated inside the switch. Cable ends are to be soldiered in connector and to be inserted for easy maintenance. One Fifty (150) percent of full scale IP-65 or better (Explosion/Flame proof for NEC Class-1, Division 1 area) As applicable for all switches Pump and compressor discharge lines For all steam lines For fuel oil & corrosive liquid lines. Local (in LIE/LIR for BTG package).

- Over range protection Enclosure Class Accessories - 3 / 5 valve manifold - Self cleaning type pulsation dampners/Snubber (Material SS316) - Syphon - Protective separating diaphragm Mounting 3.03.03

: :

: :

: : :

PRESSURE & DIFFERENTIAL PRESSURE GAUGES (PG & DPG) Applicable standard Type/Construction -760 mm to 1.0Kg/cm2 -Above1.0Kg/cm2 - Suction side of pumps Materials - Bourdon tube - Bellows - Movement - Case : IS:3602-1966, IS/3624, ASME B 40.1

: : :

Bellows/Diaphragm Bourdon Tube Compound gauge

: : : :

316 SS 316 SS 316 SS SS 316/ Die-cast aluminum with stoved enamel black finish. Epoxy coating

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- Protective Diaphragm Dial size Scale Details

: : :

shall be provided for corrosive atmosphere. Teflon 150mm with shatter proof glass Graduations in black lines on white dial, on white dial, 270 Deg. pointer deflection scale provided with glass cover. Smallest scale division shall be one (1) percent of full scale value or smaller. Pointer stop for all gauges. + One (1) percent or better 1/2 inch NPT Male Bottom Local 1/2 inch NPT Male (Back entry) mounted on local gauge board. IP-65 or better (Explosion/Flame proof for NEC Class-1, Division 1 area)

Accuracy Connection - Instrument Process Mounting Enclosure Class Accessories

: : : : :

- 3 way needle valve/manifolds : - Self cleaning type : Pulsation dampener/snubber (S316) - Syphon : - Protective separating : Other particulars - External Zero adjustment - Safety device Ranges 5 to 20 Kg/cm2 Ranges above 20 Kg/cm2 - Over range protection Other Requirments : : : :

For all gauges Pump and compressor discharge lines For all steam lines For fuel oil and corrosive liquid lines

For all gauges

Rubber blow out disc with open front construction. Neoprene safety diaphragm at the back with solid front construction. One Fifty (150) percent of full scale Movement mechanism shall be glycerin filled for oil services & vibration prone area. For Fuel oil & corrosive liquid lines diaphragm type sensors required. Armored capillary of 10 M for Fuel oil & Corrosive liquid service.

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Contact type pressure gauges are not acceptable for interlock & protection. For condensate storage tank the pressure gauge in terms of0-10000 mm wc or suitable range having dial size of 300mm or bigger size shall be provided.

3.03.04

TEMERATURE TRANSMITTERS Type : SMART type configurable from control room through HART protocol (HMS System). Indicating type (5 digit LCD Display), +0.10%, 0.1% per 10C change 4-20 mA DC (2 wire system) HART compatible signals for analogue monitoring inputs to the distributed control system (DDCMIS), DCS & PLC. NEMA 4/IP66 or equivalent degree of protection for enclosure)/ (Explosion/Flame proof for NEC Class-1, Division 1 area)/ flame proof (IEC-79.1, Part I). As applicable). SS316. + 0.1 % or + 0.1 deg C of reading (whichever is great) for 2 years in case of RTD inputs and for 1 year in case of Thermocouples inputs. 16 48 V DC as per NIST monograph 125 for T/C & European Curve Alpha = 0.00385 for RTD . Provided Locally adjustable, Non interacting Provided Provided Provided Provided

Display type Accuracy Ambient temperature error Output

: : : :

Protection class

Material of accessories Stability

: :

Operating Voltage Calibration

: :

Ref. Junction compensation Span/zero adjustment Auto calibration Burn out protection upscale Input - output isolation Circuit ungrounded

: : : : : :

Any RTD & Thermocouples shall be directly wired to DDCMIS/DCS/PLC for metal temperature application, bearing & winding temp application only. The Temperature transmitter shall accept Universal dual inputs of all types of thermocouples & RTD, 0-5V input signals etc.

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Temp. Transmitter shall be extremely stable against Ambient temp variation, The accuracy figure shall be inclusive of effect due to ambient temperature variation. Considering the application & distance involved for monitoring parameters wireless technology shall be adopted by interfacing with DDCMIS through OPC connectivity. However Wireless technology as adopted by Bidder shall be reliable and field proven in power plants and same shall be approved by Owner. 3.03.05 RESISTANCE TEMPERATURE SENSORS WITH THERMOWELLS Applicable Standard : ASME PTC 19.3 - Latest Revision DIN EN 60751:1996, BS EN/IEC60751: 2008 Platinum, R0=100 ohm 4-wire Duplex for Process Temp. Measurement Platinum, R0=100 ohm 3-wire Duplex for Bearing & Winding Measurement Sheath Material/ Insulation Sheath O D - Gauge Terminals : : : :

Element

Temp.

316SS/Compacted Magnesium Oxide 8 MM 18 AWG Spring loaded high temperature ceramic base with silver plated brass for high vibrating locations. As per DIN Standard 43760, Class A Hex Head, Die Cast Aluminum (Screwed) with galvanized SS chain 6-10 Sec bare & 30 Sec. With protective sheath/thermowell + 0.35 degree C or Class-A whichever is better. Gold plated Plug in type. Double entry one unused entry with blind plug IP-65 or better (Explosion/Flame proof for NEC Class-1, Division 1 area)

Calibration Head Response Time Accuracy Electrical connection Enclosure Class THERMOWELL Applicable Standard - Construction - Material

: : : : : :

: : :

ASME PTC 19.3 TW - 2010 Tapered drilled from Bar stock (Straight for Air & Gas systems) - 316 SS/F11/F22/F91 - water and steam Services depending upon process parameters. - Inconel for air & flue gas services For furnace zone, impervious ceramic protecting tube of suitable material along

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with Incoloy supporting tubes and adjustable flanges. For Mill classifier outlet long life solid sintered tungsten carbide material or better of high abrasion resistance. Bidder shall provide calculation for thermowell as per ASME PTC-19.3 2010. All Thermowells in high velocity steam service shall be checked for Strouhals frequency limit to arrive at a safer size and design of Thermowells. - Process Connection : (i) M 33 x 2 (ii) SS316 Flanged, for Air & Gas systems, with mating flanges, fasteners, gaskets etc. Threaded union (SS316) 1/2" NPT (F) with two nipples of SS 316 having 1/2"NPT(M) threads at both ends Within + 10 mm of center line of pipe and as per ASME PTC-19.3 - 2010 Minimum 100 mm above insulation of pipe and Minimum 160 mm when there is no insulation on pipe. For high pressure service, Steam Temp., Fuel oil temp. measurement as per IBR rules and regulations Extension /Compensating/paired cable exposed to atmosphere in the conventional method melts away due to high temperature at the top of mill or due to coal burning. Hence The terminals of temperature sensors shall not be at the top of mills itself. The temperature sensors wires are to be laid up to JB though SS tube of required diameter and the head shall be placed nearer to the JB.

- Extension

Immersion length Extension neck length

: :

IBR Certification Note

: :

3.03.06

THERMOCOUPLES WITH THERMOWELLS Applicable standard Element - Sheath - Sheath Material - Spring Loaded - Nipple/Union - Packed connector : : : : : : : ASME PTC 19.3- Latest Revision ANSI-MC 96.1 1982, IEC 584-2 Duplex 8 MM OD 316 SS Yes Yes Compacted magnesium Oxide ungrounded

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DESEIN - Type : i. ii. iii

Vol-V : Instrumentation & Control Works

Type K (Chromel - Alumel) Type S/R (Platinum RhodiumPlatinum) Type T (Cu-CuNi) with special limits of error according to ANSI-96.1 - 1982.

- Gauge Head Electrical connection Enclosure Class Thermowell - Construction

: : : :

16 AWG Die Cast Aluminum Gold plated Plug in type. Double entry one unused entry with blind plug IP-65 or better (Explosion/Flame proof for NEC Class-1, Division 1 area)

Tapered Drilled from Bar stock (Straight for Air & Gas systems) - 316 SS/F11/F22/F91 - water and steam Services depending upon process parameters. - Inconel for air & flue gas services For furnace zone, impervious ceramic protecting tube of suitable material along with Incoloy supporting tubes and adjustable flanges. For Mill classifier outlet long life solid sintered tungsten carbide material or better of high abrasion resistance. Bidder shall provide calculation for thermowell as per ASME PTC-19.3 2010. All Thermowells in high velocity steam service shall be checked for Strouhals frequency limit to arrive at a safer size and design of Thermowells.

- Material

- Process Connection

(i) M 33 x 2 (ii) SS316 Flanged, for Air & Gas systems, with mating flanges, gaskets, fasteners etc. Threaded union (SS316) 1/2" NPT (F) with two nipples of SS 316 having 1/2"NPT(M) threads at both ends

- Extension

Accuracy (Special Class as per IEC-751/ANSI-C-96.1) (For Type K T/C) : + 1.1 deg.C (for 0 to 277 deg.C) + 0.4 percent (for 277 to 1280 deg.C) ClassA

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DESEIN For Type S & R T/C For Type T T/C Accessories : : :

Vol-V : Instrumentation & Control Works

+ 0.6 deg.C or + 0.1% + 0.5 deg.C or + 0.4% Bolts, nuts and gaskets for flanged connections.

Response Time (Bare Thermocouple) - For SH & RH Temp. Control - All other applications Immersion length : : : 4-6 Sec. 10 Sec. Within + 10 mm of center line of pipe and as per ASME PTC-19.3 - 2010 minimum 100 mm above insulation of Pipe and minimum 160 mm when there is no insulation on pipe. For high pressure service, Steam Temp., Fuel oil temp. measurement as per IBR rules and regulations. Extension/Compensating cable exposed to atmosphere in the conventional method melts away due to high temperature at the top of mill or due to coal burning. Hence The terminals of temperature sensors shall not be at the top of mills itself. The temperature sensors wires are to be laid up to JB though SS tube of required diameter and the head shall be placed nearer to the JB.

Extension neck length

IBR Certification

Note

Thermocouples provided for steam services like super heater / de super heater area, where the process pipe is inside the insulation of boiler penthouse, Thermowells are inaccessible and terminal head and connecting cable cannot withstand high temperature, for such services thermocouples shall be provided with flexible extension SS316 Sheath of 10-15 meters. 3.03.07 Metal Temperature Thermocouples Measuring Medium Material of Thermocouple. Type of Thermocouple Insulation Thermocouple wire gauge Protective sheath Protective sheath dia : : : : : : : Metal Temperature Chromel Alumel Type K Duplex with separate hot junctions, ungrounded Mineral Insulation Magnesium Oxide. 16 AWG SS 321 8 mm O.D

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Characteristics Thermocouple Mounting accessories

of

: :

Cold end sealing : Minimum bending radius Length of T/C Enclosure Class : :

Special limits of error as in ANSI thermocouple MC 96.01.1975 1/2" BSP SS sliding end connector, weld pad, clamps of heat resistant steel SS310. SS pot weal with colour coded PTFE headed sleeve Insulated flexible tails. Sealing compound- Epoxy resin. 30 mm 30 Mtr. (minimum) IP-65 or better (Explosion/Flame proof for NEC Class-1, Division 1 area)

3.03.08

TEMPERATURE SWITCHES (TS) Type/Construction - Switch

Industrial type inert gas filled with capillary and separable thermowell and contacts directly connected to Bourdon element/vapor pressure sensing, gas filled bellows type preferred. Bar stock

- Thermowell Material - Bulb - Capillary - Bourdon - Bourdon Movement - Casing

: : : : :

316 SS Armored Stainless Steel 316 SS SS 316 Die-cast aluminum with stoved enamel black finish Epoxy coating shall be provided for corrosive atmosphere. Adjustable + One (1) percent of setting and differential One half(1/2) percent of setting.

Setting and Differential Accuracy Repeatability Contacts - Number - Type - Rating Connection Pipe - Extension

: : :

: : :

DPDT/2 SPDT Auto reset with internal Adjustable snap action micro switch 5 Amp, 240V AC / 0.2 Amp, 220V DC M33 x 2 Threaded union (SS316) 1/2" NPT (F)

: :

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with two nipples of SS 316 1/2"NPT(M) threads at both ends

having

Thermowell Electrical

: :

To suit Temp. switch with same design criteria as specified for RTDs. Suitable for Plug in type. All the switches are internally connected and brought to the surface with Amphenol male/female connection. Cabling need not terminated inside the switch. Cable ends are to be soldiered in connector and to be inserted for easy maintenance.

Other Particulars - Capillary length - Immersion Length - Extension neck length : : : As per requirement (min 10 meters) Within + ten (10) mm of center line of pipe with adjustable nuts. Minimum 50 mm above insulation of pipe /As per approved hookup drawings. Yes For high pressure service, Steam Temp, Fuel oil temp. measurement as per IBR rules and regulations Switches designed for cross ambient operation shall be used in applications where the ambient temperature will approximate or exceed the switch set point.

- Packing glands IBR Certification

: :

N.B

3.03.09

TEMPERATURE GAUGES (TG) Applicable standard Type/Construction Thermometer Thermowell : : Industrial type, Gas in Filled type with separable thermowell Bar stock : IS : 3602,BS:5235 ISA:RP:8.1 except as modified in this specification

Material - Bulb - Capillary Casing

: : :

316 SS Armoured SS (Applicable for capillary Type) SS 316/ Die-cast aluminum with stoved enamel black finish. Epoxy coating

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shall be provided for corrosive atmosphere Dial Size Scale Details : : 150mm with shatter proof glass 270 degree dial rotation/deflection. Graduations in black lines on white dial provided with glass cover. Smallest scale division shall be one (1) percent of full scale value or smaller .Pointer stop for all gauges + One (1) percent or better Maximum 15 seconds without thermowell and 30 seconds with thermowell M33 x 2 To suit instrument with same design criteria specified for RTDs. (i) M 33 x 2 (ii) SS316 Flanged, for Air & Gas systems, with mating flanges, fasteners, gaskets etc. Threaded union (SS316) 1/2" NPT (F) with two nipples of SS 316 having 1/2"NPT(M) threads at both ends

Accuracy Response time Connection - Pipe - Thermowell

: :

: :

- Process Connection

- Extension

Other Particulars - Capillary length - Immersion Length

: :

5Meters/10 Meters as required Within + ten (10) mm of center line of pipe with adjustable nuts. Minimum 50 mm above insulation of pipe /As per approved hookup drawings. For all gauges of scale Externally adjustable In general, Contact type Temp. gauges are not acceptable for interlock & protection. Contact type Temp. gauges are acceptable for interlock & protection in case of bearing temp. only.

- Extension neck length

- Stop at Maximum value - Pointer

: : :

- Over range protection Enclosure Class IBR Certification

: : :

150 percent (%) of full scale IP-65 or better (Explosion/Flame proof for NEC Class-1, Division 1 area) For high pressure service, Steam

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Temp., Fuel oil temp. measurement as per IBR rules and regulations 3.03.10 TEST THERMOWELLS (TW) Applicable Standard Type/Construction Material Connection - Pipe - Test Instrument Accessories IBR Certification : : : : : : : ASME PTC 19.3 TW - 2010 Machined from Bar Stock 316 SS/F11/F22/F91 M33 x 2 To suit test instruments Plug with chain For high pressure service, Steam Temp., Fuel oil temp. measurement as per IBR rules and regulations Bidder shall provide calculation for thermowell as per ASME PTC19.3 TW - 2010.

Test wells shall be provided on main steam, reheat steam, extraction steam, feed water, condensate, spray water lines and other piping as required to meet ASME test requirements. 3.03.11 DIRECT MOUNTED LEVEL TRANSMITTERS (LT) Displacer type level transmitter shall not be used in the process anywhere in the plant. 3.03.12 Ultrasonic Level Transmitter (for Water sump/Tank level, Raw water reservoir level, Cooling water fore bay level measurements) Detection of reflected ultrasonic pulse Up to 30 meters (typical) Microprocessor Controlled Signal Processing 10 KHz to 50 KHz (typical) Head mounted alpha-numeric back lit LCD/LED Calibration & Configuration : Accessible from front of panel & HART calibrator. Diagnosis : On-line Status : For power, Hi / Lo / V. Hi / V. Lolevel indication, fault etc. Construction : Plug-on board Power supply : 240 V AC 50 Hz / 24V DC Signal Output : 4-20 mA DC with HART (isolated) - 600 Ohm load. Hysteresis : Fully adjustable preferred Output contacts : 2SPDT Potential free changeover contacts @ 8A 230V AC. Accuracy & Repeatability : + 0.25% of span or better Resolution : + 0.1% of span Temperature Compensation: To be provided with Transducer. Principle of Operation Measuring Ranges Signal Processing Operating Freq. Display : : : : :

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Operating temp. MOC Sensor Humidity Enclosure Cable Connection Mounting Accessories

: : : : : : :

Transmitter-50 deg C and Sensor 80 deg C Body- PVDF and Face Polyurethene 1% to 95% non condensing. IP-67 Epoxy painted die cast Aluminum or SS316L housing. 3/4" ET 2 4 NPT or flanged Cable gland, prefab cable, mounting accessories like EPDM seal, SS316 flanged etc. Additional separate local display unit with large Alphanumeric back light LCD/LED & to be provided for the applications which will be decided during detailed engineering.

3.03.13

CAPACITANCE TYPE LEVEL TRANSMITTER The total system shall consist of capacitance probe, pre-amplifier and transmitter Type Probe : : Capacitance type a) Rod or suspended electrode. b) Rope type probes may be used only where required probe length is greater than 3 meters Stainless steel 1-1/2 ANSI RF Flange / NPT (M) 316 SS PTFE Part/Full as per service. The transmitter shall receive output of the preamplifier and convert it into 4-20 mA DC output signal. + 1% of Full scale + 0.5 % of Full scale Min 600 Ohms Powder/Epoxy coated Die cast aluminum. with neoprene gasket conforming to IP-65. (Explosion proof for NEC Class-1, Division 1 area). 0-60 C. Wall / Surface 240V AC, 50Hz / 24V DC 100 m sec or better ET Counter flange, Cable gland, prefab cable if any Alarm output contacts with adjustable set point facility

Probe Mounting Material of construction Insulation Transmitter Accuracy Repeatability Load Enclosure

: : : : : : : :

Ambient temperature Mounting Supply voltage Response time Cable connection Accessories Preferable features 3.03.14

: : : : : : :

GUIDED WAVE RADAR/RADAR LEVEL TRANSMITTER Type Application : : Guided wave Radar (Contact type)/Radar (Non contact type) as finalized by owner. For Turbine Lube oil tank, HFO & LDO tank level,

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Environment Class Orientation Probe Type Probe Material Connection Size & Type Connection material Accuracy Resolution Type (Transmitter) Operating Principle Output Electrical Connection Enclosure Class Electrical Power Housing material Vent & Drain Plug material Side Flange Material Local Display Units of Measurement

: : : : : : : : : : : : : : : : : : :

Condenser Hotwell, LP heaters, CBD tank level, Stator water expansion level, and other Low pressure, Vacuum vessels. Highly abrasive with Gases and Fumes Vertical Flexible Single lead with chuck SS 316L 2 Flanged ANSI 300 lb SS316L material SS 316L +/- 5 mm + 1 mm SMART, 2 Wire Time Domain Reflectrometry 4-20 mA, DC with HART protocol and 600 output load. NPT IP-65 or better (Explosion/Flame proof for NEC Class-1, Division 1 area) 11-42 V DC Die Cast Aluminum SS SS Provided (LCD Digital) Length M EN-61326

Electromagnetic compatibility: 3.03.15 Type Application Temperature compensation Operating Principle Frequency Range Accuracy Resolution Output Display Unit: Type Location Protection Class Material Of construction: : : : : : : : : : : :

3 D TYPE ACOUSTIC WAVE LEVEL TRANSMITTER Acoustic Wave Level Transmitter (3 D type) Coal and Ash Bunker Level, Volume & Mass. Required for high temp applications Non - Intrusive acoustic transmission & Reflection 3 10 KHz wave

+/- 0.25 % for even surface & + 0.5% for uneven surface. 1 mm 4-20mA DC with HART Head mounted LCD Display with Engg. Units Suitable location at bunker / Silo operating floor area IP 65 or better// flame proof (IEC-79.1, Part I) As applicable).

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DESEIN Housing Flange Sizes: Flange Size Electrical connection size Accessories : : : : : Polypropylene Polypropylene

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2 ANSI 300 # RF SS NPT (F) i. Double compression type Nickel Plated Cable glands ii. Suitable Mating Flange, necessary gaskets, iii. Local display unit and Suitable mounting brackets, necessary mounting hardware for Local display unit. iv. Complete software as required to have 3 D view on monitors.

3.03.16

Electronic Water Level Indicator Application - HP heaters & Boiler Separator Stoarge tank

This electronic level indicator shall be provided by bidder, in addition to continuous level transmitter used for modulating control of respective level. Electronic Remote level Monitoring System working on principle of difference in electrical conductivity between steam and water. The Monitoring System shall meet the requirements as indicated below. The sensing electrodes shall be placed in equal pitch. The maximum distance (gap) between two electrode shall be 50 mm and the electrodes shall be arranged in such a way that the last and the first electrode shall not be at any alarm or trip level. Both indication and validation system shall be supplied with double isolation valves in water, steam, drain and vent lines. Each electronics unit shall be provided with 2x100% redundant power supply pack converters to be fed from two feeders of 24V DC or 240V AC UPS system as per system requirement. These two power supplies shall be internally fused and failure of one power supply shall not affect the performance of the system. Self-monitoring facility to detect and alarm the loss of power supply shall be provided. The detector unit, logic units, 2x100% redundant power supply units/packs shall be housed in separate and independent cubicles for pressure vessel on each side of the tank. The Electronic unit mounted locally should have detector units, logic units etc. & shall be independent for each pressure vessel. The min enclosure rating IP 65. Indication shall be provided at field for both indication and validation system. Remote indication is to be provided for indication system at unit control panel in CCR. Local Indication should be inbuilt in local electronic unit.

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Electrode assembly shall have blow out and leakage proof sealing arrangement. Field proven ceramic/zirconia probes with insulation suitable for design pressure and temperature are to be provided. The system design shall be such that it shall ensure that failure of one probe circuit shall not affect another probe circuit and failure of any electrode will not hamper the system function and operation. Further the entire system shall be of proven fail-safe design. The logic shall be such that the trip and alarm relay circuits shall be independent for each for Low, Low-Low, High and High-High levels of tank. Monitoring of set time for trip generation and provision of setting time delay shall be available in the system. Trip logic shall be independent and separate from faultfinding logic. The system shall have fault diagnostic features such as process fault, system hardware fault, probe failure, circuit board failure, shorted wire etc. Further the system shall be able to distinguish between a cable fault and an electrode fault. The necessary relays and relay modules for the Output Contacts shall be of proven design and each contact shall be rated for 5A, 240V AC/0.25A 220V DC rating. All these contacts shall be 2SPDT type. The vessel holding electrodes shall be IBR certified. The system shall be proven and approved by Factory mutual, USA of equivalent, IBR etc. 3.03.17 LEVEL SWITCHES (LS) Type/Construction : a) External float cage type with magnetic switch actuator for tanks and vessels. Electrode/Capacitance (for oil tanks) Displacer -Top mounted for all clean water sumps. Conductivity type for high Pressure and high temperature enclosed vessel like drain pot, HP heaters etc.

b) c) d) Materials - Body

Cast Carbon Steel/Die cast Aluminum suitable for specified pressure and temperature ratings For corrosive liquids suitable anti-corrosive coat/lining shall be provided. 316 SS 316 SS + 12 mm minimum (Adjustable) DPDT/2 SPDT Snap action micro switch Auto reset with internal Adjustable 5 Amp 240V AC 0.2 Amp 220V DC One (1) inch SCRD NPT Female Or One (1) inch ANSI Flanged Four(4) inch ANSI Flange for sump services. Suitable for Plug in type connection

: - Float/Displacer - Wire rope Differential Contacts - Number - Type - Rating Connection - Process : : : : : : :

Electrical

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DESEIN Temperature/pressure rating : Accessories :

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As per service conditions Counter flanges, still pipe of requisite length with anticorrosive coating for sump services.

Nuclear, capacitance, or ultrasonic type level switch for bulk material applications shall be provided. 3.03.17.01 Conductivity Type Level Switch Type Mounting Probe MOC Probe rating Input : : : : : Conductivity discrimination. Flanged on standpipe. Stainless steel with high purity ceramic. > Maximum design pressure of vessel. Four independent channel with selectable switching threshold for water conductivity. Four isolated output relays for Hi, Lo, Hi-Hi, Lo-Lo. 2SPDT or 1 DPDT @ 5A 30V DC. Power Fail/Electrode Connection Open circuit/short circuit to ground, Ground failure. In built Fail Safe Logic. One Red LED for steam/ one Green LED for water/ Two no. LED one each for Process & system fault. Dual 240V AC, 50 Hz, 1Ph. From UPS IP65, corrosion resistant & wall mounting type. i. PTFE cable from probe to electronics unit. Electronic unit shall be separate. Head mounted electronic unit is not preferred. ii. Mounting accessories iii. standpipe iv. Washer & gasket Two times rated pressure

Relay Output Contact type & rating Faults Detection

: : :

Indicator

Power supply Enclosure Accessories

: : :

Test pressure 3.03.17.02 Capacitance Type Level Switch Type Probe : :

Probe Mounting Material of construction Insulation

: : :

Capacitance type a) Rod or suspended electrode b) Rope type probes may be used only where required probe length is greater than 3 meters. Stainless steel 1-1/2 ANSI RF Flange / NPT (M) 316 SS PTFE Part/Full as per service.

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DESEIN Enclosure :

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Ambient temperature Mounting Supply voltage Relay output Contact rating Response time Cable connection Accessories

: : : : : : : :

Powder/Epoxy coated Die cast Aluminium. with neoprene gasket conforming to IP-65. (Explosion proof for NEC Class-1, Division 1 area). 0-60 C. On Top 240V AC, 50Hz from UPS/ 24V DC 2SPDT 5A min. at 240V AC on resistive load 100 m sec or better ET Counter flange, Cable gland, prefab cable and stainless steel name plate engraved with alpha-numeric.

3.03.17.03 A.

RF TYPE LEVEL SWITCH Electronic Controller 1. 2. 3. 4. 5. 6. 7. Input Supply Construction Relay Output Contact Rating : Class of Protection Ambient Temperature Local Indication Green Red Yellow Cable Connection Repeatability : : : : : : : : : : : : 240 V AC from UPS Cast Aluminum Housing 2 Nos. Relay Changeover Potential Free Contacts( 2SPDT) 5A at 240 V AC & 0.25 at 220 V DC IP-66 55 Deg. C(Max) Local LED Indications Normal Level Alarm Level Probe Healthy 3/4 ET(2 Nos.) for Supply and Output 5/8 ET(1 No.) for Probe Connection 100%

8. 9. B.

Sensing Probe 1. 2. 3. 4. Type of Probe Material Probe Head Housing Insulation (B/W Active & Shield And Shield & Ground) Probe Head Protection Mounting Cable Connection Process Connection Signal Cable : : : : Rigid Stainless steel SS 316 Cast Aluminum PTFE

5. 6. 7. 8. C.

: : : : :

IP-66 Side Mounted 5/8 ET(1No.) 40 NB BSP THREADED Coaxial cable for Connection Between Sensing probe and electronic Controller(@ 10 Mtrs. Per Level Probe)

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DESEIN D. 3.03.18 Application :

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Ash Silos

LEVEL INDICATORS (Gauge Glass) (LI) Type/Construction : a) b) Reflex Tubular (For tanks open to atmosphere only)

Material: a) Glass b) Case c) Integral cocks and

: : :

d) Fittings

e)

Packing

: : : : :

Tempered borosilicate resistant to thermal shock Carbon steel i) Forged carbon steel with drain valves stainless steel internals ii) Rubber lined corrosion resistant 316 stainless steel (for Demineralised and Osmosis water service) i) Forged carbon steel ii) Rubber lined 316 steel/PVC for corrosive liquids Demineralised and Osmosis water service) iii) 304 Stainless Steel for non-corrosive liquids Teflon 150 mm /1.5 Meters maximum length with Aluminum/SS316 scale Graduated in mmwc 25 Nb/40 Nb ANSI Flanged a) Integral cocks b) Drain valves c) Bolts, nuts and gaskets d) Illuminating lamps as required e) Periscope as required Tested at two hundred (200) percent of the maximum process pressure For larger lengths, additional gauge glasses shall be provided with minimum of 50 mm overlap.

Dial size/scale Scale details Connection Accessories

Tests Other details

: :

3.03.19

FLOAT & BOARD TYPE LEVEL GAUGE Type of Instrument Service/ Application Measuring Range Material Specification a) Float Material b) Float Wire Pulley : : : : : Mechanical Type (Float Operated) As per service requirement as per requirement SS316 having 2 nos. Guide wires Shall comprise of 2 nos. Cast Aluminum Pulley hosing Assembly with SS 304 pulley and pulley shaft. Steel ball bearings shall be provided in pulley housing for easier float movement. Float wire material shall be

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SS316L. Between 2 pulleys, 1 NB G.I. short pipe with tentative length as per P&ID c) Guide wire Assembly CS chamber with spring and adjuster having 1 Class 150 ANSI RF MS flange. Guide wire rope shall be SS316L. d) Counter Weight : MS counter weight with Aluminum Pointer and Brass assembly Pull Chain. e) Scale : SS 316/Aluminum material in mm with 1 % accuracy. Nozzle Details : For float wire pulley assembly, one tapping and for guide wire assembly two tapping at the top of the tank; Size 1 NB (Top Mounting Type) Process Connection : Flanged as per ANSI B 16.5 to suit 1 NB nozzle (Nozzle length - 150 mm for float wire, 100 mm for guide wire) Accessories (to be supplied with the instrument) a) Counter flange : All mating Flanges, Nozzle b) Mounting Accessories : All mounting accessories c) Tag Plate : To be provided (material SS316) MASS FLOW METER Sensor Measuring Principle Primary Element Heating Arrangement Temperature Control For Heating Process Connection Drain Accessories Transmitter Measured quantities Input Signal Processing Display Output : : : : Mass Flow rate, Total Mass Flow, Density, Temperature as minimum. Digital Processing. Digital Display (LCD). 2 Nos. isolated output of 4-20mA DC selectable from four measured quantities. < 750 ohms. 240V AC, 50 Hz. From UPS 0.15% of measured value for Liquid 0.5% of measured value for Gas 0.05% IP 65 (Explosion proof for NEC Class-1, Division 1 area) FM Standards. : : : : : : : Coriolis Mass flow. Flow Tube of 316SS or better Integral with Flow meter. To be provided. ANSI RF Flanged and rating as per process requirement. Self-draining facility Counter flanges, Mounting nuts, bolts, gaskets etc. :

3.03.20

Load Power supply Accuracy Repeatability Housing Hazardous duty Version

: : : : : :

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DESEIN Nameplate Accessories : :

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Application 3.03.21 Turbine Flow meter Sensor Type Output Signal Material of Construction

Tag number, service engraved in stainless steel tag plate a) As required for field mounting, Handheld configurator & complete Software, External zero adjustment facility b) Mounting U-bolts, nuts, bolts, prefab cable etc. HFO main line, LDO lines, HFO recirculation lines etc.

: : :

Turbine (in line full-bore, based on magnetic pick of pulses) Pulse a) b) c) Body : AISI 316 Rotor: AISI 431 or 410 Bearings: Tungsten Carbide / Stellited Sleeve As required. 0.25% or better. 0.02% or better. 50 deg C On-Line mounting with ANSI RF flanges of stainless steel. IP 65 Solid State 240V AC, 50Hz. UPS Input from Sensor 4 1/2 digit LCD Isolated 4-20mA DC HART 0.5% of full scale range Required IP-65 (Explosion proof for NEC Class-1, Division 1 area) Tag number, service engraved in stainless steel tag plate a) clamping strip, bracket, prefab cable etc. and Calibration or configurator kit.

Flow rate range Linearity Repeatability Ambient temperature Mounting Enclosure Transmitter Electronics Power Supply Input Display Output Measuring Accuracy Totalized Value Housing Nameplate Accessories

: : : : : : : : : : : : : : : :

3.03.22

VORTEX FLOW METER Sensor Type

Vortex

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DESEIN Output Signal Material of Construction Sensor Seal Flow range Linearity Repeatability Ambient temperature Mounting Enclosure Accessories Transmitter Electronics Power Supply Input Display Output Measuring Accuracy Totalized Value Housing Nameplate Accessories 3.03.23 Flow Transmitter (Ultrasonic) Type Sensing element Output Accuracy Supply Enclosure class Transmitter Mounting Mounting position Housing Display Process connection Electrical connection : Turn Down ratio Measuring range Totaliser Accessories : : : : : : : : : : : : : : : :

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Pulse AISI 316 PTFE / higher based on temperature As required. 0.25% or better. 0.02% or better. 50 deg C On-Line mounting with flanges of stainless steel. IP 65 Nuts, bolts, gaskets etc.

: : : : : : : : : :

Solid State 240V AC, 50Hz. UPS Input from Sensor 4 1/2 digit LCD Isolated 4-20mA DC HART 0.5% of full scale range Required IP-65 (Explosion proof for NEC Class-1, Division 1 area) Tag number, service engraved in stainless steel tag plate Clamping strip, bracket, prefab cable etc. Special tool kit for calibration/ configuration .

ULTRA SONIC, 2-wired Non-contact 4-20mA with HART Protocol + 0.1% FS 24 V DC IP-65

: : : : : : : : :

On Nozzle Top mounted Plastic Head mounted LCD Display and remote LCD display NPT/Flanged NPT 1:100 Adjustable (as per process requirement) Required As per process requirement Additional separate local display unit with large Alphanumeric back light LCD/LED & to be provided for the applications which will be decided during

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detailed engineering. 3.03.24 Positive Displacement Flow Transmitter Positive displacement flow transmitters shall be offered. An electronic totalizer shall be provided for each flowmeter and the location of the totalizers shall be acceptable to the Owner. Air eliminators shall also be provided to ensure maximum accuracy. Type Body Material Wetted part Material (Like Piston, Bearing, gear etc) O ring material Flow range Accuracy Repeatability Ambient temperature Mounting : : : Hall Effect Sensor AISI 316L/Die Cast Aluminium. AISI 316L/Die Cast Aluminium.

: : : : : :

PTFE / higher based on temperature As required. + 0.5% or better of reading + 0.03% or better. 50 deg C On-Line mounting with flanges of stainless steel. Solid State 230V AC, 50Hz. UPS 4 1/2 digit LCD for Flow rate & totalized value. Isolated 4-20mA DC 1:30 Required IP-65/ (Explosion proof for NEC Class-1, Division 1 area)/ flame proof (IEC-79.1, Part I). As applicable). Tag number, service engraved in stainless steel tag plate a) Clamping strip, bracket, prefab cable, battery etc.

Electronics Power Supply Display

: : :

Output Turn Down ratio Totalized Value Housing

: : : :

Nameplate

Accessories

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DESEIN

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b)

Nuts, bolts, gaskets, mesh etc. Special tool kit for calibration/configuration.

3.03.25

Electromagnetic Flow meter Electromagnetic flow meters shall have separate transmitter having accuracy +0.2% with zero stability feature, suitable for process medium with <= 5 micron Siemens conductivity, flanges material SS-316, electrode & measuring tube material SS-316, liner material Teflon and enclosure IP-66, local digital display configurable as totaliser, 4-20 mA output signal HART compatible with zero and span field adjustable. Application DM Water and for other application as decided by owner.

3.03.26

FLOW GAUGES (FG) Type/Construction : a) b) Material - For On-line type Metering Tube Float Packing End fittings -For Bypass type Metering Tube Float Packing End Fittings Orifice Plate Carrier ring Flanges & Mating flanges : : : : : : : Borosilicate glass 316 SS Teflon 304 SS 316 SS 304 SS Same as pipe material, 200 lbs ANSI - RF Same as pipe material 2000 ANSI, SW ends to match with pipe material. 250 mm Direct reading type engraved on detachable Aluminum scale + Two (2) percent Half (1/2) percent 1:10 SCRD NPT : : : : Borosilicate glass 316 SS Teflon 304 SS On-line type Rotameter for 50 Nb and below lines Bypass type Rotameter for above 50 Nb lines.

Impulse pipe Fittings Dial Size/Scale length Scale Details Accuracy Reproducibility Rangeability Connection

: : : : : : : :

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DESEIN Accessories : a)

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Tests 3.03.27 SIGHT FLOW GLASS INDICATORS Type/Construction Materials Body Glass Gaskets Bolts & nuts Flappers / Rotating Wheel Flappers / Rotating Wheel holder Process Connection Accessories Tests 3.03.28 SOLID FLOWMETER Type Measuring Principle : : : : : : : : : : : : :

Isolating valves (for Bypass type only) b) Bolts, Nuts and Gaskets as required Shall be tested at two hundred (200) percent of the maximum process pressure

Flapper type.

Carbon steel/SS316 as per process requirement Toughened Borosilicate Neoprene SS 316 SS 304 SS SW (Socket Welded) Scale, Bolts, Nuts, Cover plates and Gaskets as required Tested at two hundred (200) percent of the maximum process pressure.

Online Impact type Microprocessor Based The system measurement is basically pertains to the measurement of horizontal deflection using LVDT, created by the impact of solid flow upon online sensing plate. The horizontal deflection being proportional to the impact forces, LVDT convert this horizontal movement into electrical signal. The inbuilt integrator convert this signal into time based flow rate indication & provide totalized flow also. 316 SS Sensing mechanism shall be mounted outside the process flow line. 316 SS IP 67 class +/-1% +/- 0.2% Both zero & span + 2% / month 4-20mA DC isolated, load 600 ohm (min) yes, (HART) facility 240 V AC, 50Hz. UPS Temperature -600 C, RH-95% Environment Highly Dusty

Sensing plate Sensing head Enclosure Enclosure protection Accuracy Repeatability Drift Output Digital communication Power supply Ambient condition

: : : : : : : : : : :

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DESEIN Accessories :

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Shall be complete with all the accessories including digital display for flow rate, integral vents, baffles for air separation, etc. which ever required for satisfactory operation.

Note:1. The above on line flow meter shall not create any obstruction on flow. 2. Users list shall be submitted to support on proven satisfactory performance for similar process application.

3.03.29

Instrument Air System The instrument Air Supply System for various pneumatic Control & Instrumentation devices like pneumatic actuators, power cylinders, I/P converters, pneumatically operated valves etc. shall be complete in all respect with necessary Air Filter Regulators, valves, piping/tubing etc.. Each pneumatic instrument shall have an individual air shut off valve. The pressure-regulating valve shall be equipped with an internal filter, a 50 mm pressure gauge and a built in filter-housing blow down valve. Filter shall be of minimum 5-micron size & sintered bronze material. On collection of water in the drains of instrument air lines, mechanical automatic drains and periodically solenoid operated drains (with electronic timer - 15m, 30m, 60m and 2 Hours & Timing adjustable) are to be provided. For mechanical type & Electrical type, the locations to be provided in the instrument air lines of boiler area, Chimney area, turbine area etc., shall be decided during detailed Engineering. Bulk header nearby the crowded applications shall be provided and from this bulk header individual air lines with necessary isolation values are laid to the application. These bulk header are to be provided with mechanical / electronic based automatic Drains. Individual moisture separator for O 2 analyzer or vital application shall be provided nearby the instrument so as to enhance the cell life or the performance of vital final control elements.

3.03.30

Air Filter Regulator (AFR) Constant bleed type AFR with an accuracy of + 1.0 % inlet pressure range of 5-8 kg/ cm2 and suitable spring ranges (AFR) for use with positioners in control valves, control damper, E/P convertors and shut off valves for phosphor bronze filter element; Filtering particles above five microns. Weather and water proof enclosure. Material of accessories will be SS316. Air filter regulators shall be provided in the : (a) (b) Air supply line to valve positioners / power cylinders Air supply line to electric to pneumatic converters.

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DESEIN (c) (d) 3.03.31

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Air supply line to pneumatic interlocked block valves. For each instrument rack, field instruments enclosure for purging.

Electro-Pneumatic Convertors (E/P) Two wire type E/P convertors with an accuracy of +0.25% accepting 4-20 mA dc signals from control system and converting to 0.2 to 1 kg/cm2 air pressure to operate valve positioner of all final control elements; Housed in cast aluminum casing (with polyurethane paint); NEMA 4 or equivalent degree of protection for enclosure. Material of accessories will be SS. E/P convertors shall have fail freeze (stay put) feature also. Process connection shall be 1/4 NPT (F) and Electrical connection shall be NPT (F). Zero/span adjustment facility shall be provided. The E to P converters shall retain the pneumatic signal (last value) even in failure of control signal and shall have self volume boosters. Necessary air lock devices and pressure switches for air pressure low alarming shall be provided.

3.03.32

Solenoid Valves Solenoid valves shall be provided with control valves / pneumatic control valves hooked up with process interlock requirements and where direct tripping is involved. The number of ways for solenoid valve shall be provided as indicated below: (a) (b) Two (2) way solenoid valves shall be provided, where process line of less than 50 mm with low pressure and temperature application. Three (3) way solenoid valve shall be provided commonly, where the pressure is admitted or exhausted from a diaphragm valve or single acting cylinder, e.g, Pneumatic operated spray water block valve. Four (4) way solenoid valve shall be provided for operating double acting cylinders, e.g, Pneumatically operated on-off type dampers. For operation of the fuel oil corner nozzle valves, fuel oil trip valves etc., double coil solenoid valve ( latch coil & relatch coil) shall be adopted. Single coil usage requires always power and loss of power leads to closure of above valves resulting the unit trip or loss of generation. Solenoid Valve coils shall be Class-H high-temperature or Class-F construction as applicable and shall be designed for continuous duty. Three-way solenoid valves shall be designed for universal operation so that the supply air may be connected to any port. Solenoid enclosures shall be NEMA-4)/ (Explosion proof for NEC Class-1, Division 1 area)/ flame proof (IEC-79.1, Part I) As applicable). Body material of solenoid valve shall be Die Cast Aluminum or SS316. All solenoid shall be with varister, LED indication, surge suppress diode and circuits.

(c) (d)

(e)

. (f) 3.03.33

Power Cylinders (Pneumatic) Mounting Type : : : a) Fixed position mounting (End mounting). b) Trunnion mounting 0.2 to 1 Kg/Sq. cm. from I/P converter for modulating purposes. 24V/48VDC operated solenoid valve operating on pneumatic line.

Control Signal

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Supply Air Selection

: :

Casing Accessories (as required)

: :

Fail-safe operation

Repeatability Hysterisis 3.03.34

: :

The Pilot solenoid will have separate coils for open closing purpose. 0-7 Kg / Cm2. Based upon thrust / torque, stroke length, angular movement, full-scale travel time, repeatability, space factor etc. Provision for air-to-open and air-to-close operation. IP-65. a) Air lock relay b) Hand wheel. c) Air filter regulator with gauge. d) Volume Booster. e) Limit Switches. f) Positioner with Input, Output and supply pressure gauges. g) Pilot Solenoid Valve (Double Coil type) h) Position Transmitter (4-20 mA DC linear output, LVDT or non contact type). Stay put, open or close position on pneumatic / electrical power supply failure as per process safety criteria. Better than 0.5% of full travel. Less than 1% of full travel.

Nucleonic Type Density Meter (For Ash Handling Plant):Type Application Accuracy Orientation System Type Meter Material Connection material Compensation Type (Transmitter) Operating Principle Output Electrical Connection Enclosure Class Local Display Accessories : : : : : : : : : : : : : : : Nuclear type radiation Abrasive Slurries & Corrosive Chemicals < 1% of Span As per requirement. Radiation Source & Scintillation Detector SS 316L/ Aluminium with PVC coating SS 316L Temp. Compensation required SMART, 2 Wire HART based As the density increase, the lower the radiation field at detector and vice versa. With photomultiplier, 4-20 mA, DC NPT IP 66 Provided Radiation Survey Meter and all erection/installation hardware

3.03.35

Non - Nucleonic (Vibration) Type Density Meter (For DM & AHP Plant):Application Detector : Liquid Density measurement

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DESEIN 1. Orientation 2. Case Material 3. Wetted part material 4. Operating Principle Convertor 1. 2. 3. 4. 5. 6. 7. 3.03.36 Output Electrical Connection Enclosure Class Local Display Accuracy Response time Power Supply : : : : : : : : : : :

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As per requirement. SS 316/ Cast Aluminium alloy SS 316 Vibration Density measurement 4-20 mA DC isolated. NPT IP 65 Digital 5 digit, density display with temp. compensation. +/- 1% < 1 minute. 240 V AC, +/- 10%, 50 Hz. From UPS

PULL CORD SWITCH Type Body Contact rating No. of contact Reset facility Type of enclosure Degree of protection Local trip indication Accessories : : : : : : : : : Addressable Type Cast Iron Continuous 10 Amp, Breaking 2 Amp. (240 V AC) 2 NO + 2 NC Manual Reset Die Cast Aluminum Flame proof/Explosion proof for NEC class 1, Division 1 area Required 1. Canopy over lever of pull Cord switch. 2. Linking of switches through a single cable for each section. 3. Each pull cord switch shall be provided with red LED indication lamp for prominent visible indication of tripping. 4. One number indicator panel which shall display the exact number of safety switches (pull cord and belt sway switches) operated in a loop of conveyor. It shall also monitor the condition of field cable connecting the switches in series & generate signal if field cable is found broken or short. The indicator panel shall display the operated switch number. The same indication shall also be available in CHP PLC operator station.

3.03.37

BELT SWAY SWITCH

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Type Body Contact rating No. of contact Reset facility Type of enclosure Degree of protection Accessories

: : : : : : : :

Addressable Type Cast Iron Continuous 10 Amp, Breaking 2 Amp. (240 V AC) 2 NO + 2 NC Auto Reset Die Cast Aluminum Flame proof/Explosion proof for NEC class 1, Division 1 area 1. Canopy 2. The belt sway switches shall be provided with a common bridging push button which may be kept pressed to bypass the limit switch before restarting the conveyor. 3. Same as above 3.03.36 (4).

3.03.38

ZERO SPEED SWITCH Type Body Contact rating No. of contact Reset facility Type of enclosure Degree of protection Accuracy Repeatability Differential Accessories : : : : : : : : : : : Microprocessor Based Cast Iron Continuous 10 Amp. (240 V AC) 2 NO + 2 NC Manual Reset Die Cast Aluminum Flame proof/Explosion proof for NEC class 1, Division 1 area +/- 5% +/- 1% +/- 5% Canopy

3.03.39

CHUTE BLOCK SWITCH Type Sensor Material Mounting Insulation Material Contacts Type of enclosure Degree of protection Electrical Connection Repeatability Local Indication Accessories : : : : : : : : : : : RF Based SS 316 Flanged PTFE 2 NO + 2 NC Die Cast Aluminum IP 66 ET 0.05% To be provided a) Neoprene Gasket and Stud Bolt b) SS Tag plate, Nickel plated brass double Compression type cable gland

3.03.40

Humidity & Temperature Sensor with LCD display for AC Plant Humidity Sensor

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DESEIN Measurement range Range of use : :

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0-100%r.h. 0-100%r.h. +2% <0.05% r.h./ C DC4-20mA = 0-100%r.h.

Measurement accuracy at 23 : C 0-100% r.h. Temperature dependency : Output signal, linear (terminal : l1) Temperature Sensor Range of use Sensing element : :

0-50 C & -35 to 35 C Pt1000 class A +0.5K DC4-20mA = 0-50 C & 35 to 35 C

Measurement accuracy at 15-: 35 C Output signal, linear (terminal : l2) General Sensor Data Power supply Operating voltage :

AC 24V +20%

Degree of Protection & Safety Class Degree of protection of housing With enclosed cable gland : Safety class Environmental Condition Temperature (housing electronics) Humidity Location with : : : :

IP 65 to IEC 529 III to EN 60 730

-40 to 70 C 5 to 95% r.h. (non condensing) In each AHU room and Control room

3.03.41

DEW POINT METER Type Overall Range Accuracy Material Features : : : : : 2 Wire Loop Powered Dew point Transmitter -60C to +20C Dew point 2C Dew point SS316 (wetted parts) AUTOMATIC CALIBRATION Can be Configured for Linear 4-20mA signal in C & F Dew point, ppm(v), ppb(v), g/m3 Temperature Compensation

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3.03.42 Junction Boxes v. vi. vii. viii. ix. x. xi. xii. xiii. xiv. xi. xii Type Enclosure : :

Failure Diagnostics Long Term Stability Fast Response IP 66 / NEMA4X Protection Supplied with Calibration Certificate Traceable to National & International Humidity Standards Sensor protection with sintered filter Local LCD Display for Dew Point

Xiii xiv 3.03.43

Flame proof/weather proof IP-65/Explosion/Flame Proof as per area classification. Material : FRP with protective Coating Cable entry : Bottom or Side Cable glands : Double compression type Nickel plated brass with PVC hoods. Mounting : Indoor/Outdoor No. of terminals : As required with standardization with 20% spare of each size & type. Terminals : Phoenix/Wago (screw less cage clamp type spring loaded) Grounding : Two terminals for body and shield ground Door : Hinged, lockable type. Suitable mounting clamps and other accessories shall be in scope of bidder. The brackets, bolts, nuts, screws, glands, lugs required for erection shall be of brass, included in bidder scope of supply. High voltage & insulation resistance test shall also be conducted. M6 Ni plated Brass earthing stud shall be provided (external 2 nos. internal 1 no.) Gasket (Normal)- Neoprene thickness 6.0 mm

Interposing Relays (IPR) Electro magnetic type IPRs with modular design, plug-in type connections, suitable for channel/DIN rail mounting in cabinets; coil rating 24V D.C; 2 set of silver plated change over contacts rated for 0.5A 220 V DC/8 A 240 V AC. Free wheeling diode across relay copper coil and self reset type status LED indicator flag (electronic) shall be provided. Manual forcing/override facility is required. The test voltage for relay shall not be less than 4 KV with operating temperature from 20 deg. C to 60 deg. C. The relay shall have the necessary approvals like V0 inflammability class in accordance with UL94, IEC60664/IEC60664A/DIN VDE 0110. Facility to stimulate IPR manually shall be provided.The VA burden of relays shall be suitable to match the capacity of output modules. Interposing relay & sockets for mounting the interposing relay shall be of same make only.

3.03.44

RECORDERS (CHARTLESS) Type - No. of Channels : : Micro-processor based, Digital TFT display type Forty Eight (48) point).

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Input Signal Recording method Display colour Bar graph facility Digital indication Accuracy Programmability Data Storage Data Retrieval Scan rate

: : : : : : : : : :

Power Supply Ambient Temperature Mounting Application software Internal Memory Screen Resolution Type of Display

: : : : : : : :

Event Sampling Zoom & Scroll Facility OWS and printer connectivity port Communication

: : : : :

6 Nos. of recorders shall be supplied with BTG packages and the parameters shall be decided during detailed Engineering. Quantities of recorders for BOP packages shall be decided during detailed Engineering. (Simultaneous parameter display preferred) Fully configurable multi range (Programmable) universal (input) Continuous with different colour, for each channel Selectable from 30 Colours To be provided To be provided +/- 0.1 % for reading for DC V Input And 0.1 Deg for TC/RTD input Front key board hard disk/ Flash Memory Compact 4 GB flash Memory card and USB port with 8 GB USB drive. < 20 m second for individual channel. Selection of scan time for individual channel is required. 240 VAC 1 Phase UPS 0-50 Degrees Front panel mounted weather & Dust proof IP 65 Yes, To be provided 400 MB or more > 10.5 colour LCD TFT > 640 X 480 Pixels i) Trends ii) Bar Graph iii)Digital display/ values 1/2/5/10/30/60/120 sec. Required Required Necessary software shall be supplied for uploading the data. Additional MODBUS/PROFIBUS ports connectivity between recorder and third party systems.

3.03.45

DIGITAL INDICATOR Type Input Number of inputs Range : : : : Programmable electronic digital indicator with floating point decimal. 4-20 mA DC/1-5V DC/RTD/T/C. One As per requirement/adjustable by end user

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Number of digits Digit height Display Input over range/open sensor (T/C) Input hold time Accuracy Power supply Mounting Size Other Particular

: : : : : : : : : :

through key pad available on the indicator. Four plus sign 20 mm or larger Fluorescent red All digits to flash 0.7 seconds max. +0.25% of span 240V AC, 50Hz Flush panel, compatible for mounting on mosaic grid panel 96x48 mm Indicator receiving thermocouple signal shall have automatic cold junction compensation. Retransmission Output 4-20 mA isolated required. 24 V DC inbuilt power supply Alarm contact with 2 NO/NC contact (rating 5A/230 V AC)

: : :

3.03.46

RECEIVER INDICATORS (SINGLE/DUAL CHANNEL) Type Input Signal Scale Measurement Accuracy Resolution Dead band Repeatability Full scale response time Power Supply Connection Accessories Other Particulars : : : : : : : : : : : : Analogue indicator Universal input (T/C, RTD, 4-20 mA, Voltage) Range fully configurable and programmable + 0.2% of span + 1 count 0.5% Span + 0.2% of span 0.2% of span Less than two(2)seconds 240V AC, 50 Hz Plug in type Mounting Bracket for Bins Indicator receiving thermocouple Signal shall have automatic cold junction compensation. Retransmission Output 4-20 mA isolated required.

: 3.03.47 Temperature Scanner Type No. of channels Input Accuracy Number of digits Digit height Display color Display mode for : : : : : : :

Microprocessor based Electronic Digital Scanner. 16/24 (as per the application) RTD /Thermocouple/4-20mA + 0.1 of FS + 1 count 4 digit (7 segment display with Engg. Units) 12 mm or larger Fluorescent red/green

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DESEIN Input over range/open sensor Mounting Zero and Span Serial communication communication Memory Capacity Alarm output Contact rating Power supply Properties : : : : : : : : :

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All digits to flash Panel mounting Adjustable by digital calibration Isolated RS232/485 for modbus-RTU 5MB Flash Required 2A at 220 V AC 240 V AC/24 V DC i. Any channel shall be configured for Data Logging ii. Channel to Channel online Isolation shall be provided iii. Real Time RTC Interface for Printer shall be provided Auto/manual mode, Run mode, Verify mode, Calibration Mode, Program mode.

Operation Modes 3.03.48 AMMETERS (AMM) Input Mounting Face Dimensions Scale/Type Zero adjustment Accuracy Indication Magnetic Shield Quantities

: : : : : : : : :

4-20 mA DC Flush panel, compatible for mounting on mosaic grid panel 96 x 96 mm Moving coil, circular, FSD 240 deg. With six times suppression scale Screw on meter face + 1 percent (class 1) Pointer with scale Shielded Case For all HT Motors & LT motor with rating > 30 KW and other critical application motors/drives.

3.03.49

VOLTMETER: Input Mounting Face Dimension Range Accuracy Indication Magnetic Shield Connection Quantities : : : : : : : : : 4 - 20 mA DC Flush Panel, compatible for mounting on mosaic grid panel 96x96 mm As per requirement + < 0.5 % Digital type 4 1/2 digit Shielded Case Plug in type For 230 V AC input power supply, UPS power supply, 24 V DC interrogation voltage & 220 V DC.

3.03.50

FREQUENCY METER/MW METER (DIGITAL)

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Type Input Mounting Number of digits Face Dimension Digit size Range Accuracy Display Connection Magnetic Shield 3.03.51 AC CURRENT TRANSDUCERS Input Output Mounting Accuracy 3.03.52 DC CURRENT TRANSDUCERS Input Output Mounting Accuracy 3.03.53 : : : :

: : : : : : : : : : :

Electronic digital 7- segment with fluorescent display 4 - 20 mA DC Flush Panel compatible for mounting On mosaic grid panel 41/2 digit 192X192 mm Approximately 40 mm As per requirements + 0.2 Hz Red LED display. Plug in type Shielded Case

: : : :

0 - 1 A CT current Dual 4-20 mA with 500 impedance Back rail + 0.25%

0 - 75 mV Dual 4-20 mA with 500 impedance Back rail + 0.25%

AC VOLTAGE TRANSDUCERS Input Output Mounting Accuracy : : : : 0 - 110 V PT, Volts 4-20 mA with 500 impedance Back rail + 0.25%

3.03.54

DC VOLT TRANSDUCERS Input Output Mounting Accuracy : : : : System Voltage 4-20 mA with 500 impedance Back rail + 0.25%

3.03.55

TRANSDUCERS FOR POWER Input Output Mounting Accuracy : : : : CT and PT (1A) (110V) 4-20 mA with 500 impedance Back rail + 0.25%

3.03.56

TRANSDUCERS FOR FREQUENCY

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Input Output Mounting Accuracy 3.03.57

: : : :

110 V PT Volts 4-20 mA with 500 impedance Back rail + 0.25%

TRANSDUCERS FOR POWER FACTOR Input Output Mounting Accuracy : : : : PT (110V) 4-20 mA with 500 impedance Back rail + 0.25%

3.03.58

TRANSDUCERS FOR MVAR Input Output Mounting Accuracy : : : : CT & PT (110V/1A) 4-20 mA with 500 impedance Back rail + 0.25%

3.03.59

DIFFERENTIAL FREQUENCY TRANSDUCERS (FOR SYNCHRONIZATION) Input Output Mounting Accuracy : : : : 110 V PT 4-20 mA with 500 impedance Back rail + 0.25%

3.03.60

DIFFERENTIAL VOLT TRANSDUCERS (FOR SYNCHRONIZATION) Input Output Mounting Accuracy : : : : System voltage 4-20 mA with 500 impedance Back rail + 0.25%

3.03.61

PUSH BUTTONS (PB)/ ILPBs FOR ON/OFF, OPEN/CLOSE, START/STOP Type : Momentary/Miniaturised Suitable for mosaic grid 24x48 Mm with 2 PB and 3 coloured LED. 2 NO + 2 NC Hard Silver Alloy 500V / 10 A 2 KV for 1 minute between

Contact Configuration Contact Material Contact Rating Insulation Voltage terminals and earth Lamp Rating :a) Voltage b) Watt Colour

: : : :

: :

240 V AC 2 Watt (approx.)

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DESEIN Red Green Red Green Light yellow Red Green Red

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ON/Start/Open ILPB OFF/Stop/Close ILPB - energized, running, Start, valve open LED/Lamp - de-energized, stopped, valve closed LED/Lamp - abnormal, discrepancy LED/Lamp OFF/Stop/Close PB ON/Start/Open PB - Emergency trip push buttons with red flap / hinged Transperent arylic cover. Momentary mosaic grid mounted 24x48 mm size, single PB 18x40 mm Colours for DESK RELEASE - Yellow, Desk Lamp test - Blue, Desk Ack - Green Momentary (Miniaturised) suitable for mosaic grid 24x48 mm 3 PB + 5 LED

3.03.62

PUSH BUTTON FOR Control DESK:

3.03.63

PUSH BUTTON FOR SEQUENCE START/RELEASE

3.03.64

PUSH BUTTON FOR ANNUNCIATION Contacts - Number & Type - Breaking capacity : : As per requirement 1 Amp, 220V DC 10 Amp, 600V AC Different colours for Accept/Ack - Green, reset Grey, Lamp test Blue, System Test Yellow & Audio Ack - Black.

3.03.65 3.03.65.1

BELT WEIGHING SYSTEM General The mechanical design and constructional features for belt weigher has been described under mechanical section, hence not repeated here, Similarly motor specifications for the same has been covered under electrical specification, hence not repeated here. The belt weighing system shall have its own local control panel to be located in electrical equipment room. The local panel shall include: (a) Local flow rate indication (b) Integrated flow rate indications (c) System alarm annunciation (d) Local Calibration facility (e) Power on/off All these above display shall be backlit LCD type with 12mm character height. NI Cd Battery back up (60 minutes backup) shall be provided for the measurement system. (a)Application : Bulk material, Powder material (b)Drive Protection : Reverse Polarity, Communication failure

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3.03.65.2

Load Sensing Cell (a)Type (b)Enclosure Protection (c)Load (i)Nominal Load (ii)Rated Load (iii)Destructive Load (d)Supply Voltage (e)Sensing (f)Temp. Effect on Zero & span (g)Basic Resistance (h)No. Of Load Sensors (i)Mounting Type (j)Accessories (k)Accuracy (l)Spped Sensor (m)Speed Output Bidder to specify in tabular form. Bidder to specify in tabular form. Bidder to specify in tabular form. 24V DC Resistance bridge +/- 0.015%/10K Manufacture's Standard Single Four idler Mounting plate kit, cable etc. +/- 0.015% FSD Tacho/encoder Pulse train to be distributed tp (i)Local control panel for own use (ii)4-20 mA DC signal to PLC (n)Load Sensor Output 4-20 mA DC isolated signal for PLC along with provision for serial communication link standard protocol 4-20 mA DC isolated 2 numbers In Compliance with standard protocol NEMA 4X (IP 66) Special cables, electronics, cabinets etc. As required to make the system complete, with bar/chain. Application dependent 0.1% of this selected range 0-70 degC +/-0.25 % FS range Strain Gauge/Compression type NEMA 4X (IP 66)

(o)Computed Flow rate (i)Hardware (ii)Serial Link (p)Protection class for measuring cell (q)Accessories

(r)Range (s)Range increment (t)Operating Temperature (u)Accuracy 3.03.66 3.03.66.01

Hydrogen Gas System Instruments/Analysers Hydrogen Gas Hygrometer

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DESEIN A 1 2 3 4 5 6 B 7 8 Performance Measuring Range Response Time for 63% Step Change Output Resolution Storage Temp: Max Operating Ambient Relative Humidity Sensitivity Construction Measuring Principal

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-80 C to 20 C <5 sec. 0.01 mA 70C <95% < 5 seconds for 63% step change in moisture content

9 10 11 12 13

14 15 16 17 3.03.66.02 A 1 2 3 4 5 6 7 B. 8 9 10

11 12 13 14 15 16 17

Thin Film Alum Oxide intrinsically safe and explosion proof as per NEC article 500, class 1, Division 1 Enclosure Protection class area I. Display 3-1/2" Digit LCD Mounting In Explosion Proof Box Location (Hazardous) Hydrogen delivery after compressors. Service Measures Moisture content in the Hydrogen Delivery Code & Standard EMC directive 89/336/EEC and PED 97/23/EC for DN<25 - FM Standard 6320 Analog Output 4-20 mA, HART. Type of Transmitter 4 to 20 mA loop powered 24 VDC Certification CE Calibration Required every 12 months, Calibrator shall be supplied by bidder. TRACE OXYGEN (O2) in Hydrogen gas Analyser Performance Nature of Fluid Oxygen in Hydrogen Response Time for 90% step change < 10 sec. Relative Humidity 0-99 % Measuring Range 0-100 ppm Accuracy + 2% Repeatability + 0.1 ppm Sensitivity 0 - 10 ppm < 45 seconds Construction Measuring Principle Electrochemical Fuel Cell Display 3-1/2" Digit LCD intrinsically safe and explosion proof as per NEC article 500, class 1, Division 1 Enclosure Protection class area I. Mounting On Panel with Sample System Measure trace oxygen in the product Service hydrogen Location (Hazardous) Hydrogen delivery after compressors. Code & Standard ATEX Approved. II 1/2 G Ex ia II c T4 Output Current 4-20 mA, HART Type of Transmitter 4 to 20 mA Loop powered 24 VDC Calibration Every 12 months with calibration gas,

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DESEIN

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18

3.03.66.03 A 1 2 3 4 5

6 7 8 9 10 11 B. 12 13

14 15 16

17

18 19 20

21 3.03.66.04 A 1

2 3 4

Calibrator shall be supplied by bidder. 5ppm O2 in N2, shall be provided by bidder for one year after Calibration Gas commissioning of plant. Combined Gas Sensor for Hydrogen Gas System Performance Nature of Fluid Hydrogen /Air Measuring Range 0 to 100% LEL Response 50% <10 sec. Recovery to 10% <30 sec. 0-50%LEL range 51-100% LEL range Accuracy + 1% + 2% Repeatability + 1% Calibration frequency 180 days Output Range: 0-100 LEL 4-20 mA, HART Humidity RH <99% Sensitivity <12 seconds to 60% full scale Measuring Range 0-100 ppm Construction Measuring Principle Catalytically bead intrinsically safe and explosion proof as per NEC article 500, class 1, Division 1 Enclosure Protection class area I. Display 3-1/2" Digit LCD Mounting 4 mtrs above respective instruments supporting Conduit Service Monitor combustible mixture in the atmosphere of each room where hydrogen may be present. Location (Hazardous) (one in each), Roof -H2 Generation room Any other location as finalised by Roof - Compressor Room owner during detailed engineering. Roof - H2 Storage Room Code & Standard FM Standard 6320 FM Standard 3600 Type of Transmitter 4 to 20 mA Loop powered 24 VDC 2% H2 in N2, shall be provided by bidder for one year after Calibration Gas commissioning of plant. Calibration Every 6 months with calibration gas, Calibrator shall be supplied by bidder. Hydrogen Gas purity measurement Analyser Performance Range 80% to 100 % H 2 in air 0 to 100 % H 2 in pure gas * 0 to 100 % air in pure gas * Accuracy/Lineraity + 1 % of FSD Resolution/Repeatability + 0.5 % Response Time for 90% step change < 5 sec.

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DESEIN 5 B. 6 7 Enclosure Protection class Display Safety & EMC Standards Output H2 Purity Calibration Gas Calibration Note: * Pure Gas options: CO 2 , N 2 , Argon Stability/Drift Construction Measuring Principle

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< + 1 % of FSD/month Thermal Conductivity or Multi mode Oscillation type Intrinsically safe and explosion proof as per NEC article 500, class 1, Division 1 area I. 3-1/2" Digit LCD Safety Standards EN 61010-1 EMC Standard EN 61326 2 nos. 4 20 mA DC, isolated from input 99.99% shall be provided by bidder for one year after commissioning of plant. Every 6 months with calibration gas, Calibrator shall be supplied by bidder.

8 9 10 11 12 13 14

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CHAPTER-4
DISTRIBUTED DIGITAL CONTROL MONITORING & INFORMATION SYSTEM, PLC AND OTHER CONTROL/SUB SYSTEM 4.00.00 Unified Distributed Digital Control, Monitoring and Information System (DDCMIS) including Regulating Controls, Interlocking and Protection, Sequential Controls, Operator Interface Units, Monitoring and Information data archiving, Historical data storage and retrieval, SOE recorder and alarm shall be provided for unit Station C & I and BTG package including BMS/FSSS, MFT & Turbine control functions. Same family of hardware shall be used for implementing the above functions in an integrated manner. Above system shall be preferred. However, bidder can also offer separate DCS Control System for MFT & Boiler Protection (in TMR mode) and DEH / EHGC (in TMR mode) respectively. Similarly separate DCS Control System (Emergency Trip Circuit in TMR mode) for Turbine trip & protection can be offered. DCS control system offered by bidder shall be provided with same features, functionality and design criteria as same envisaged for DDCMIS. Bidder shall offer latest system available with him and shall also confirm that DDCMIS system hardware / software shall be upgraded free of cost (for hardware upto commissioning of the project and software upto handing over of the project), whenever at later stage such upgradation takes place for his system offered by him or by his collaborator. During execution of the project or at the time of dispatch, any latest product is launched or introduced and same is field proven, then the same shall be supplied with out any price implication. All the hardwares/softwares shall be latest and field proven as available in the market. 4.00.01 DDCMIS/Microprocessor/PLC/Relay based system for balanced Offsite/BoP package as per Annexure A (Control system for BOP Packages) covering the total functional requirements of modulating control, sequence control, interlocks & protection, monitoring, alarm, data logging, fault analysis, maintenance scheduling & machine monitoring & analysis etc. shall be supplied by bidder. Bidder to note that PLC system shall be from one manufacturer only. The design of the control system and related equipment shall adhere to the principle of fail safe operation at all system levels and provide reliable and efficient operation of the plant under dynamic conditions and attainment of maximum station availability. Suitable redundant gateways / soft links / protocols including all required software & hardware shall be provided for all microprocessor / PLC-based system/ microprocessor based electrical system for interfacing with DDCMIS. Master / Slave clock system shall be supplied by bidder for time synchronization of DDCMIS and all microprocessor based system / PLC, microprocessor based electrical system provided for subject plant. 4.01.00 Introduction And General Requirement Distributed Digital Control, Monitoring and Information System (DDCMIS) shall comprise of the following sub systems operating in completely integrated manner employing same

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family of hardware and software for whole plant covering SG, TG and station C&I. However, bidder can also offer separate DCS Control System for DEH / EHGC, same shall be in TMR mode only. Similarly separate control system for Turbine trip & protection can be offered by bidder, same shall be in in TMR mode only. i) The following guideline shall apply regarding the data loading of various items of DCS and the response time of the system, which will determine the extent of functional distribution. The maximum permissible loadings are as follows:a) b) c) d) ii) Multiloop Multifunction Controller 60% for Processor time max. Input / Output 80% for Processor time max. Historical Storage 75% for Processor time max. Data bus loading 50% max.

Process stations/sub system:- where function of closed loop control system (CLCS), open loop control system (OLCS) and Measurement (Including Signal Acquisition, Conditioning, Distribution, Transmission, Sequence of Event Recording, Indication and Recording) are realised. Operator Station/sub system:- which together with their computers, OS based operator station and other peripherals perform control, operation and monitoring functions including data archiving, alarm monitoring etc. Programming, and on line diagnostic station (Maintenance Engineers Station):for system programming, system configuration, system and instrument failure detection and trouble shooting. Alarm annunciation system shall be integrated part of DDCMIS system. Sequence of event recording system for presenting/acquiring 1024 events with resolution of 1 msec. shall be integrated part of DDCMIS and it should meet the requirements specified at clause no. 4.03.07. Communication Network The system shall be functionally distributed and various sub-systems shall be connected through a system of redundant communication network. Network shall also be provided with external surge protection system and industrial firewall. "The Bus systems (like OPC/Profibus/ Modbus etc) or the Serial Port Systems (like RS-232/ RS-485 etc) shall be protected with suitable surge protection devices, confirming to the latest IEC-61643-21 guidelines. The surge handling capacity of device shall at least be 10 KA, 8/20 Sec between core-core and 20 KA, 8/20 Sec between core-ground. The device shall be pluggable & on-site testable". The man machine interface between the operator and plant shall be through OS/Key Board and mouse (touch screen facility is not accepted). However, necessary recorders, indicators, A/M station, ILPBs etc. on BUP and LVS

iii)

iv)

v) vi)

vii)

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required to monitor important plant parameters and control & operation shall be provided as a back up as elaborated elsewhere. 4.01.01 Functions of Main Plant DDCMIS/DCS The principal functions of the DDCMIS/DCS are as follows:a) b) c) d) Provide the control of the steam Generator (SG) & Turbine generator (TG). Provide control of the main steam cycle, steam bypass and water cycle. Provide control of pulverizers, combustion air, burner ignition, and flame management. In case SCADA for Switchyard Circuit Breakers control is not from the same family of DDCMIS, then a redundant gateway shall be provided to monitor switch yard operation. Receive input signals that represent the status of process variables and equipment status; condition the signals; and utilize them for control, protection, monitoring, status display, annunciation and SER. Provide the output signals to modulate and control the final devices, such as control valves, control drives, dampers and pumps. Provide alarm logging and sequence-of-events recording (SER) capability with 1 ms resolution. Provide plant and equipment performance calculation, capability and plant optimizing functions. Provide Auto Plant start-up, loading, auto synchronization and shutdown. Perform information processing functions including logging and printout of historical data, trend displays, elapsed time monitoring, and totalisation of fuel and energy usage and generation. Provide a means to coordinate the load control of the prime movers in response to remote dispatch load change requests. Status of all drives, pumps, tanks, etc should also be available in central control room.

e)

f) h) i) j) k)

l) m) 4.02.00 4.02.01

Control System Basic Features/Design Requirements Design Requirements 1. The instrumentation and controls shall be designed for maximum availability, reliability, operability and maintainability. All components shall function in a satisfactory manner within their rated capacity under the specified conditions during the continuous service life of the plant.

2.

All like instrumentation, control hardware, control and protective system should be of same make and model no. in order to achieve the goal of consistent control philosophy and to minimize the diversity of I&C equipment & spares. Control system shall comply with following general failure criteria : a. b. No single fault can cause the complete failure of the control system. No single fault can cause the boiler or turbine/generator protection system to malfunction or become inoperative.

3.

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DESEIN c.

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d.

e.

f. g h i j

The grouping of control functions into system blocks shall be arranged such that failure of any one block will only partly degrade the control of the overall system. Such degradation shall always be manageable by operator intervention. The control system shall be structured to reflect the redundancy provisions of the plant so that no single fault within the control system can cause the failure of the duty equipment or make the standby equipment unavailable. Start command or stop command/trip command towards safety of process or process equipment shall be hardwired parallel from the two different DO cards. As a result of a control system fault, a plant item or control function shall always respond to its controls at the actuator level (i.e., remote manual control). That item or control function shall be required to be isolated from automatic control system. No single random fault in the entire automation and control system will cause a load loss, forced outage or unit trip. No two simultaneous faults shall lead to or potentially cause damage to plant Safety related instrumentation and control shall be designed with a failsafe mode. No single fault shall jeopardise the functioning of the entire system. The control and automation system and the field instruments and actuators as well as its support systems, power supplies and data networks shall be immune to the electromagnetic interference and shall conform to the internationally accepted standards. To meet the operational and safety requirements, the control system hardware and software shall conform to a modular, hierarchical architecture. When more than one device utilizes the same measurement or control signal, the transmitter and other components shall be fully equipped to provide all signal requirements without overloading and with proper isolation. Transmitters required to serve multiple receivers shall be arranged so that disconnecting, shorting or grounding of one receiver device shall not have any perceptible influence on any other consumer point of the same signal nor shall change the transmitter calibration.

4.

Distributed control equipment shall employ modern distributed microprocessor based technology, as required to comply with the project specification and the DDCMIS system should not be more than 5 year old. A truly integrated DCS is envisaged with all the self sustaining subsystems communicating with each other over the bus network and thus ensuring that the system has a truly global data base. The active control system including the plant protection system is the heart of the DCS system and therefore most stringent safety, availability and reliability

5.

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DESEIN

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requirements have to be fulfilled by this subsystem. The bidder must bring out very clearly in his proposal how he intends to satisfy these requirements. 6. The control system shall be functionally distributed, (For Boiler, TG and BOP and similarly the control for 2 similar equipments like ID Fan A, B and C should be in different controllers & I/O cards) highly modular and arranged to reflect the functional grouping plant equipment and systems to be controlled. This functional group control strategy shall also form the basis for the partitioning of the controller to enhance the system reliability and flexibility. In case of redundant Analogue and Binary Signals, these will be connected to different input modules and different CPU. Similarly whenever inputs are more than one and needs temperature and pressure correction, the same shall be carried out in different CPU. In case of redundant/multi Pumps/Drives for same service, all related Inputs & outputs of main pump/drive shall be in separate I/O cards and similarly all related Inputs & outputs of respective standby pump/drive shall be in separate I/O cards. Inputs/outputs of any two same services pumps/drives shall not be mixed in one common I/O card. 7. To meet the above failure criteria at sr. no. 3, the I&C system shall incorporate self-checking facilities so that internal faults can be detected within the system itself prior to any resulting disturbance to the process. In addition, the protection and safety systems shall incorporate channel redundancy or diversity of measurement as well as self-checking and adequate test facilities. For some important systems, on line test shall be employed with no effect to the proper functioning of the protection system. In order to make sure that the DDCMIS is an extremely user friendly system a centralized engineering subsystem is envisaged. An integrated subsystem has to be provided which takes over the complete task of planning, I/O allocation, generation of function schemes and wiring documentation (in design stage) and finally the automatic linking and loading of the planned functions in the target hardware. The complete engineering of all the automation and data acquisition functions should be possible from this central tool. This shall included all modulating and sequence control functions as far as the automation is concerned, generation of plant graphics, logs and other MMI functions. In addition the central engineering system must support all service, maintenance and commissioning assistance functions. 9. For protection applications, multi-channel measurements shall be provided incorporating 2 out of 3 trip action. Facilities for the on-line testing of each independent channel shall be provided without loss of protection. Each measurement channel shall include discrete transmitters and instrument loops, i.e. multi channel measurement of the same process variable shall not be derived from common instrument. As per NFPA, Triple supply viz.240VAC UPS, 24 V DC and 220 V DC shall be ensured for critical Boiler and Turbine protection. Both redundancy and diversity of trip criteria shall be considered to achieve sufficient guarantee against non operability or unnecessary operation of the

8.

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DESEIN

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protection system. The principle of de energized to trip (Fail safe logic) shall be adopted. 10. Individual control elements shall be equipped with permissive to prevent the inappropriate operation of the item and active interlocks to trip the item in case of dangerous operation conditions. Each of the multifunction controller together with its I/O and drive level control modules is to be understood as a self sustaining automation island, which executes the function allocated to it independently and is not affected by a disturbance in the adjacent island. For the purpose of lateral communication between the automation islands, a high speed redundant bus (the so-called control bus) should be provided which should be solely responsible for the automation (control) signal exchanges. Alarms shall be provided for all abnormal conditions over which the operator has control in the control room, plus those abnormal conditions which are of interest to the operator because they may affect plant operation or security. The following colors shall be selected for equipment status indicating lights: - Red----energized, running, valve open - Green----de-energized, stopped, valve closed - Light yellow ----abnormal, discrepancy - White----control power available The functions of DDCMIS System are achieved through bus communication units, bus interfaces, process controllers, I/O modules and computers. The system shall be versatile and provide the user, the flexibility to freely choose configuration and redundancy. The system shall ensure very high reliability and safety through complete distribution and decentralization which goes right down to the individual I/O level. Interposing relays with suitable contact rating shall be provided between DCS/PLC and MCC/Swgr in Interposing relay panels for giving command signals ON/OFF or OPEN/CLOSE. Interposing relays shall have minimum 2 NO and 2 NC contacts. All parameters on which protection is achieved through pressure/ temperature/ flow switches; the measurement shall also be made available through transmitters. Provision of transmitter/remote sensor will be applicable for 70% of total protection signals for such important services which will be decided during detailed engineering Also the system shall have the flexibility to easily reconfigure any controller at any time, without requiring additional hardware or system wiring changes and without disabling the devices from their normal operating mode. The system shall execute all control functions with the help of a set of preprogrammed functions resident in controllers.

11.

12.

13.

14.

15.

16.

17.

18.

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The offered system shall have provision for open system architecture to establish communication to any other system using open system standards such as UNIX, WINDOWS NT, WINDOW XP/7, TCP/IP, OSF, MOTIF, SQL Access etc. 19. 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. The system shall provide inherent safe operation under all plant disturbances and component failures so that under no circumstance safety of the plant personnel or equipment is jeopardized. The design of the control system and related equipment shall adhere to the principle of fail safe operation at all system levels and provide reliable and efficient operation of the plant under dynamic conditions and attainment of maximum station availability. The DDCMIS shall be fully capable to operate plant in all regimes of plant operating conditions, including emergency operation/trip conditions, black out conditions etc. without resorting to manual control. The DDCMIS shall be capable of bringing the plant to safety state automatically without operator interventions. All process input/output cards shall have built in galvanic/optical/electronic isolation for each input and output channel. The failure of controller module and each I/O module shall be indicated on control cubicles and all operator stations. For all the trip signals (very high/very low) employed for the boiler/Turbine Control System, the alarms (High/Low) shall appear for correcting the process by the operators. For measurement of boiler metal temperature flue gas temperature, air pre-heater grid temperature etc., The bidder shall provide permanent/removable duplex type mineral insulated thermo-couples terminated in junction boxes at boiler platforms. Remote I/O unit has been envisaged for these inputs. The remote I/O panel shall be provided with I/O cards, redundant power supply unit and redundant communication modules etc. These parameters are brought to DDCMIS via DDCMIS I/O bus or via redundant soft link (either TCP/IP on OPC or MODBUS with RS485) to have real time data. This remote I/O panel shall be powered from UPS or 24V DC source of respective unit. The unit enclosure shall be of weather proof, dust tight and water proof. Bidder shall provide necessary air conditioning unit, if require for the system. This panel shall also be accommodate able for 4-20 mA and RTD signals of monitoring parameter and not for control parameters. The quantities of remote I/O panels shall be decided during detailed Engineering. For measurement of turbine metal temperature turbine casing temperatures, stator winding temperature, Generator seal oil system, Turbine bearing temperature, Turbine oil temperature, Turbine bearing drain oil temperature, BFP turbine measurement parameters, MDBFP measurement parameters etc., The

20.

21.

22.

23.

24.

25.

26.

27.

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bidder shall provide permanent/ removable duplex type mineral insulated thermocouple/ RTD terminated in junction boxes at respective turbine side floors. Remote I/O unit has been envisaged for these inputs. The remote I/O panel shall be provided with I/O cards, redundant power supply unit and redundant communication modules etc. These parameters are brought to DDCMIS via DDCMIS I/O bus or via redundant soft link (either TCP/IP on OPC or MODBUS with RS485) to have real time data. This remote I/O panel shall be powered from UPS or 24V DC source of respective unit. The unit enclosure shall be of weather proof, dust tight and water proof. Bidder shall provide necessary air conditioning unit, if require for the system. This panel shall also be accommodate able for 4-20 mA and RTD signals of monitoring parameter and not for control parameters. The quantities of remote I/O panels shall be decided during detailed Engineering. 28. 8 Nos. temperature elements/sensors in each units control room shall be provided for monitoring the room temperature. On unit tripping, about hundred Engineers shall be informed through SMS automatically from DDCMIS. Incase of tripping of major fans/pumps/HT drive the concerned Engineer configured in such a way shall get the SMS information. To achieve the automatic SMS facility, GSM (global system for mobile Communication) with redundant Ethernet connectivity shall be provided by bidder for SMS facility. Same shall be connected with DDCMIS/OPC server/MIS server as decided during detailed engineering. 30. For Auto generation of trip message of unit & major fans/pumps/HT drive thru Email, Email facility in DDCMIS/OPC server shall be provided by bidder. All the 4 nos. 40 LED TV monitors per unit and 2 nos. 40 LED TV monitors for common system at CCR shall be erected at the false roof top of central control room.

29.

31.

4.02.02 4.02.02.1

CONTROL SYSTEM PHILOSOPHY In order to minimise the burden on the unit operator, all control functions within the operational load range shall be fully automated. The control system shall be structured in accordance with a well-defined control hierarchy to permit operator intervention at appropriate levels during abnormal modes of operation. The automation shall meet the following objectives as minimum: (a) Consistent start-up, shut down and running of the plant under all operational condition Achieve minimum run-up and loading time Maximize fuel economy during start-up, shut down and normal on load operation cycle Maximize plant life expectancy

4.02.02.2

(b) (c)

(d)

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Contribute to power grid during normal and disturbance condition To meet the operational and safety requirements, the control system hardware and software shall conform to a modular, hierarchical architecture. The system hierarchy shall be at four levels.

4.02.03 4.02.03.1 4.02.03.1.1

Different Level of Controls Drive Level The first and lowest level shall cover all the modulating, sequence and protection control functions directly associated with all remotely controlled plant items. It shall also incorporate all necessary interlocks, initiations and trip functions for starting and stopping a main drive motor. Control at this level shall either be initiated directly from the remote manual control interface or automatically by the next hierarchical level. Subgroup Level The second level shall coordinate the control of all first level drives, both closed loop and open loop, associated with a particular functional subgroup. In the case of a pump subgroup, for instance, the permissive checks, the coordination of the operation of the suction and discharge valves, the main drive initiations and the basic modulating control loops shall be executed at this control level. The major monitoring functions (e.g. turbine supervisory measurements) shall also be identified with this level. Typical control functions associated with this level are: i. ii. iii. Auto- Start and stop initiation or set point guidance from the next higher control level Start-stop- Normal initiation of the auxiliary start and stop sequence. Auto Standby-Start initiation in the event of duty item failure.

4.02.03.1.2

4.02.03.2 4.02.03.2.1

4.02.03.2.2

4.02.03.2.3

A functional group consists of different units, which individually represent and control a part of the complete plant and can be divided into two or more groups. Every sub group is controlled by an independent sub group control, which controls the operation of various drives. Once a start signal issued by a functional group, the sub group control brings the sub group from one state into another operating condition by issuing command signals in a programmed sequence. It brings the sub group from a shut down state into a working condition and vice-versa. The functional group instrumentation and control system co-ordinates the entire sub group controls belonging to one functional group. Group Level

4.02.03.2.4

4.02.03.2.4.1 The third and penultimate level shall coordinate the individual subgroup control function (both modulating and sequence controls) within the main functional groups of the system. 4.02.03.2.4.2 The group co-ordinate the sub group of a functional group. Its main function is to

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deliver start-up or shutdown command signals to the sub-group and change over from a faulty subgroup to the reserve sub group, the group co-ordination control supervises. the actual and the required position of the switchgear in the sub group and then decides whether the sub group shall be switched ON or OFF.. 4.02.03.2.4.3 The aforesaid concept of functional group control is independent of the control techniques-freely programmable. 4.02.03.2.5 Unit Co-Ordination Level

4.02.03.2.5.1 The fourth level, which stands at the apex of the hierarchical triangle, shall perform the overall unit coordination. It shall incorporate, for example, the master load control function which should regulate the load generated by the generator to the demand set point value. In general for automatic start-up and shutdown control, the sequential initiations of the functional group sequences should be generated at this level. 4.02.03.2.5.2 The typical sequence control functions to be implemented at this level would include: i. ii. iii. The sequential initiation of the subordinate functional group sequences for automatic start up and shutdown. The sequential initiation of the subordinate functional group sequences for automatic start up and shutdown of a part/full. The sequential transition to the various combination of subordinate functional Groups.

4.02.03.2.5.3 The modulating control functions to be implemented at this level would include the following: i. ii. Unit load control with frequency regulation incorporating load balancing (remote set point adjustment from the CCR /LCR shall be provided). Station load demand and demand rate limiting

4.02.03.2.5.4 In general the operator shall have direct access to all four control levels where these are identified, through the operator control interface located in the CCR. 4.02.03.2.5.5 Communication links shall be provided between the various control systems to allow for access to the system from any of the operators interface stations. 4.02.04 4.02.04.1 CONTROL SYSTEM - LEVEL OF AUTOMATION The unit control and monitoring shall be performed from control room by means of OWS/KB operation interface mounted on unit control desk, through a microprocessor based distributed Digital control monitoring and information system. The unit shall be remotely controlled, but a fully automatic system of the plant shall be provided, i.e. all valves, motors, final control elements and other equipment that have to be operated during start up, operation and shut down, belonging to the Main Systems, shall be remotely controllable from unit control room by the operator through Distributed digital control monitoring and Information system.

4.02.04.2

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4.02.04.3

Subordinated drives belonging to one main aggregate shall be managed by means by sub group control systems. Automatic open/closed loop controls shall be installed wherever it is possible to lighten the work of the operation. CLOSED LOOP CONTROL SYSTEM (CLCS) The CLCS shall control the process variables automatically both under steady state and dynamic conditions with in the limits specified under guarantee clauses over the entire operational range of the equipment/system. The CLCS shall have the following features: (a) Provision of predictive and/or adaptive controls in addition to PID controls as required by the system. Availability of advance control techniques/Algorithms ensuring process optimization. Set point adjustments and indication from operating work stations/ KBs for process variables which need to be changed during load changes, start-up, shutdown, normal or under any other emergency conditions. Fixed set point at the software level/hardware level (only changeable by the maintenance engineer) and indication for those process variables which need not be changed with respect to load or otherwise. Bias adjustment with indication where a single controller is controlling more than one final control element (control valve, control damper, speed drive etc.) to maintain the same process variable. Auto and manual control facility shall be transferable in both directions without bump of the value of the process variable to control the parameter during manual operation. Both master Auto Manual station and Auto / Manual station for individual control element shall be provided in OWS. Auto tuning facility shall be an inherent feature of the DDCMIS. Availability of control loop of process parameters in auto for different loads. If required, the system shall have the feasibility of auto changing of PID constants (K constants) in microprocessor/controller for different loads so as to avoid hunting of control valve. Characterization of final control element to suit the various applications with respect to load or otherwise as dictated by the process. Function generator to provide necessary characterization or variation of set points with respect to load, speed or any other requirement. Soft Auto /Manual station interlocks to drive the final control elements to a suitable position for safe plant operation in the event of process/equipment abnormal conditions. Blocking/Interlocking function as dictated by process/equipment. Monitoring of loop failures or any hardware failure in the loops. Fail safe operation of final control elements in case of failure of motive power or

4.02.05 4.02.05.1

4.02.05.2

(b)

(c)

(d)

(e)

(f) (g) (h)

(i) (j) (k)

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DESEIN Signal. (l)

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Redundancy criteria of sensors for CLCS shall be dictated as per NIT, Vol. V, Cl. No. 2.05.05. Redundancy criteria of I/O cards and Wiring for redundant or non redundant signals from field to control system (I/O cards & controllers) shall be dictated as per NIT, Vol. V, Cl. No. 4.02.08.02 and 4.02.08.02.1 respectively.

(m)

4.02.06 4.02.06.1

OPEN LOOP CONTROL SYSTEM (OLCS) Protection, interlock and sequence controls constitute OLCS. This system shall enable the operator for safe start up and shutdown and carryout normal operation both from control room and local areas. Protection and Interlock shall be provided for all the equipment and system to safeguard the equipment against abnormal conditions which may result in the failure and less utility of the equipment and protect the operating personnel. Controls shall be provided to start/shutdown various systems and/or any equipment with associated auxiliaries and to operate the Unit on line with optimum number of operations and higher safety. The OLCS shall have the following features as a minimum: Features-General Requirements (a) (b) The logic and sequence control shall be Digital distributed microprocessor based and programmable. Enable the operator to start/stop various unidirectional motors, to open/close various valves and dampers and carry out inching operation of bypass valves or any other similar equipment both from control room and local areas. The system shall be designed based on the philosophy of command to energise a relay or solenoid valve. Where there is more than one pump or fan for the same service (say 2 pumps), auto standby features shall be provided to select the standby unit and this standby unit shall start automatically on failure of running pump or on applicable process criteria (say low discharge pressure) with an annunciation. All the contacts of the sensors used in protection circuit shall be monitored. Triple redundant sensors shall be provided when used in protection circuits for major critical equipment and 2 out of 3 logic shall be derived for further use in protection circuit

4.02.06.2

(c) (d)

(e) (f)

4.02.06.3

Features-Interlock Requirements (a) Permissive conditions for a equipment start shall be provided. The permissive conditions within the equipment are bearing temperature normal, winding temperature normal, adequate suction pressure, bearing vibrations normal, bearing lubrication oil pressure normal, switchgear in service, switchgear not in test, no protection trip command persisting (as applicable) etc. The permissive conditions from a process system related equipment are

(b)

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establishment of free path for the flowing medium under all start-up, emergency and shutdown conditions, closure of discharge valve for the starting of first of the identical pumps/fans and then opening the valve after the operating condition is established etc. (c) Selection of standby equipment and starting the equipment automatically on the tripping of running equipment and/or desired process parameter conditions (say loss of discharge pressure or low level in the discharge tank etc.) Isolation of the tripped equipment from the main process. Any other conditions for safe starting and shutting down the equipment.

(d) (e) 4.02.06.4

Features-Sequence Control Requirements Sequence control shall be provided to start and stop the equipment and the associated auxiliaries. The sequence control shall have the following features: (a) Once the start-up or shutdown of an equipment is initiated either manually or automatically from the system, the control of associated auxiliaries shall be automatic with facility for manual operation at each stage (step). Criteria check up for each stage of operation with monitoring and displaying. Bypass facility for each criteria when only the feedback signal/display is incorrect but the actual condition is fulfilled. This activity shall be logged and annunciated in control system (DCS / PLC). Adequate time delay between the steps as dictated by the process to establish an operating parameter or healthiness of an equipment. Normally, the auxiliaries of the standby equipment should be running (as applicable) so that the standby equipment is started without loss of time.

(b) (c)

(d) (e) 4.02.06.5

Features-Protection Control Requirements The following minimum protection shall be provided for the various equipment/system as applicable to trip the equipment. (a) (b) (c) Any condition which endangers the safety of the plant personnel Any of the permissive conditions becoming abnormal thereby producing a dangerous condition in operating the equipment. The conditions from process such as dry flow conditions, flashing conditions or any other conditions that may create cavitation.

4.02.06.6

Redundancy criteria of sensors for OLCS shall be dictated as per NIT, Vol. V, Cl. No. 2.05.05.

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DESEIN 4.02.06.7

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Redundancy criteria of I/O cards and Wiring for redundant or non redundant signals from field to control system (I/O cards & controllers) shall be dictated as per NIT, Vol. V, Cl. No. 4.02.08.02 and 4.02.08.02.1 respectively. System Architecture for Main Plant Control System (unit wise) Following Operating work stations & Engineering work stations per unit except wherever specifically asked for both unit, are envisaged for control & operation of main power plant from Unified Distributed Digital Control, Monitoring and Information System (DDCMIS) (Refer System Configuration Drawing, # 114-01-0100).

4.02.07

4.02.07.01

Option 1 For Unified DDCMIS

4.02.07.01.01 Operating Work stations:i. 6 nos of Operating Stations (one no. of boiler control system like MFT, two nos., for BMS (FSSS), Boiler auxiliaries, two nos. for Turbine auxiliaries and one no. for electrical system & BOP) shall be connected directly on Proprietary/ preferably Industrial Data Highway/higher level network of DDCMIS with 2 LJP A4 B/W and 1 LJP A4 Color. 2 nos. of Operating Stations for Turbine Control System (governing system), like DEHGC, ATRS, ATT, ETS from the respective system shall be connected directly on Proprietary/ preferably Industrial Data Highway/higher level network of DDCMIS with 1 LJP A4 B/W & 1 LJP A4 Color. 1 no. of Operating Station for TSE for Unit incharge (shift supervisor) with 1 LJP A4 Color (if this is not integral of DDCMIS, TSE shall be connected with DDC MIS through redundant OPC connection). 1 no. of Operating Station for Unit incharge (shift supervisor) - Printer not required 1 no. of Operating Station for Station incharge (in the cadre of Executive Engineer) with 1 LJP A4 B/W. 1 no of Operating Station for performance calculations & optimization for Unit incharge (shift supervisor) shall be provided with 1 LJP A4 B/W. 1 no. of Operating Station for performance calculations & optimization at the Office of Executive Engineer/Efficiency shall be provided with 1 LJP A3 B/W. 1 no. of Operating Station for water chemistry parameters connected with performance calculations & optimization at the SWAS / Chemical Express lab shall be provided with 1 LJP A4 B/W. 1 no. common Operating Stations at Factory manager, and 1 no. common Operating Stations at Electrical System incharge room shall be provided for both units, operation/ command shall not be executed from these three consoles to start/stop the equipments. Software and hardware security lock shall be provided not to use these controls for any operations. 1 LJP A4 Color with each Operating station shall be provided.

ii.

iii.

iv. v.

vi.

vii

viii.

ix.

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x.

2 nos. of common Operating Stations for both units at common DDCMIS network in CCR with A3 sized color LJP.

4.02.07.01.02 Engineering Work stations & Servers:i. 2 nos. of Engineering Stations for system maintenance Engineer for unit DDC MIS system with 2 LJP A4 Color, 1 No. A3 sized Scanner, copier cum printer, 1 LJP Heavy Duty Industrial grade A3 Color. 1 no. Engineering Station for system maintenance Engineer for Turbine Control System with 1 LJP Heavy Duty Industrial grade A3 Color. 1 no Engineering Station for Turbine Stress Evaluation with 1 LJP A4 Color (if this is not integral of DDCMIS, TSE shall be connected with DDC MIS through redundant OPC connection). 1 no. of Engineering Station for Sequential Event Recording with 1 no. A3 sized DMP Redundant Historian server (Historical Data Storage & Retrieval system) with Work station and 2 no. A3 sized DMP. 1 no. redundant server system for performance calculation & optimization (PADO) with Engineering work Station and Heavy Duty Industrial grade A3 Color printer. Redundant OPC server for OPC connections with DDCMIS from other systems with Work station & 1 LJP A4 B/W. Redundant MIS server with one no. MIS work station, and 1 no. LJP A4 B/W. Common Redundant OPC server for OPC connections with both units DDCMIS from other common systems with Work station & 1 LJP A4 B/W.

ii.

iii.

iv.

v.

vi.

vii.

viii. ix.

4.02.07.01.03 The local operating stations 6 nos. per unit namely at locations like ESP, Zero M Elev. Turbine building, Boiler - A Elevation, HT Switchgear room, SWAS / Chemical Express lab room & CWPH (with 1 no. A4 sized B/W LJP) and 1 nos. namely at common locations like FOPH shall be provided with 24 LED color screen/OWS, with minimum configuration connected to DDCMIS on redundant connection to show the status/ conditions of various process parameters/equipments in process mimics, trends, logs etc with real time data. Operation/command shall not be executed from these local operators consoles to start/stop the equipments. Software and Hardware security lock shall be provided for not using these consoles for any control/operations. Specification of these local stations shall be same as specified at cl. no. 4.03.03.04 respectively. All the locations/rooms availing the operating stations namely FOPH, CWPH, Boiler A elevation, Turbine 0 meter, ESP, Ash handling Control room, HT Switchgear room, 400 KV switchyard control room and SWAS / Chemical Express lab, DM Plant are to be air conditioned.

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4.02.07.01.04 All operating stations connected on redundant data highway shall be interchangeable and operation of the plant shall be possible from Engg. station after security check. All operator stations shall have full access to the entire plant data base and shall have identical functionalities. The system shall have full data base redundancy. The data base shall be independent and shall reside separate from the operator stations. 4.02.07.02 Option 2 i. Separate DCS based control system is provided for Turbine integral control and DEHGC, ATT, same shall be provided with complete configuration (OWS & EWS with printers) as specified above at cl. No. 4.02.07.01.01 (ii) & 4.02.07.01.02 (ii) and TSEs work stations & TSEs Engineering stations with printers & TSI work station with printers as specified else where in the specification. Separate DCS based control system is provided for Turbine protection (ETS Emergency trip system), same shall be provided with one no. operating station and one no. operating cum engineering station and one no. A4 sized B/W LJP. Separate DCS based control system is provided for MFT & Boiler protection controls, same shall be provided with one no. operating station, one no. operating cum engineering station and one no. A4 sized B/W LJP and one no. A4 sized color LJP. For option 2, Qunatities of OWS & EWS shall remain same with DDCMIS as specified above at cl. No. 4.02.07.01.01 (i & iv to viii), 4.02.07.01.02 (i & iv to vii) & 4.02.07.01.03 irrespective of separate control systems (DCS) for Boiler integral controls and Turbine integral control respectively. In case bidder provide separate Turbine control system & Boiler control system from DDCMIS. Then configuration of LVS shall be 4 no. LVS with Display controller as part of DDCMIS package, 1 no. LVS with display controller as part of Turbine control system and 1 no. LVS with display controller as part of Boiler MFT control system.

ii.

iii.

iv.

v.

4.02.07.03

Option 3 i. Separate DCS based control system is provided for DEHGC, TSC, ATT & Turbine protection (ETS Emergency trip system), same shall be provided with complete configuration (OWS & EWS with printers) as specified above at cl. No. 4.02.07.01.01 (ii) & 4.02.07.01.02 (ii), one no. OWS for ETS/Turbine protection, and TSEs work stations & TSEs Engineering stations with printers & TSI work station with printers as specified else where in the specification. MFT & Boiler protection controls shall be part of DDCMIS. For option 3, Qunatities of OWS & EWS shall remain same with DDCMIS as specified above at cl. No. 4.02.07.01.01 (i & iv to viii), 4.02.07.01.02 (i & iv to vii) & 4.02.07.01.03, irrespective of separate control systems (DCS) for Turbine integral control system.

ii. iii.

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DESEIN iv.

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In case bidder provide separate Turbine control system from DDCMIS. Then configuration of LVS shall be 5 no. LVS with Display controller as part of DDCMIS package and 1 no. LVS with display controller as part of Turbine control system.

4.02.07.04

Total 6 No. 80/84 diagonal sized LVS per unit shall also be provided for monitoring, operation and control of power plant as per details specified elsewhere in the specification. 2 no. common 80/84 diagonal sized LVS with their own display controller connected to both unit DDCMIS on common redundant OPC network to show the status/ conditions of various process parameters/equipments in process mimics, trends, logs etc of common BOP/Offsite packages with real time data shall be provided by bidder. These two nos, LVS are common to both 2 X 660 MW units and shall be located in CCR. Operation/command shall not be executed from these LVS to start/stop the equipments. Software and Hardware security lock shall be provided for not using these local LVS for any control/operations.

4.02.07.05

Modulating Controls (CLCS) and Discrete Open Loop Control (OLCS) shall be designed to eliminate the necessity of operator action except manual / auto selection, set point changes, biasing and similar actions during normal operation. Bumpless and balance less transfers between automatic and manual operation modes and vice-versa shall be provided automatically without need of operator action. Complete backup shall also be provided for safe shutdown operation of plant. The system shall have built in redundancies for all system functions both at the processor and device level. No failure of any single device or processor shall lead to any system function being lost. It shall have redundant data highway on a "master less" principle. Redundant equipment wherever provided shall be powered from redundant power supply units in order to improve system availability and reliability. The system shall have the capability and facility for expansion through addition of station/drops, controllers, processors, process I/O cards etc., while the existing system is fully operational. The system shall have the capability to add any new control loop in CLCS and new group, sub group, drive functions in OLCS while existing system is fully operational. Intelligent I/O cards will be preferred. All the basic systems shall be connected through redundant data high way/bus system. The local bus system with associated bus couplers shall be provided for communication between different I/O modules and processors. The communication system shall be designed keeping in view the integrity & security aspects for the control system. In case the system employs master communication controllers, facility for 100% hot back up controllers with automatic switch over shall be provided and it shall be ensured that no loss of data takes place during failure of communication controller. The DDCMIS shall be fully capable to operate plant in all regimes of plant operating conditions, including emergency operation/trip conditions, black out conditions etc. without resorting to manual control. The DDCMIS shall be capable of bringing the plant to safety state automatically without operator interventions.

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DESEIN

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The application programmes for the functional controllers shall reside in EPROMS or in non volatile RAMS. The application programme shall be alterable by access through programmer's console. Parts replacement or parts removal shall not be required for accomplishing changes in application programmes including control loop tuning. Each controller shall be equipped with the amount of functional capacity required to perform its specified functions and still have an overall spare capacity of 40%. 4.02.08 Redundancy & Availability Requirements The CPU / Controllers, communication modules, data highway, power supply modules, etc for all DDCMIS/DCS/PLC shall be 100% hot standby redundant. I/O cards redundancy shall be as per cl. No. 4.02.08.02. 4.02.08.01 Controller Redundancy All functional controllers for sequence control, functional controllers for closed loop control and functional controller for DAS & monitoring shall be provided with hundred percent hot standby controllers. However controller redundancy is not mandatory, where controller is purely executing data acquisition & monitoring functions. DAS function can also be integrated within CLCS/OLCS controller. All processors for modulating controls shall have self-tuning facility. All the 100% hot back up controllers shall be identical in hardware and software to their corresponding main controllers. Further, each of the 100% hot back up controller shall be able to perform all the tasks of their corresponding main controller. The 100% hot back up controller shall continuously track/update its data corresponding to its main controller. There shall be an automatic and bumpless switchover from the main controller to its corresponding back-up controller in case of main controller failure and vice versa. The changeover shall take place within 50 msec. Engineered solution for redundancy in CPU are not acceptable. Dual redundant controllers shall be placed separately and shall not share the same motherboard or shall not have any other common sharing point. Any switchover from main controller to 100% hot back up controller and vice versa, whether automatic or manual shall not result in any process upset or any change in control status. The transfer from main controller to the back-up & vice-versa shall be indicated as alarm on all operator station OSs. In case of switchover from main controller to back up controller, the back-up controller shall be designated as the main controller. All the input variables shall be available to the main controller as well as its 100% hot back up controller so that any failure within the main controller shall not degrade the input data being used by the 100% hot back-up controller and vice-versa. Each controller shall have 40% spare functional capacity to implement additional function blocks, over and above implemented logic/ loops under worst load conditions. Each controller shall have battery backup or EEPROM/NVRAM for program memory. Parts replacement or parts removal shall not be required for accomplishing changes in application programmes including control loop tuning.

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DESEIN

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Each of the corresponding communication controllers shall also have same spare capacity as that of controller. For controller, the worst loading condition shall include the following tasks: (a) (b) (c) (d) (e) (f) 4.02.08.02 All process inputs scanning and processing is in progress and all the data is transmitted over the main data bus every one (1) second. All closed loop controls in operation All open loop controls in operation All output devices are in operation with rated performance/speed. Control/information request is initiated on all control Operating stations. In burst mode operation (in case of major equipment trip), 100 digital alarms are generated per second for a period of 10 seconds.

Redundancy in Input/output Modules Hot standby 100% redundancy shall be provided for all input/output cards where inputs/outputs are used for CLCS and OLCS. All input/output of SCADA from/ to breaker & isolators shall be redundant. No redundancy at I/O card level is required which are executing purely data acquisition/monitoring functions. I/O card shall have 16 channels per AI/RTD/TC/AO card and 32 channels for DI/DO card. No. of channels per I/O card indicated are maximum, which may also further reduced to meet the I/O cards features specified elsewhere in specification. Wherever redundant I/O modules/cards are used as per specification requirement, both (1:1 redundant) input or output modules shall execute the designated functions parallely. The offered system shall have facility to enable final output from any of redundant input/output module, in case both modules are healthy. In case one of redundant card/module is unhealthy, the system shall detect the same and the output to and from system shall be given from the healthier card. I/O card redundancy shall not be achieved through relays, diodes or any other additional hardware or software, Engineered solution for redundancy in I/O cards are not acceptable. Wherever redundant sensors are employed each sensor shall be wired to both input modules of redundant modules so that even if one input module fails, the both signals will be available from the other input module. This arrangement is necessary to avoid loss of both input signals due to failure of one input module where both the signals are connected. In addition to above, 20% fully wired input/output spare channel should be provided for each I/O modules. Bidder to note that all type of hardwares & electronic modules like controllers, I/O cards, communication modules and interface modules etc used in DDCMIS/DCS/PLC shall be sourced/supplied from their Principals works.

4.02.08.02.1 Wiring Scheme for inputs/outputs to/from control system shall be as follows:

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DESEIN i.

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Each of the triple redundant binary & analog inputs shall be wired to separate input modules. In addition, for functions employing 2V3 controllers (eg. Turbine protection, MFT, Boiler protection, DEHGC etc.), each of the triple redundant binary & analog signals shall be wired to separate input modules associated with each controller, so that even if one input module fails, the signal will be available from the other input module. In case of dual redundant binary & analog inputs, each of the signal shall be wired to both input modules of redundant modules, so that even if one input module fails, the both signals will be available from the other input module. These redundant modules shall be placed in different racks, which will have separately fused power supply distribution. Implementation of multiple measurement schemes of these inputs will be performed in the redundant hardware. Loss of one input module shall not affect the signal to other modules. Other channels of these modules can be used by other inputs of the same functional group.

ii.

The single (i.e. non-redundant) binary & analog signal required for control purposes shall be wired as follows: All single analog & binary inputs (used for OLCS & CLCS) including the limit switches of valves/dampers MCC/SWGR check-backs of all drives, SOE & information related signals shall be wired to redundant input modules. The binary and analog outputs from one subsystem of the Control System to other which are required in these systems for control & protection purposes, shall be made available from triple/dual redundant binary and analog output modules. Other binary & analog outputs used for DAS shall be non-redundant only. Failure of any single module shall not affect operation of more than one single drive.

4.02.09

DDCMIS/DCS Controller Grouping/Partitioning All controllers shall be dual redundant except Triple modular redundant controllers for Turbine DEHC, Turbine protection & Boiler MFT/protection. Following tentative segregation for controls (OLCS, CLCS) & DAS is proposed, however final segregation shall be subject to Owners approval during detailed engineering:a) b) c) d) Coordinated master controls, FTP, Oil System, Misc. Drives, Burner Tilt IDF A, FDF A, Air flow and excess air correction, PA fan A/AH A/SCAPHA/PA header Pr. Control. IDF B, FDF B, Furnace draft, PA fan B/AH B/SCAPH-B Mill related controls such as air flow/feeder rate/outlet temperature, Mill Lube controls; Two mills per redundant processor i. AB ii. CD iii. EF iv. GH v. JK vi. MN Feed water/BFP Scoop control/CBD

oil

e)

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f)

TDBFP - A integral controls per redundant processor i. ATRS 1 SGC & Turbine Protection ii. ATRS 2 SGC, TSI & CLCS iii. DEHC (Digital Electro Hydraulic Governing System) TDBFP - B integral controls per redundant processor i. ATRS 1 SGC & Turbine Protection ii. ATRS 2 SGC, TSI & CLCS iii. DEHC (Digital Electro Hydraulic Governing System) MDBFP C & Aux and Boiler fill up Pumps Deaerator (three element controls), CEP, hot well, & Hot well makeup Pumps. HP heaters 5, 6, 7 & 8. LP Heaters 1, 2, & 3. SH steam temperature control (multi variable control) & RH steam temperature control (multi variable control), Metal Temp. DMCW Pumps & DMCW system for SG & TG and CPU* (* CPU incase DDCMIS controlled) . COLTCS, HP & LP Dosing System and Cooling Tower & Aux. Electrical system 1 Electrical system 2 Electrical system 3 Remote I/O panel with redundant processor from DDCMIS family is to be implemented with following grouping for CW & ACW system i. ii. CW Pump A, CW Pump C, ACW Pump A & CW lines to/from unit # 1 Condenser/Hotwell. CW Pump B, ACW Pump B, CW makeup system & CW lines to/from unit # 2 Condenser/Hotwell.

g)

h) i) j) k) l) m) n) o) p) q) r)

s)

Turbine integral controls per redundant processor i. ii. iii. iv. v. vi. ATRS SGC Oil Supply, Turbine & Drains ATRS SGC Condensate & Evacuation System GSPC (Gland Steam Pressure Control), LP Bypass GAMP (Generator Aux. Monitoring) TSC (Turbine Stress Evaluation Control System) & TSI ATT (Automatic Turbine Tester)

t)

SG integral controls per redundant processor i. ii. iii. iv. v. vi. vii. viii. ix. Oil A B & Oil CD Oil E F & Oil G H Oil J K & Oil M N Coal A B Coal C D Coal E F Coal GH Coal JK Coal MN

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DESEIN x. xi. xii. u)

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SADC & APRDS SBC controls, SBC PR & Drain Temp. controls. HPBP

v)

Steam Turbine controls like DEHGC (TMR Triple modular Redundant philosophy) and Turbine Protection (TMR Triple modular redundant philosophy) with fail safe design cards can be Integral or separate stand-alone. Triple Modular Redundant (TMR) processors for MFT & Boiler protection with fail safe design cards can be Integral or separate stand-alone.

All controllers at sr. no. a to t shall be dual redundant (92 Nos. total) and at sr. no. u to v shall be triple redundant (9 Nos) for each unit. Hence, altogether minimum 101 processors are envisaged for each unit. During detailed engineering, processor task allocation will be done amongst these processors (and shall be subject to owners approval) taking into consideration the turbine control, boiler control and the station C&I portion altogether. In addition, loading of signal interfacing from other BOP packages, Aux. & control/monitoring system shall be considered for finalization of quantity of controllers. For common system between two units, following redundant controller grouping shall be provided with unit 1 DDCMIS, which shall also be interfaced with unit - 2 DDCMIS for control & operation. Remote I/O panel with processor from DDCMIS family is to be implemented because of the long distance. Controllers shall be 1 no. dual redundant (2 Nos. total). i) BTG (FOPH) Fuel Oil System

Above quantity of controllers is minimum, indicative and tentative only. However final quantities of processors in addition to above quantities shall be finalized depending upon I/O handling capacity of the processor and design parameters like response time, communication bus speeds etc. Overcrowding of control loops in controllers shall be avoided. Each group has sufficient spare capacity of at least 25% to meet modification/extension of the system. Multi-function processors can incorporate the corresponding interlocks (open loop control tasks of the system). Interlock and modulating controls are to be so assigned to the processors in such a way that failure of any processor does not lead to shut down of the entire unit. In no case CPU loading should exceed 60% of its capacity. Bidder to submit calculation of CPU loading along with his bid. 4.02.10 Response Times The system shall have adequate speed of response through all regimes of system loadings. The minimum criteria to be ensured are as follows:a) Key board command to field equipment shall be executed and its confirmation shall be displayed on the screen within1 second. The response for operator requested display (time between pressing of last key and appearance of last character on screen) shall be of the order of one to two seconds under all loading conditions. Dynamic parameters in the OS displays shall be updated in one second interval.

b)

c)

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d) i)

The cycle time for open loop and closed loop controls shall be as follows:For critical closed loops like Steam Separator level control, main steam temp. control, feed water flow control, HRH steam temp. control, HP/LP bypass control, furnace draft control & combustion control, the loop cycle time shall be max. 100 milli seconds preferably 50 milli seconds. For non-critical closed loops it shall be max. 250 milli seconds (preferably 150 milli seconds). For all open loops, sequential interlocks & protection it shall be max. 100 milli seconds. (The loop cycle time is defined as the time taken from change at input module to change in output module for command).

ii)

iii)

e)

All analog inputs to CLCS shall be acquired and data base updated within an interval of 50 milli seconds. Data for critical loops shall be acquired & data base updated at a faster rate to suit the requirements of (d) above. The digital inputs for SOE shall be monitored at 1 milli second resolution. The system shall acquire & check all inputs at the input scan rate. If the input is in alarm state (i.e. the input is in an off normal condition) the alarm status shall be annunciated, printed out and displayed within 1 second after the input is scanned.

f) g)

4.02.11

Established Reliability i) All components and systems offered by the Bidder shall be of established reliability. The minimum target reliability of each component shall be established by the Bidder, considering its failure rate/meantime between failures (MTBF) & meantime to repair (MTTR), such that the availability of the complete system is assured for 8700 hours / year (99.7%) or better. In order to ensure the target reliability the bidder shall perform necessary availability tests and burn in tests for major systems. Surge protection for electronic control systems, annunciation system and other solid state systems conforming to SWC test per ANSI C 37.90a (IEEE standard 472) and selection of proper materials, manufacturing processes, quality controlled components and parts, adequate derating of electronic components and parts shall be ensured by the Bidder to meet the reliability and life expectancy goals. 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. In general, failure of equipment used for alarm purpose will cause switching to the alarm state.

ii)

iii)

iv)

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DESEIN 4.03.00

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System Basic Design, System Structure And Basic Features / General Requirements System Basic Design/System Structure/Architecture The schematic diagram showing the basic structure of the system is shown in drawing (enclosed herewith drg. no. 114-01-0100). System Architecture should be secure and deterministic. Each processor in the data bus system shall perform dedicated functions and the system shall be capable of determining the system performance at any stage of the system implementation. The Open side of the system shall run on IEEE 802.3 (TCP/IP on Ethernet) standards and will be used as the information network with connectivity to OWS environment. This shall be Information Domain. The operator station shall directly reside on the Main Bus running on IEEE 802.4 or 802.5 (Token Ring or Token Bus) to facilitate Determinism in the Data transfer. The plant bus and the lower control modules will form the control Domain.

4.03.01

4.03.01.1

MEASUREMENT SYSTEM (MS) The measurement system consist of primary sensors, various function modules, processors, OWSs and peripherals, back up panel hardware and power supply racks integrated together to perform monitoring function of non-controlled variables and interact with other parts of DDCMIS/DCS/PLC. All analogue parameters will be displayed. For all drives, status indication will be displayed. The system requirements are specified subsequently. All the transmitters shall be SMART type using HART protocol and with remote calibration station including configuration and Diagnostic software. For measurement of Boiler and turbine parameters refer clause no. 4.02.01 (26 & 27)

4.03.01.1.1

The MS shall have the following features: a) b) c) d) e) f) Linearisation for temperature measurement i.e. mv Vs Deg. C Square root extraction for flow measurement, where the measurement is in differential pressure. Integration for totalising the flow measurement, whenever applicable. Compensation for variation in pressure or temperature or density for flow/ level measurement. E.g.: Feed water flow. Limit value monitor for generation of contacts for alarm/interlock purpose. Eg.: Boiler Tube metal, Bearing, winding temperature measurements Each of the analog transmitters shall be Smart type with the following: (i) 4-20mA DC signal with 24V DC interrogation. (ii) HART protocol based digital communication All these Transmitters shall be hooked up to a PC based Centralised Calibration system (HART System), which shall have Diagnostic and Configuration software. This system shall be located in Computer room. All contact inputs shall be interrogated with 24 / 48 V DC

g) f)

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DESEIN 4.03.01.1.2 Measurement Using Multiple Transmitters

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Multiple transmitters and monitoring concepts shall be envisaged wherever specified to ensure that failure of single transmitter does not lead to mal operation or reduced availability of related control systems. I Measurement using triple redundant transmitters: The control system shall select the median value for normal control purpose. In case of deviation of one transmitter output from the other two or failure of one transmitter, the same shall be automatically isolated and average output of the remaining transmitters shall be fed to the control and measurement system and the control loop in this case shall be maintained on auto, with an alarm on the operators monitor as well as engineers monitor. In case of failure of the two remaining transmitters in circuit, deviation of one transmitter output is more than the preset limit compared to the other transmitter, there shall be automatic bump less transfer and changeovers shall have suitable alarms. II. Measurement using redundant transmitters: The control system shall use average value of two signals. In the event of excessive deviation between these two signals, the control system shall trip to manual and it shall be annunciated to bring operator's attention and the operator shall have facility to select any of the transmitter through OS operation. In the event of failure of one of the transmitters, it shall select the healthy transmitter and the control system shall remain in auto mode. The failure of transmitter shall also be annunciated in OS/ES to draw operator's attention. 4.03.01.2 Plant Automation System To automate the Units, The Bidder will be required to do the complete sequencing for start-up, raising the load to full load operations, emergency shut downs etc. under various conditions. i) The system shall be capable of three (3) modes of operation: a) Automated coordinated master control mode requiring no operator intervention except at the start. In this mode, operator will be informed of various steps being performed. In case any missing criteria occur, this will be informed to the operator. System guided modes in which extensive operator guides will be provided by the system. The operator will start/stop the major sequences based on the operator guides. The major sequences will however, be programmed into the system.

b)

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DESEIN c)

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Manual step by step mode in which the operator can directly intervene at the drive level. Detailed operator guides shall be provided by the system under such mode also.

ii)

The system shall be capable of cold starts; warm starts and hot starts. The operator guides will take into account the mode of start up and give appropriate messages. The automation range shall cover from starting of the CW system to bringing the unit upto target load. For this purpose all check listing and Boolean and other calculations required will be done by the system and displayed vide appropriate displays on the OS. The system shall be capable of interfacing with HP and LP bypass systems to ensure integrated operation completely on auto mode. The system shall also be responsible for cutting in the auto controls without operator intervention in the auto mode. For shut down, the system shall be capable of handling automatically decrease of load on an auxiliary failure and shutting down the equipment completely from load decrease to all auxiliary equipment stop. The system shall perform the boiler light up, air flow/coal feed control, super heater pressure up/down control, all fans control, feed water control from no load to full load and finally operation of unit on coordinated master control.

iii)

iv)

4.03.02

Process Station (Automation System) The analogue/binary input/output modules, multi loop multi function controllers etc. shall form part of the Process Station. The system with reduced number of different types of modules/cards has the advantage of easier servicing, modification, reduced spare inventory. The failure of controller module and each I/O module shall be indicated on control cubicles and all operator stations.

4.03.02.01

Main Controller Characteristics Each controller envisaged for this project shall have following features as minimum:i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) Processing word length of 32/64 bit (Preferably 64 bits) 16 Mbytes RAM minimum. Redundant power supplies Power fail/auto start feature Watch Dog timer Memory protection Direct Memory Access feature Self monitoring & diagnostic feature Easy modification of control functions RISC/CISC based Real time data controller, Computer/PC based soft controller are not acceptable. Adequate capacity of volatile memory as specified above and non volatile memory. Memory expandibility of 15% of offered capacity shall be provided. Ni-Cd / lithium type battery backup for at least 72 hrs continuous Operations during power failure.

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DESEIN 4.03.02.02 Controller Functions (i) Mathematical functions

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The system shall include the following blocks to perform various mathematical operations-Sum of N inputs, multiplication, division, minimum of N inputs, periodic average, period summation, period maximum, period minimum, rate of change, logarithm, trignometry, exponential, polynomial, matrix function, absolute value, integration greater than, greater than or equal to, equal to, not equal to, any other function as necessary to meet the functional requirement, and software provision to add more algorithms at a later date. (ii) Logic functions The system shall provide facility to perform various boolean operations. The following minimum function logics shall be included AND / NAND, OR / NOR, Exclusive OR, ON time and OFF time delays and any other as necessary. The sequential control function shall be accomplished through a versatile mix of algorithms which are available in logic points. The logic points shall have upto twelve (12) input connections, twelve (12) output connections and upto sixteen (16) logic blocks. (iii) Control technique The system shall include the following control techniques: Multivariable, feed forward, feedback, cascade, auto tracking, ratio and bias dynamic dead band, proportional, integral, derivative and their combinations, auto inching, auto limits, blocks, run-ups, run downs, auctioneering, over rides, analogue hold, State variable based predictive control for SH/RH temp. control, Advanced control algorithms like matrix smith predictors, sequencer adaptive gain scheduler and any other techniques as may be necessary. During interlock operations, all affected controllers will not be permitted to continue integrating action. On removal of interlocks / override, all the controllers shall be balanced to the existing conditions without causing process upset. In-built function blocks for various control algorithms must be available without software programming. 4.03.02.03 Analogue/RTD/TC Input and AnalogueOutput Modules/cards (16 Channel) 1. Analogue input module shall be capable of accepting inputs like 4-20 mA current signals, RTD (PT 100), Thermocouples or Voltage input signal. Analogue input module shall have the following features:a) b) c) d) Independent CPU Time tagging of input variables at I/O level. High accuracy of conversion, minimum 14 bits, plus sign bit. Linearization and error checking of TC and RTD signals and reference junction temperature correction facilities for T/C (for cold junction compensation).

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DESEIN e) f) g) h)

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i) j) k)

l) m) n) o) p) q) r) s) t) u)

v) w) x)

Acquisition of TC and RTD input shall be directly in the input module itself. Power supply for transmitters via. Galvanic / Electric isolation and supervised fusing for each transmitter circuit. Limit setting with minimum four limits for each analogue settings. Monitoring facilities for input/output signal wire short circuit, open circuit, ground connection sensor break etc. shall be provided in addition to self monitoring of hardware and software faults within the module and shall be displayed in OS. In case of smart I/O cards square root extraction. CMRR (Common Mode Rejection ratio) for thermocouple signals shall be > 120 db @ 50 Hz. For RTDs, provision of both 3 wire/4wire connections is required. Use of Temperature transmitters shall be restricted. For all thermocouples the Extension cables shall be brought up to T/C module. Fuse Protection and Fuse failure detection Input filtering for Noise level. Monitoring of A/D conversion. Conversion to Engineering Units. Galvanic/optical channel to channel Isolation shall be built in Module. The current limitation shall not be considered as channel isolation. Detection of Open Circuit for Thermocouples. Direct or reverse operation Loop check back of Output and responsibility checks of all inputs (analog signals), validate and quality tagging like good bad, suspects. Default options upon failure Failure of individual channel shall not disturb the other channels for AI/TC/RTD card. Contact bounce filtering with adjustable time constant. HART compatible. The non HART compatible AI card shall have input loop resistance > 250 ohms for interfacing transmitter and giving 4-20 mA analog signals along with superimposed HART interface signals.

2)

Analog Output Modules shall have the following features:a) b) c) d) e) f) g) h) i) j) k) l) Type of output : 4-20mA DC Accuracy : 0.1% or better Load : 600 OHM Diagnostic : Channel fault Direct or reverse operation D/A per output and power regulator per output Loop check back of output Default options upon failure 5-segment output characterization Go to zero current Failure of individual channel shall not disturb the other channels for AO card. Galvanic/optical channel to channel Isolation shall be built in Module. The current limitation shall not be considered as channel isolation.

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DESEIN 4.03.02.04

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Binary/Digital Input/output Module/Card (32 Channel) The Binary signal conditioning processing shall be performed in distinct binary input modules which can accept voltage free contacts, digital signals, and also pulse inputs and shall meet the following requirements:a) b) c) Binary inputs are monitored, conditioned and time tagged in binary input module. The modules shall process different inputs such as volt free contacts, proximity switches and logic signals. The contact input from fields shall be monitored in the binary input modules for non-co-incidence, wire break, ground, short circuit, proof, etc. for all important signal used for control & protections. After signal conditioning, all signals are set with their validity status and acquisition time before being marshelled to the bus system for further functional processing. In case of invalid signals the same shall be flagged in the messages in order to be identified in the received module. The binary input/output modules shall have the following features:High insensibility against noises and other disturbance (e.g. Walkie-talkie). High insensibility against over voltage (IEC-255-4 Class-II). Supply of contacts voltages with 24/48 V DC It shall be possible to read status of all binary channels from the engineering station and monitoring / diagnostic should be possible from diagnostic station. Installed supervised fusing for input circuits, contact bounce suppression, etc. adjustable upto 15 milli seconds. The modules shall have facility to transmit the identified fault signals to the central diagnostic station and displayed therein clear text. These include power supply failures, transmitter fuse failure, open circuit, short circuit & ground connections of input lines non coincidence of change over contacts, etc. In addition to the above, modules hardware and software faults shall also be monitored. Contact chattering protection Supervised fusing for the input circuit. All the inputs shall be isolated to 600V between any input point and ground or between any pair of inputs & shall comply with ANS C.37.90a for transient surge protection to 2000 volts. Non-coincidence monitoring. 1 milli second resolution for all binary inputs. Short Circuit Protection Output read back verification Galvanic/optical channel to channel Isolation shall be built in Module. The current limitation shall not be considered as channel isolation. All binary I/Os must have isolation between system and field. Control, Plant Information and Monitoring

d) i) ii) iii) iv) v)

e)

f) g) h)

i) j) k) l) m) n) 4.03.03

Operator Station, Operator Stations/Operator Sub System Operator Station

4.03.03.01

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DESEIN

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Operator stations shall perform operation, control function, plant monitoring and display function, alarm functions, SOE recording etc.. All functions required for supervision & remote manual control of the unit shall be performed by this station. The functions shall be performed with the help of standard pictures on OS which shall include plant mimics. Issuance of control command may be realised through function key board or mouse/trackball. Remote control using OS Screen/Key board operation for all remotely operated final control element has been envisaged. 4.03.03.02 Plant Monitoring Display & Logging

4.03.03.02.01 Displays The OS displays shall be capable of presenting all system process input values including analog, digital, composed and Boolean. The system shall also display all control loops with all associated parameters. Typical displays shall be single and group point displays alarm displays, bar charts, graphic pictorials, operator guidance displays, loop displays, X-Y plots and summaries. The use of colour on the OS shall serve to rapidly draw operator attention to important data. The colour of each item shall be as per clause 4.02.01(13) or as determined by the Owner. All alarm displays shall be updated at least once every two seconds. The system shall permit the operator to create new OS displays, modify existing displays and request displays on-line by using any utility OS with keyboard in a conversational mode. The capability to transfer the displayed OS display to copy (printed paper) shall be included. System's response time to display full screen of real time and historical information (from historical storage functions) on demand shall not exceed more than one seconds and three seconds respectively under worst case loading conditions. The display & logging system shall also be able to accumulate the Process & other plant important parameters for hour, shift, day, month and year and be able to point out on demand. a) Following Important Parameters shall be displayed on each Graphic Page Sno. 1. 2. 3. 4. 5. 6. 7. 8. b) Parameters Generator Load MW Generator Voltage KV Generator Frequency Hz Turbine Speed RPM Main Steam Pressure Kg/Cm2 Main Steam Temperature deg C Main Steam Flow TPH Furnace Draught mmwc

Motor current shall be displayed near the respective motor in the graphic.

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DESEIN c)

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Flashing rate of symbol when the drive is fault shall be 8 Hz/sec and flashing rate of symbol when drive status changes from open to close / close to open shall be 2 Hz/sec. Individual Point Data Displays This shall cover all the analog and digital plant data available on the bus and shall contain the following data:a) b) c) d) e) f) KKS number Point description Correct value in engineering unit Sensor/transmitter tag number Current alarm status Alarm limit

(i)

(ii)

Bar Graph Display: Bar chart display are used to quickly obtain an over view of the current process status in the power plant. To accomplish this, analog variables related to each other by control requirements are grouped together and output to the colour display unit of operator station. The bar chart display can be selected from the functional key board or via. operator action directly on a display unit. Each bar chart group contains a heading which indicates the plant section or functional group to which it relates. The display length of the bar chart shall be freely selectable. Normally its scale shall be in the length of 0 to 100%. It shall, however, be possible to increase the resolution by limiting the scope of measurement range i.e. to the range of interest during steady state operation. Provision shall be made for displaying minimum 20 number of bar chart groups (vertical or horizontal). Each group shall be designed for assigning upto six parameters. The points assigned shall represent parameters which yield information when viewed in comparison with each other at any instant of time. Real time updating shall be provided for data values over laid.

(iii)

Group Displays/Overview Displays The group display/overview displays shall show process variable profiles such as boiler metal temperatures in bar chart form. Variables in alarm shall be displayed in a different colour than the variables within alarms limits. Bars may be displayed horizontally or vertically. Upto 64 points shall be displayed per screen (in a bar group).

(iv)

Trend Displays: Three different types of OWS trends are envisaged. a) Real time trending:

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System shall be capable of trending any analog point defined on the highway. Each operator station shall have the facility of real time trending for 60 process freely configurable variables with sampling frequency of 15 sec., after which data shall be automatically transferred to Historical Data Storage & Retrieval system. "Bidder shall clearly specify in his proposal and ensure that no manual operator intervention is required for transfer of data from operator station hard disk to historical storage devices. b) Short Term Historical Trending: OS trend shall be able to trend minimum six variables preferably 12 variables simultaneously on the screen in order to assess their inter relationship. System shall have capability for selecting variable at random for on-line trending instead of pre-defined groups. The alphanumeric information shall be displayed on the same screen to identify points, scales, current values and related information. In addition each Work station should have provision for retrieval of all data from Historian with sampling rate of 1 sec. c) Historical Trends: It shall be possible to trend any value stored in the historical data base including analog primary and calculated values. It shall be possible to trend six variables simultaneously ranging from one minute to 7 days. Compression and expansion of trends between predefined scales shall be possible. Scrolling back and forth in time shall be allowed. Trend facilities for on line and historical shall be available on the system for 25 trend groups of six points each for on line trending. It shall also be possible to recall these trends using archived data for historical trending. d) (v) All the important digital status change leading to any abnormalty shall be configured in the trend log for analysis purpose

X-Y Plots: The OS's shall be able to graphically display the relationship between two analog points. This display shall permit up to eight points on the Y- axis. The system shall permit the operator to display maximum and minimum operating curves for the Y-axis variable as a function of the X-axis variable. There shall be up to 10 X-Y plots stored for recall by the operator.

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(vi)

Alarm & Event Display, Alarm Monitoring and Reporting The alarms and return to normal shall be displayed on any operator OS. System shall have facility to assign any OS as alarm OS, at any stage. Alarm message shall be reported to the alarm OS within one second of alarm detection The system shall have capability to store minimum 1000 alarms. The system shall display history of alarms in chronological order. The alarm display page on any OS shall have a 20 to 24 line capacity. Each line shall have 80 characters. The alarms will be built bottom up with the most recent alarm at the top of the list. When a point returns to normal, the associated alarm line shall be blanked out, the alarms below the blank lines shall move upward to fill the empty lines. If the 24 line capacity of the OS is exceeded, a second 24 lines of alarm capacity shall be maintained in memory to accept the overflow. A message indicating a second page of alarms in memory shall be displayed in the screen. This second page shall be displayed upon operator demand. When a point goes into an alarm state and appears on the alarm screen, the time of alarm will flash until acknowledged by the operator. Acknowledgment by the operator will cause the time to stop flashing. When a point returns to normal, it will disappear from the screen. All alarm initiations and return to normal, shall be logged on a printer. The system shall also have the capacity to use alarm suppression schemes. The system shall have the capability of prioritizing alarms and suppressing alarms associated with a particular priority. The operation shall have the capability of scanning all alarms by using any utility OS. All digital point should be categorized with severity 1-5 and all analog signals must be colour coded in such a way that during normal range its value will be green and after normal range up to certain level it should be yellow and in the dangerous zone it should change its colour to red to give alert signal to operator. The following features shall be provided as a minimum:1. Process operating limits, viz. high limit, low limit or both high and low limits, high - high, low - low, and both high - high and low - low limits, rate of change limit etc. shall be assigned to specified analog inputs and calculated variables. The system shall check for violations of these limits to detect alarm conditions. Every limit shall have a dead band associated with it. Dead band shall be of absolute values or a percentage of range (maximum 8 dead bands). Alarm reporting/actions:

2.

The following sequence shall be followed for detection of alarms:a) Display of alarm message on alarm OS

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b)

Printing of alarm message on alarm printer

Alarm annunciation sequence on OWS: S.no 1. 2. 3. 4. Condition Normal Alarm Alarm ACKED Alarm return To Normal Alarm return To Normal and Acknowledged Visual OFF Window Flash Steady ON Text Flash Audible OFF ON (Sound-1) OFF ON (Sound-2)

5.

OFF

OFF

(vii)

Mimic Displays Plant Mimic shall be displayed with current operating parameters, equipment operating status, operator guidance, alarm points etc. Process mimics shall be 3D in nature and dynamic on operators console. The Bidder shall provide with the system a elements as defined by the owner. minimum of 50 macro pictorial

System shall have facility to handle & store on hard disk for at least 100 nos. of display pages of any kind. The system shall show process data in history mode in a normal process mimic. In history mode, the data produced is retrieved from the history data base and can be shown in process mimic. The same picture shall be run in parallel in both real time mode and history mode for comparing the situations. (viii) Process Graphic Displays: The process graphic displays shall provide representations of plant layouts and measurements. The information included on each display shall be matched to the expected operator objectives when selecting that display. Process information and equipment status shall be presented as dynamic text values and symbol colors. For ease of recognition, controllable equipment shall be identified on the display by a consistent means such as specially colored locator codes. Operator control action shall be effected by first selecting the equipment to be controlled using the cursor or keyboard then initiating the desired control action utilizing the keyboard.

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Faceplate Displays: Faceplate displays consist of an intelligent grouping of manual/auto station or control switch "faceplates" associated with a given piece of equipment or process. Operator control action shall be as described above, first selecting the appropriate faceplate then initiating the desired control action. Permissive Displays & Step Indicator: Permissive displays and step indicator shall group, into a single display, the conditions which must be met for a designated piece of equipment to be started or continue operating. The permissive display and step indicator shall be dynamic to rapidly indicate to the operator sequential start/stop or open/close and the reason a piece of equipment tripped or failed to start. A similar type of display shall be used to serve as a checklist when operating in the semiautomatic or manual startup modes.

(x)

4.03.03.02.02 Reports & Logs: The system shall print logs/reports as defined in these clauses. The printing of these logs/reports shall be initiated automatically at prescribed time intervals, or initiated on demand or by the occurrence of predefined events. All logs/reports shall be made from stored data so that once a log is initiated it can be completed without interruption. Multiple logs when printed from stored data shall print consecutively without interruption. Programmed log formats shall include but not be limited to all required headings, sub-headings, and word descriptors. The exact format and printer assignments for each log will be defined by the Owner after award of contract. In addition to the logs specifically defined in these specifications, the operator shall be able to create new logs and modify existing logs and reassign them among the printers on-line. Sub-headings, column formats, point number assignments, data collection frequency, and printing intervals shall be produced via. a OS/keyboard combination. The system shall be capable of handling up to 40 printed pages (30 lines per page and 132 characters per line minimum) of logs in addition to those specified with 10 formatted columns of data per page. These 40 pages shall be subdivided into separate logs by the operator. i) Pre and Post Trip Logs: The pre and post trip log is used in the post trip analysis of the plant or auxiliaries. The system continuously scans and store in memory, the values of pre defined variables for a specified time interval before and after disturbances. The data shall be saved at pre defined intervals (four, ten, twenty seconds) for a period of 10 minutes before trip and 10 minutes after trip. It shall be possible to use minimum 15 analog values per log. The post trip log output is triggered automatically by a specified system disturbances or event. The analog values are printed in a tabular form with a time reference.

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The binary status changes over the post trip log period are printed chronologically with the details like time of event, binary status, point identification/description etc. The engineer shall be able to assign or delete variables from the log and enter the pre and post trip time intervals from OS console on line. ii) Trend Logs: a) Single Point Trend Print the value of a single point at a selectable period variable from one to ten minutes. b) Group Trend Print/display the values of a selected group of inputs. There shall be available a total of 300 groups of 8 points each from the 75 equipment/system a parameter groups. Groups one to 290 shall have a fixed complement of points, while the points associated with group 290 onwards shall be selectable by the operator. It shall be possible to trend any group at any one time at a selectable period from one to sixty minutes. . The projection period will be one (1)minute to 48 hrs. c) Trend Log Summary This summary will list all groups described above. The display/print out shall include each group identification (group heading) and shall list all points associated with each group. iii) Alarm Logs: Print all points (analog, calculated, digital) that are off-normal at the time request is made by the operator. iv) Log Operator Action: The system shall have the capacity to store all operator actions for a twenty four hour period. Both the nature of the actions and the individual time of each request shall be stored. This information shall be printed automatically once each twenty four hours in the form of a summary log. The log shall also be available for printing upon operator demand. v) Shift Log/Reports The system shall print at the end of the shift a report parts. The first part will include the following: a. which shall have two

Summary of alarms and returns to normal, indicating time and maximum/minimum value of the corresponding variables.

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DESEIN b. c. d. e. f.

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Summary of bad inputs. Status changes. Alarm limit changes and substituted values by the operator. Deviation of system/equipment efficiencies. Accumulated data.

The second part will consist of 100 points subdivided into 10 groups of 10 points each. The values shall be stored each hour and shall be cumulative, averaged or instantaneous as decided by the Owner at a later date. The shift report shall be automatically printed at the end of each shift. It will also be simultaneously stored on DVD/Blue ray disc/DAT drive. Capability shall also be provided to print this report at any time on operator's demand. However the demand print out shall not eliminate the requirement to produce a shift report at end of each shift. vi) Daily Log/Reports The system shall print at end of each day a report in two parts. The first part shall include the following: a. Summary of important alarms (trip and pre-trip alarms) Equipment equipment b. in service time and number of start-ups for all major

Daily fuel statement

The second part will consist of 100 points subdivided into 10 groups of 10 points each. The values shall be stored automatically each hour on the hour and shall be cumulative, average or instantaneous value as selected by the Owner at a later date. The report shall be printed automatically at midnight every day and shall also be stored on cartridge tape. The capability shall also be provided to print this report on operator demand. However, this will not eliminate the requirement to produce a daily report at midnight. vii) Maintenance Log: Provision shall be made for logging operating information about certain plant equipment for the purpose of scheduling preventive maintenance and routine equipment inspection. The log shall be capable of including all equipment for which an "equipment status" digital input has been provided and such other equipment as shall be designated by the owner. The specific equipment included in the log shall be selected from the programmer's/engineer's terminal.

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

d)

e)

viii)

Turbine Run up Log: A log of up to 100 turbine and generator data points shall be collected and automatically printed at either 1, 2, 3 or 5 minutes intervals as selected by the operator. The log shall be initiated by turbine roll-off and shall remain in operation until stopped by the operator. Boiler Start-up Log: A log of upto 100 boiler data points shall be collected and automatically printed at either 1, 3, 5 or 10 minutes intervals as selected by the operator. The log shall be initiated at the start of the boiler for purge sequence and stopped by the operator. Turbine and Generator Diagnostic Log: The turbine diagnostic log shall contain upto 100 turbine and generator data points to be used in analyzing possible turbine and generator trouble. The data shall be printed out once every 24 hours at a time selected by the operator. Once the log printout is initiated, data shall be collected and printed out every minute until four sets of data have been recorded. Turbine Recall Log: The turbine recall log shall be initiated by the occurrence of any one of several alarms and shall consist of all data defined for the turbine diagnostic log. The system shall store information whenever the turbine generator is on-line. The data shall be stored in the computer memory at one minute intervals. A total of 30 minutes of data shall be stored in the memory. Following the initial 30 minutes of operation, the oldest data in the memory shall be discarded and replaced with new data. The log printout shall be initiated by pre-

ix)

x)

xi)

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selected alarm conditions and shall continue at 1 minute intervals after initiation of the log until the alarm conditions has disappeared or until stopped by the operator. xii) Turbine Shutdown Analysis Log: A log of upto 100 turbine data points shall be printed whenever the generator is taken off line. Data, except turbine speed, shall be collected at 1minute intervals. Turbine speed shall be collected at 1 second intervals, for the first 5 seconds after the shutdown is initiated and at 2 minutes intervals thereafter. The log shall continue until terminated by the operator. Special Logs: Several special logs shall be provided by the data distribution control system computer as follows:a) Printing of data shall maintain assigned columns. The engineer's/ programmer's terminal shall include capability to edit logs to move all data columns currently in use to adjacent locations. A log of all vibration inputs shall be made on demand. A summary log of all bad inputs shall be made on demand. A log of temperature devices including, but not limited to bearing temperatures of all 6600 volt motors, stator hot spot temperatures of 6.6 KV motors and bearing temperature of all driven equipment equipped with temperature detectors shall be made hourly. A log shall be made to provide a record and warning of 6.6 KV motor start limits. Provisions shall be made for a test log consisting of 50 parameters obtained in a very short time span through a priority interrupt. The program shall be repetitive at the selected standard sample rate until manually halted. The test log shall be printed on the programmer's printer only.

xiii)

b) c) d)

e)

f)

xiv)

Performance Log: Provision shall be made for logging upto 100 variables which can be used in unit performance calculations. This log shall be initiated and printed on demand by the operator. The log shall consist of averaged data which is accumulated over an adjustable period of time from 10 to 30 minutes. Other Reports: The system shall store on bulk memory at suitable time intervals for further processing data to generate the following information:a) b) c) d) e) Normalised values of data accumulated. List of all major equipment trips sub-systemwise. Plant and major equipment availability. Fuel statement. Long term performance deterioration trends. Nos.

xv)

4.03.03.02.03 A.

List of Displays

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DESEIN a) b) c) d) e) f) g) h) i) j) B) a) b) c) d) e) f) g) h) Individual point display Overview display Plant/mimic displays Bar group display Trend displays X-Y plots Alpha Numeric Group displays Alarm & event displays Operator guidance display No. of Groups List of Logs/Reports Pre and Post trip log Trend log Alarm log 10 10 1

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All analog & Digital points 10 300 20 for 750 process variables 10 7 All OS alarms 50 300 min. (8 points per group)

Log of disrupted & simulated values 1 Log of operator action Maintenance log Shift log/Reports Daily log/Reports 1 16 10 5

Above quantities of displays & logs is minimum and indicative. The actual nos. displays & logs will be finalized during detailed engineering only. 4.03.03.03 Historical Data Storage and Retrieval Historical Data Storage & Retrieval system shall be redundant (2x100%) and shall comprise redundant server based Stations with one no. operating work station, and two nos. 132 Col Dot matrix printers. Operator station based non-redundant distributed history data bases shall not be accepted. Historical storage and retrieval facility shall allow collect and store data parameters including trends, alarms and events from control system data based periodically and automatically removable data storage devices once every 24 hour for long term storage and retrieval.

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The Historical storage unit (HSU) shall augment the global memory in the system and will archive data and parameters for logs and historical storage unit shall be a stand-alone unit on the data highway performing as file server. Historical storage unit shall be redundant. Redundant facility has been envisaged for both the historical storage units by dual disc imaging and other such technique so that any single failure will not lead to any loss of historical data. The memory capacity of the HSU shall be determined based on the monitoring requirements for plant data indicated in the logs. The average minimum and maximum values are to be indicated. Parameter can be archived/ configured at Historian with selectable sample time. Module shall also have the capacity of strong both snapshots and average value. Facility for archiving the historical data in DVD & BLUE RAY disc shall be provided. Historian node shall have DVD & BLUE RAY disc read write (for CD, VCD, DVD & BLUE RAY disc - with read & write). The historical data storage and retrieval system shall collect and store process system data from the data bus. The system shall be furnished with facilities for an automatic storage of data on a DAT drive for long term storage and its retrieval by the operator for subsequent processing and printing. The operator shall be able to display and print the retrieved data on colour OS and printer. 4.03.03.04 Specifications for Operator Station, Engineering Work Stations Each operating station & Engineering work stations and any other work stations/PC envisaged in plant shall meet following minimum requirements & as per latest trends at the time of supply: On board Intel Xeon quad core, 3.46 GHz processor with 1066 MHz bus with Hyper threading or higher. 4GB DDR3 RAM (min.) 1 x 1000 GB IDE Hard Disc Drive of 7200 RPM or higher 1024 MB Graphic Accelerator System chipset: Intel Express 2 x RS 232 ports 1 x parallel port 4 nos. USB ports. (2 nos. on front side) 1 x 52X DVD/CD Read Drive 16 X DVD R/W Drive 2 x Ethernet (10 / 100 / 1000MB) cards (Industrial Grade) UXGA graphics and monitor 1920 X 1080, 256 colours with MRPII compliant, viewing angle 178 vertical & Horizontal and fastest response time. 1 x windows XP/7 Professional or latest & proven version of Windows OS professional with Multimedia Ethernet adapter Third party operating system, graphical users interface and software, if required. 2 nos. graphic output crads minimum

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DESEIN -

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Optical mouse Sound card Internal speakers Wireless internet & Blue tooth Interface Redundant power supply (In built) General MS Windows latest, MS-Office Professional, Adobe Acrobat, anti-virus McAfee or equivalent, AutoCAD etc. Application engineering & HMI software - to suit project Specific requirement All OWS shall be interchangeable

Preferred makes of OWS/EWS/PCs are DELL, HPCOMPAQ, NEC & IBM. 4.03.03.04.01 Peripherals for Operator Station, Engineering Work Stations & Server System 4.03.03.04.02 Full flat Monitors with LED back lighting The bidder shall furnish OWS/EWS/Servers/PC with coloured Full flat Monitors with LED back lighting. OWS/EWS/Servers/PC with Monitors shall have a fast cursor control device like a track ball/optical mouse. All Monitors shall be of high resolution colour graphics type and with not less than 32 colours. The picture frequency shall not exceed 85 Hz. The resolution required is 1920 X 1080 pixel or better. The picture shall be stable and completely free of any flickering. The screen illumination shall be enough to give good readability. The screen dimensions shall not be less than 24" screen diagonal. Antiglare hard coating shall be provided. High reliability and long life 24 (Industrial type) or better size monitors shall be supplied by the bidder. Monitors shall be equipped with all adjusting elements accessible on the front plate. Monitors with 3D capabilities for graphics shall be provided by bidder. Monitors along with keyboard & optical mouse shall be mounted on supervisory control console specified elsewhere in the specification. 4.03.03.04.03 Key Board: Functional key boards for plant operator station shall be of special type adopted to operation tasks and monitor functions. It shall contain all keys necessary for plant operation arranged in an ergonomically manner. Multi function keys shall be provided with automatic display for modified functions. Freely programmable keys (Minimum 101) shall be available for special user application. Key Board shall be integrated into supervisors control consoles horizontal part. Provision of functional keyboard shall be in addition to facility for operator control through mouse/track ball. Membrane type keyboard shall be provided for operator interface with process for plant control and display functions to access plant data in conjunction with control OPERATING STATIONs. Membrane keypad shall be assignable with LED alarms, dedicated display selection keys with spare provision, hardware locking facility to set OPERATING STATION in engineer, supervisor or operator mode. The keyboard

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shall have a minimum of 101 configurable keys for assigning most frequently used displays. A minimum of forty of those keys shall have two independently lit LED's used for event-specific alarm annunciation. Keyboard shall be provided to enable the shift supervisor to develop graphic displays, control system software and system configuration for the DDCMIS. It shall be possible to perform operating interface functions from engineering OPERATING STATION. Assignable function keys shall be provided for execution of command, program etc. Hardware facility shall be provided to set OPERATING STATION in engineer or operator mode. QWERTY type keyboard shall be provided for engineers functions. QWETRY type Key Board may be offered alternatively for OWS. 4.03.03.04.04 PRINTERS Line Impact Heavy Duty Dot Matrix Printers All printers shall be low noise (less than 60dB) type with a minimum of 136 columns. Printing speed shall be a minimum of 300 characters per second. Since the control room printers are high-speed printers, the system shall output to these printers at the rate of 1000 lines of printout per minute as a minimum. This rate shall be independent of the number of printers in simultaneous operation. Style of printing available shall be indicated by the Bidder. The printers shall have graphic capability and any OPERATING STATION display may be printed on the printer. The printing shall be bi-directional and in two colours black and red for sequence of event recording. Paper input capacity shall be with continuous paper feed. Printers shall accept and print all ASCII characters via an E.I.A. RS-232 C or twenty milliamp current loop interface. Parity checking shall be utilized. All printers mounted shall be provided with a separate printer enclosure each. The enclosures shall be designed to permit full enclosure of the printers at a convenient level. Plexiglas windows shall be used to provide visual inspection of the printers and ease of reading. Printer enclosures shall be designed to protect the printers from accidental external contact and each should be removable from hinges at the back and shall be provided with a lock at the front. If one of the printers fails to operate, it's functions shall automatically be transferred to the other printer. Failure of the printer shall be indicated on all OPERATING STATION's. Printer shall be offered and supplied from reputed manufacturer with latest proven technology. 5 Rims of papers shall be provided by bidder for each printer provided with subject plant. Coloured Laser Jet printer Printing Speed Resolution Memory External Port 20 ppm (min.) 1200 X 600 dpi 128 MB (min.) 1 no. USB 2.0 port, and TCP/IP 10/100 Ethernet, Blue tooth interface

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DESEIN Duty Cycle Pages size

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40,000 pages per month A3, A4, and Transparency etc. with automatic duplex printing facility.

Laser Jet printer (B & W) Printing Speed Resolution Memory External Port Duty Cycle Pages size Ink Jet Printers (Coloured) Printing Speed Resolution Memory External Port Duty Cycle Pages size Duplex printing 30 ppm (min.) 1200 X 1200 dpi 64 MB (min.) 1 no. USB 2.0 port, and TCP/IP 10/100 Ethernet, Blue tooth interface 5,000 pages per month A4, Transparency etc. Automatic 30 ppm (min.) 1200 X 1200 dpi 128 MB (min.) 1 no. USB 2.0 port, and TCP/IP 10/100 Ethernet, Blue tooth interface 15,000 pages per month A4, A3, and Transparency etc. with automatic duplex printing facility. Paper tray - 2

Five sets of print cartridges and Five rims of papers shall be provided with each printer provided anywhere in the plant by bidder with each DDCMIS, DCS & PLC system and any other system specified elsewhere in specification. Preferred makes of printers are HP, Canon, Fuji Xerox, & Epson. 4.03.03.04.05 External DAT Drive The DAT drive is a serial back-up device. The DAT drive shall have read/write capability and shall be provided with all required hardware interface including error detection and correction facilities in each control room. The tape (total 10 nos.) of Sony make shall have the capacity of 12/24 GB min. The tape drive shall be specified as follows:DC drive Tape format - QIC-80 Data Transfer Rate 5MB/minute. Seek time 22 milli second

4.03.03.04.06 Hard Copy Facilities The system shall be capable of copying hard copy of OPERATING STATION graphics through a video colour copier switch able to any OPERATING STATION. The printer/copier offered shall be capable of copying OPERATING STATION image in 20 seconds.

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4.03.03.04.07 USB Port Pen Drive Twenty Five (25) no. USB Port pen drive per unit having 32 GB memory with read/write facility shall be provided. Preferred makes of USB pen Drive are HP, Sandisk, Kingston, Strontium. 4.03.03.04.08 Scanner, Copier cum Printer (A3 size) Resolution Colour Depth Scaling USB interface Memory Printing Speed Duplex printing 4.03.03.04.09 DVD Writer The DVD writer should be capable to read and write any DVDs as well as CDs. and shall be provided with all required hardware interface including error detection and correction. The DVD writer shall meet following minimum requirements: DVD write speed 16x CD write speed 52x Cache / Buffer size 2MB Buffer under protection technology : : : : : : 1200 x600 dpi (optical) (min) for Printer 600 x600 dpi (optical) (min) for Scanner 48 bit 10 to 2000% in 1% increments required. 1 GB 30 ppm (min.) for A4 size 20 ppm (min) for A3 size Automatic

Five nos of DVD (Re-writeable) shall be provided with each OWS/server provided anywhere in the plant by bidder with each DDCMIS, DCS & PLC system and any other system specified elsewhere in specification. 4.03.03.04.10 Digital B/W Copier cum Printer (A3 size) 01. 02. 03. 04. 05. 06. 07. 08. 09. 10. Type Printer Memory Speed Resolution No. of color (Basic) Duty cycle Power supply Humidity Size of paper : : : : : : : : : Laser, tabletop / latest 512 MB (min.) Monochrome 30 ppm - A4 20 ppm A3 600 x 600 DPI Monochrome Monochrome more than 75000 pages / month 240 V, 50 Hz, 1 phase UPS 0-50 C 95% non-condensing. Paper weight of 45 to 165 g/M2

Ambient temperature :

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DESEIN 11. 12. 13. Networking Capability : Coping Accessories : :

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USB / Ethernet Max Original Size A3, Continuous Coping ( 1-999) i) ii) iii) iv) Adapters Connector Cable Duplex Unit. Automatic Optional Paper feeder- 2 Nos

4.03.03.05

Lap Top The LapTop shall meet following minimum requirements: a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) Intel CentrinoTM Mobile Technology. Intel Core i7 Processor with 3.46 GHz, 4 MB L2 cache, 1066MHz FSB. 14 WXGA LED Screen with wide angle viewing. 500 GB 7200 rpm HDD with shock absorber. 4 GB 800 MHz DDR3 SDRAM (slot for 1no. additional RAM slot should be provided) 1 x windows XP Professional or latest & proven version of Windows OS with Multimedia Slim type DVD-RW/DVD ROM combo drive. Internal 10/100/1000Mbps Ethernet card IEEE 802.11B connectivity port IR port Optical mouse 2Nos. USB ports & Wireless INTERNET & blue tooth interface External mouse connectivity and optical mouse Minimum 8 hrs battery backup. Recovery software tools. Sound cards Internal speakers General MS Windows latest, MS-Office Professional, Microsoft Visual Studio, Adobe Acrobat, anti-virus McAfee or equivalent, etc. Application engineering & HMI software - to suit project specific requirement

q)

Preferred makes of Laptop are DELL, HPCOMPAQ, VAIO (Sony), Lenovo. 4.03.03.06 General Specification of the server: Enclosure : 6U Rack Mountable server / Tower type Sever Intel Xeon Quad (4) Core 64 bit Processor capable 3.6 GHz with 16MB L3 cache memory per processor, Dual independent 1333 MHz system bus (2 way SMF) or better. 64GB ECC DDR 3, 800 SDRAM

Processor

Memory

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DESEIN

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Video Resolution Drives

: : :

Integrated with 64MB SDRAM 1920 x 1080 HDD RAID 5 (1000 GB) Ultra 320 SCSI adaptors with internal storage capacity 3.6 TB DVD/CDROM 24X CD RW/DVD IDE combo USB 4 ports DAT 36 / 72 GB PS/2 keyboard Optical Mouse Windows 2008 server version standard / latest Enterprise Edition or latest & proven version of Windows Operating system VERITAS \ CA \ Tivoli \ any other Operating Temp range - 10C to 35C Humidity range - 8 to 80% (Non-Condensing) Vibration 0.25 G at 3 to 300 Hz for 15 Minutes. General MS Windows latest, MSOffice Professional, Adobe Acrobat, antivirus McAfee or equivalent, etc. Application engineering & HMI software - to suit project Specific requirement i. ii. iii. iv. v. vi. vii. viii. ix. x. xi xii. 1 Parallel port 1 Serial port 4 10/100/1000 MB/1GB network ports Two non-boards and two added External SCSI port Dual hot plug power supplies Dual Hot plug fans 2 PCI Express slots (1x4 lane and 1x8 lane) 2 PCI X slots (64bit/100MHz) 2 PCI slots (one 32bit/33MHz, 5V & one 64bit/66Mz) Redundant Server shall be provided, wherever required. LED based 24 sized Monitors.

Peripherals

Operating system

Backup & Disaster Recovery : Environmental :

Software

Miscellaneous

Preferred makes of OWS & Servers are DELL, HPCOMPAQ, Lenovo.

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DESEIN 4.03.03.07

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Industrial grade managed type Ethernet switches Industrial grade managed type Ethernet switches shall be provided with in built diagnostic features, 20% spare ports & inbuilt redundant 24 V DC power supply features and Integrated Security features (IPS, ACL, Firewall). Industrial grade managed type Ethernet switch shall be rack mounted and comply with the IEC 61850 (3) and IEEE 1613 requirements. Switches shall have 10 GB module support for future upgradeability

4.03.03.08

The Firewall shall meet following minimum requirements: Industrial grade Firewall appliance should facilitate multi-vendor, multi-application environment and should support third-party products on open alliance. It should support Active-Active configuration. i. The firewall should contain following features: (a) (b) (c) ii. iii. iv. Stateful inspection of packets. NAT functionality, including dynamic and static NAT translations Latest version of SNMP

v.

vi.

vii. viii. ix. x. xi. 4.03.03.09

The firewall must send log information to a separate log server via an encrypted connection. Firewall logging must not impact firewall performance. Remote network access to the firewall should only be possible through the administration interface. The firewall administration station must be capable of pushing firewall security policies and configurations to individual or multiple firewalls through a secure, encrypted connection to the firewall administration interfaces. Graphical User Interface (GUI) and a Command Line Interface (CLI) for making changes to the firewall rules set should be provided. (Access to the firewalls via the GUI or the CLI must be through an secure encrypted channel). Any changes or commands issued by an authenticated user should be logged to a database configured on any of the machines in the LAN. The administration station must allow for a hierarchical architecture for rules set administration and viewing of firewall configurations Management. The firewall must not support any unencrypted means of access to the firewall. It should Monitors ALL network traffic-traffic at Firewalls (Internet and external networks), in the DMZ and detect known threat through deep packet inspection. Detects unknown threats via anomaly scanning. Detect unknown threats via behavior pattern to protect from zero day attacks. Keeps up-to-date on new threats and vulnerabilities.

Software License: The Bidder shall provide software license for all software being used in DDCMIS/PLC/simulator/any other electronic/microprocessor based system. The software licenses shall be provided for the project (e.g. organisation or site license) and shall not be hardware/machine-specific. That is, if any hardware/machine is upgraded or changed, the same license shall hold good and it shall not be necessary for Owner to seek a new license/renew license due to upgradation/change of hardware/machine in

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DDCMIS/PLC/simulator/any other electronic/microprocessor based system at site. All licenses shall be valid for the continuous service life of the plant. In case the s/w license is dependent on no of points, then quantity to be considered is 30% above the finally implemented points. Software Upgrades As a customer/owner support, the Bidder shall periodically inform the designated officer of the Owner about the software upgrades/new releases that would be taking place after the each system is commissioned and handing over to owner, so that same can be procured & implemented by bidder at site. The future updated version of any type of software shall be supplied free of cost as and when such software is upgraded, on request by owner until 5 years from the date of commissioning of the unit. 4.03.03.10 Separate Laptops shall also be provided with all master software loaded and engineering of DDCMIS, DCS, simulator & any other control system individually. Similarly additional Laptops shall be provided with all master software loaded and engineering of PLC system individually. As explained above, One No. Lap top with necessary master software loaded and engineering of each control System shall be supplied individually. 4.03.03.11 SOFTWARE DOCUMENTATION AND SOFTWARE LISTINGS All technical manuals, reference manuals, users guide etc., in English required for modification/editing/addition/deletion of features in the software of the DDCMIS, DCS & PLC /any other microprocessor based control system/simulator etc shall be furnished. The Bidder shall furnish a comprehensive list of all system/application software documentation after system finalisation for Owners review and approval. The software listings shall be submitted by the Bidder for source code of application software and all special-to-project data files. 4.03.04 Programming, Diagnostic and Engineering Work Station There shall be Two (2) no. work station with 24 sized (Industrial type) LED monitor, associated hard disk 3, Two color laser jet printer and associated peripherals, as like 52X CD drive, DVD Drive, DVD/CD writer, 1 No. A3 sized Scanner copier cum laserjet printer, and A3 heavy duty industrial grade Coloured LJP with DDCMIS. For PLC based control system, same shall be provided as listed in Annexure A. The Engineering stations provided wth DDCMIS, DCS & PLC shall have all the function of programming/ configuration/modification/ reconfiguration and documentation. The features and facilities to be included are as under:a) b) c) Configuration or re-configuration of a system. Possibility to introduce or modify parameters. Documentation of system configuration.

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DESEIN d) e) Calculation program functions. Graphic editing programme.

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This work station shall be able to design, configure, monitor document or trouble shoot the process activities as desired. The work station shall be used for designing and redefining control strategy, configure system modules, modify the configuration, build and implement computing logics, alarms and display functions, save and retrieve system configuration schemes, monitor process variable, tune or adjust process parameters, display and trend information, produce system documents etc. The station shall be able to produce generic logic control drawings, configuration drawings etc. Control Engineering Software system include text, computer aided design, ladder diagrams, logging data base, graphic package etc. Combined with a printer, the engineering work station generates logic control drawings configuration drawings, module list, specification list, function blocks for cross reference list. Engineering station shall have capability of on-line and off line programme modification without effecting the performance of the system / process. While on-line, connected to process, the engineering work station shall provide real time tuning and trouble shooting. On off-line, the engineering work station allows control system configuration. The proposed work station can be used to implement or redefine process control strategy for control computing, logic, alarm, list display of process functions. In addition, the station shall have elaborate facility for diagnostic functions. The diagnostic station shall assist in detection of system faults and malfunctions and faults in field inputs along with identification of their locations. It provides automatic display and recording of such disturbance and thereby enhance the system availability. Sensors, binary switches, transmitters, input/output processing modules, controllers, peripherals and multi purpose bus communication system etc. are fully and comprehensively monitored. For this purpose all processors, modules etc. shall have self diagnostic features and disturbance shall be communicated to central diagnostic station. All failures, anomalies and missing functions shall be automatically detected, alarmed & displayed with clear text, showing the exact origin and the kind of failures. The failure shall also be signaled at concerned equipments. Detailed information of disturbance message shall be displayed in Engineer's OS and printout. Typically a Engineer's OS shall also have facility to windows for progressive detailing of diagnostic information wherein a permanently displayed window for plant diagnostics shows disturbance of the over-all system level. By activating a cursor/key a station diagnostic window is opened to show the details of station with all installed equipments. The diagnostic data for a item of equipment identified as disturbed can be called up for subsequent windows and finally the last window can be opened to obtain information such as type, location and possible causes of disturbance and suggestion for its rectification. Any alternative method of diagnostic display is also acceptable, which provides the detailed information during disturbance.

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DESEIN

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The system shall have extensive diagnostic software to identify all failures up to card level as well as field inputs. This shall include failure of power supplies, I/O cards, peripherals controllers etc. Failure of Analogue I/O cards, binary cards / modules shall also be displayed on the Engineering cum diagnostic station. The alarms regarding major subsystems shall be displayed on the alarm OS. Further details shall be available on the Engineer's/ Programmer's OS in form of a graphic and in other display formats. The field input faults/ failures shall be reported with nature and type of fault/failure clearly identified. 4.03.05 4.03.05.01 Communication Network Bus System Bus System and Data Highway Characteristics Bus System Basically two types of bi-directional bus systems shall be envisaged. Remote bus system to communicate between stations by use of co-axial cable or fiber optic cables. Industrial grade managed type Ethernet switches with in built diagnostic features, 20% spare ports & redundant 24 V DC power supply shall be provided with control system. Industrial grade managed type Ethernet switch shall be rack mounted and comply the IEC 61850 (3) and IEEE 1613 requirements. Local bus to communicate between the different modules/cards of the same station/system and extensions. The bus system shall have the following features. Redundancy in the system for high reliability of communication. The redundant buses work continuously. All bus couplers, bus interfaces etc. shall also be redundant. Insensibility against external disturbances, noises etc. Insensitivity of a fault in one bus system to other bus system. High data transmission rate to communicate with the system response requirement. Availability of information of all modules at each point of the system. The characteristics of the local bus (I/O Bus / Peripheral Bus) and control bus (Data highway) shall be as follows or better: I/O Bus / Peripheral Bus / Local Bus / Cubicle Bus Redundant Transmission rate Transfer procedure Control Data Protection No. of users : : : : : : yes 10 Mbps or better SDLC Master-Slave 16 bit CRC 126 or more

Control Bus (Data Highway)

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DESEIN Redundant Transmission rate Control Transfer procedure Data Protection Proprietory Bus Ethernet,TCP/IP No. of users Standard : : : : : : : : :

Vol-V : Instrumentation & Control Works

yes 100 Mbps or better Masterless Token Passing SDLC 16 bit CRC yes No 126 or more IEEE 802.4/802.3

Industrial Ethernet Bus for MIS (To make the System Open) Redundant Transmission rate Standard : : : Yes 1Gbps (min.) IEEE802.3

Above mentioned speed are the minimum requirements to be met by bidder, in case any other better fast speed are available at the time of supply, same shall be provided by bidder. 4.03.05.02 Highway Characteristics Communication between the operator station and the functional groups of control microprocessors shall be by means of redundant data highways. The system shall be fully operational with one highway out of service, with no degradation in performance. The data highways shall be effectively immune to the types of electrostatic and electromagnetic interference that can be expected in the power plants. To end this fiber optic highway is preferred. If the vendor does not supply a fiber optic highway, he must state, in detail, the precautions which must be observed in installing the highway in order to immune interferences and shall also state whether precaution must be observed to avoid ground loops due to differences in ground potential through out the plant. The protocol employed will be the Bidders standard provided that it meets the following requirements. 1. 2. No single failure will prevent the orderly and timely transmission of data. Check before execute will be employed for all changes in plant status transmitted over the data highway. As a minimum this will include set point changes, control drive bias changes, transfers between automatic and manual, changes in control drive positions, open and close instructions. In case of failure of any station on the highway or its physical removal, shall not interrupt communication of other stations. Both redundant highways shall operate at all times. There shall be no need to "fail over" and initialise to a standby cable. Diagnostics to check the status of both the highways will run continuously. Failure of a data highway or one of the stations of the highway shall be alarmed and reported on the appropriate video screen display.

3.

4.

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DESEIN 5. 6.

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The data highway transfer rates shall be a minimum of 100 mega baud. Hot repair capability of the highway shall be furnished.

The communication network shall have the possibility of adopting "open architecture" to enable the user to get the benefit of flexibility in choosing hardware & software. Network shall also be provided with external surge protection system and industrial firewall. 4.03.05.03 DDCMIS/DCS & PLC network shall have the Intrusion Detection System (IDS) and Intrusion Prevention System (IPS) and network management software as in built features as same specified at cl. No. 4.14.00. Interface with Other Control system 1. DDCMISs data exchange with other systems like SG side remote analogue inputs panels for boiler metal temperatures, flue gas temperatures etc, SG side remote analogue inputs panel for fans bearing temperature, Other monitoring parameters nearer to 0m boiler area, TG side remote analogue inputs panels for turbine side temperature points shall be via DDCMIS I/O bus or via redundant soft link (either MODBUS with TCP/IP or OPC or MODBUS with RS485) to have real time data. Data exchange between any control systems for SOE, annunciation, control, interlock & protection and information shall be through hardwired input/output in the form of galvanically isolated 4 - 20 mA signal and potential free contact input, output. Quantum of such requirements shall be finalized during detailed engineering. 2. MODBUS/OPC/IEC Interface Ports The Bidder shall provide MOD BUS/OPC/IEC Protocol as decided during detailed engineering to interface with other control systems like Incase Turbine Control System & BMS are different, then interfacing with Turbine Governing system, Turbine Protection System and Burner Management System or FSSS, DM/RO Plant, Coal Handling Plant, Hydrogen Plant, DG set control system, ESP, AHP, Plant Compressor control system, TSI, Vibration monitoring system, OCAMMS, AAQMS, Numerical protection Relays, EDMS, A/C System, Ventilation System, Fire Protection & Detection System, SWAS panel, Flame Monitoring System, Boiler Tube leak System, UPS, 24 V DC system, battery health monitoring system, Switchyard & Electrical system and any other system indicated in specification elsewhere etc. The Bidder shall include in his scope the relevant software & hardware for communication with the equipment/systems. Minimum of 25 nos. of gateways/ports of bidirectional nature (15 Nos. redundant + 10 Nos. non redundant) shall be provided by the bidder for interfacing in each DDCMIS & common system respectively with other control systems. All the interfacing shall be individual and not in daisy serial link. Above quantities is minimum & guaranteed by bidder, which shall be finalised as per requirements during detailed engineering.

4.03.06

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DESEIN

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Applications for redundancy & bidirectional shall be decided during Detailed Engineering. In addition to above, HW signal interfacing shall also be provided for any signal required for interlock, control & protection. The interfacing between two systems shall be effectively immune to the types of electrostatic and electromagnetic interference that can be expected in the power plants. To end this, If the control system is located in different building then the communication link cable for the OPC gateway shall be through fibre optic cable with necessary EI-Optical converter and de-converter units at both the ends and this special cable are in the scope of the bidder. 3. Redundant OPC Client Interface server shall be provided with DDCMIS with work station & A4 sized B/W LJP for connecting to MIS server, and Performance & Optimization server (In case separate system) and other OPC based Control system as listed in Annexure A and specification elsewhere etc. Common Redundant OPC server for OPC connections with both units DDCMIS from other common systems with Work station & 1 LJP A4 B/W. The OPC system interface shall comply with the following requirement as a minimum (a) (b) (c) (d) 6. OPC Data Acess (OPC DA) OPC Historical Data Access (OPC HAD) OPC Alarm and events (OPC A&E) Supervisory Control: - Transmission of operating commands (start/stop or On /off) from DDCMIS to PLC system of Utility/ BOP/ offsite package.

4.

5.

DDCMIS system shall have suitable interface arrangement so that pre-selected plant parameters and process mimics can be viewed at selected nodes on the plants local areas network (LAN) or wide area network (WAN) or from remote locations via dial up or internet connection. Bidder shall provide two nos. work stations with A4 laser printer (B/W) each along with necessary software & internet connection at Owners Corporate office for remote monitoring. However to protect against unauthorized access to network, sufficient security arrangement in the form of firewall or any other suitable hardware / software keys etc., shall be deployed. For automatic refresh features for viewing Web based Plant information extending option for additional 25 viewers shall be provided. Communication to any third party system shall be via industrial grade anti spam, anti virus Firewall only.

7. 4.03.07

High Resolution Sequence of Event Monitor Sequence of Event Monitoring System forming an integral part of the DDCMIS. In order to fulfill the requirement of the sequence of events recording functions, all field inputs are time tagged on acquisition (i.e. at the I/O card level only). A separate printer & 24 sized (Industrial type) LED monitors with work station shall be provided for SER for printing &

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DESEIN

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displaying the events in a chronological order. The sequence of event monitor shall have 1 ms resolution with 1024 points. SOE with all digital point status and alarm summary status must be separate. Time stamping at CPU level is not acceptable. 4.03.08 Power Supply System Each electronic cabinet shall be equipped with redundant power supply source with auto change over circuit with changeover time less than 10 ms in order to guarantee hold capacity of feeders for modules and I/O signals. 24 DC power supply system shall furnish power supply to the equipment located inside the cabinet, via. selector circuit mounted on DC output, made of block back-up diodes, with the aim of preventing energy exchange between power sources. A continuous monitoring apparatus watches the voltage and alarms power supply failures. DDCMIS & PLC system shall work on 24V DC supply and computers & peripherals shall work on single phase AC supply from UPS. Power Supplies for DDC MIS & PLC a) i) AC Supply Requirement: The system AC power source wherever required shall be nominal 240V, 50 Hz, single phase, ungrounded power supplied from parallel redundant un-interruptible power supply system (UPS) of the Bidder. This power supply system may be subject to a period of potential interruption of one cycle on 50 Hz basis which shall not lead to control system malfunction, process upsets or danger to main equipment being controlled by the system. ii) All equipment requiring power from the system power source (UPS) shall not impose any ground connections on it. If ground connections are required by equipment design the Bidder shall provide isolation transformers to prevent transmission of these grounds to the system power source. DC Power Supplies i. For 24 V DC power supply requirments, Bidder shall furnish the separate parallel redundant 24 V DC charger system for each unit for MFT control panels, Turbine protection panels, and Solenoid valves in BTG package. Parallel redundant 240 V AC to 24 V DC convertor with 50% sharing shall be provided for 24 V DC power supply in each cubicle separately as per requirements for DDCMIS, DCS, PLC package and microprocessor based system provided with BTG & BOP packages as per chapter 4 & Annexure A. AC to DC convertor shall be SMPS based and shall have wide range of AC/DC input voltage (85-264 V AC & 90-350 VDC). It shall have the necessary diagnostic functions like indications for DC OK, automatic overload monitoring etc. The MTBF for the power supplies shall not be less than 500,000 hours (in Accordance with (IEC 1709) with operating temp. from 25deg. C to 70 deg. C.

b)

ii.

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DESEIN iii. 4.03.09

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Each DCS/DDCMIS/PLC CPU rack & I/O rack shall be provided with redundant power supply modules.

System Grounding i) The automatic control system shall be designed for grounding to the station ground mat at a single connection point. Insulated ground bus from this point shall be furnished to the control logic cabinets and shall be connected to an insulated copper grounding strap in each cabinet. The control panel and local instrument cabinets shall be grounded to the station ground mat. Shields on electronic cables shall be grounded as required. When shielding terminations are required in cabinets furnished under this specification, suitable terminals and supports shall be furnished. The control logic cabinets shall be equipped to accept the single point system ground, which at this point will be isolated from the building ground. Any internal component grounds or commons shall be connected at the system ground, which shall be kept isolated from the building ground. Any required electrical ground or common from components not mounted in the control logic cabinets shall be brought to a terminal block connected within the component. This terminal block connection shall be located with the other terminals and shall be available from connection through the shield of the field wiring to the system ground specified within the logic cabinet. Isolation from building ground and case ground shall be inherent in the component design.

ii)

iii)

iv)

4.03.10

List of Peripherals for DDCMIS per unit 1. 2. 3. 4. 5. 6. 7. 8. Bulk Memory (Capacity) 1000 GByte each (min.) Laser Printer (Heavy duty Industrial Grade colored) (A3 size) Lime impact A3 sized Dot matrix printers Laser Jet Printer (A4 size) DVD/CD Writer (16x or better) Scanner, copier cum printer (A3 size) Laser Jet Printers (A4 size) Laser Jet Printers (A3 size) for all Operating & Engineering Work Stations 3 Nos. (For PADO, TG Control System, DDCMIS) 3 Nos. 6 No. (Colour) For all Engineering work Stations & servers. 1 No. (DDCMIS) Colored 8 nos. (B&W) 1 nos. (B&W)

Note The above peripherals does not include workstations/Server/printers/LVS for independent control systems and not part of main DDCMIS such as ETS DCS, SG DCS, (in case separate control systems),TSI, OCAMMS, Performance & Optimisation Package, ESP, HART Management System, CEMS, MIS, ERP, Furnace flame viewing system, Acoustic Pyrometers, C&I Lab, common system etc. Other then above listed workstations/Server/printers, these equipments shall be provided as specified in specification. 4.03.11 General I/O requirements and Spare capacity

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DESEIN (i)

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I/O requirements for process shall be hardwired as per approved and as commissioned PIDs, as per interrelated control sub system requirements and as per redundancy criteria described in cl. No. 2.05.05. Similarly I/O requirements for drives shall be hardwired as per Drive Control Philosophy, Annexure B and as per redundancy criteria described in cl. No. 4.02.08. Hardwired I/Os shall also be included by bidder for UPS, 24 V DC charger system, 220 V DC Charger system etc. in respective package I/O list. The DDCMIS, DCS & PLC shall be provided with the capacity and capability to handle either 20% additional modules for each type of modules or 20% over and above the specified number of modules connected to the system bus without any additional hardware or software requirements. These additions shall not result in decrease in system response time (i.e. control response time, display response time, SOE resolutions etc.). 20% spare relays of each type and rating, mounted and wired in relays cabinets. All contacts of relays shall be terminated in terminal blocks of relay cabinets, Additionally in each of the relay cabinets, 20% spare terminal blocks shall be 'provided so that additional relays can be mounted and wired. In case bidders system employs marshalling cabinet for all inputs, the spare terminals, fully wired up to marshalling cabinets are also to be provided. Above criteria shall also be applicable for PLC based control system. Separate DI, DO, AI & AO shall be considered by bidder for HW Annunciation windows, Mimic, ILPB, PBs, lamps, Indicators, recorders, A/M stations & other HW etc mounted on back up control desk/panel & UCP. Similarly control system related Hard wired Signals like Cooling Fan fail alarm, 240 V AC/24 V DC convertor Fail alarm, 24 V DC under voltage alarm, 24 V DC over voltage alarm, loss of UPS power supply feeder alarm, loss of 24 VDC power supply feeder alarm, loss of non UPS power supply feeder alarm & Flame & Smoke detector alarm etc shall also be included by bidder in the respective package I/O list. Wired-in "usable" space for 20% modules in each of the system cabinets for mounting electronic modules shall be provided by the bidder. Empty slots between individual modules/group of modules, kept for ease in maintenance or for heat dissipation requirement as per standard practice of Bidder shall not be considered as wired-in "usable" space for I/O modules. Field Terminal assemblies, PCB/ Connectors (if any in the offered system), corresponding to the I/O modules shall be provided for above-mentioned 20 % blank space. 20% spare fully wired I/O channels shall be provided in each I/O module. In addition to this 10% or minimum one no. extra assigned complete spare cards (which ever is more) fully wired mounted in the cabinets for each type of I/O modules shall also to be provided. Electrical I/Os required as per Energy Distribution Management System (EDMS), Energy Management System (EMS) and any other electrical system shall also be considered/included by bidder in respective package I/O list. The spare capacity as specified above shall be uniformly distributed throughout all controller systems. The system design shall ensure that above-mentioned

(ii)

iii.

iv.

v.

vi.

vii.

viii.

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additions shall not require any additional controller/processor/Peripheral drivers in the system delivered at site. Further, these additions shall not deteriorate the system response time/ duty cycle, etc. from those stipulated under this specification and shall meet other redundancy / functional requirement. Above criteria shall be applicable for DDCMIS, PLC & any other microprocessor based control system. ix. In case of redundant/standby/multi Pumps/Drives are provided for same service, all related Inputs & outputs of main pump/drive shall be in separate I/O cards and similarly all related Inputs & outputs of respective standby pump/drive shall be in separate I/O cards. Inputs/outputs of any same services pumps/drives shall not be mixed in one common I/O card.

4.03.12

Training The bidder shall provide training on the proper application and maintenance of each type control system like DDCMIS, DCS, PLC etc. The bidder shall be responsible for hiring specialist help from vendor for training of the plant management and O&M engineers. Such training shall be as specified under General Technical Requirements in Volume-II of Specification.

4.04.00

PLANT REGULATION REQUIREMENTS:

AND

CLOSED

LOOP

CONTROL

FUNCTIONAL

The closed loop control functions shall include coordinated master control, boiler control and balance of plant controls. They shall in general include the following:i) ii) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv) xvi) xvii) xviii) xix) xx) xxi) xxii) Co-ordinated Master Control Separator water level control Firing rate control & air flow control Mill Outlet Temperature Control and mill level control , mill air flow control Primary Air header pressure control Furnace draft control Feed water flow control & BFP control Condenser hotwell level and minimum condensate flow control Three element Deaerator level control Deaerator pressure control Boiler feed pump recirculation control Heater level controls (LPH 1, 2 & 3 and HPH 5, 6, 7 & 8) Mill Seal Air DP Control H.F.O., L.F.O. Pressure Control and secondary air temperature at SCAPH outlet Auxiliary steam to ejector pressure control SH steam temperature control RH steam temperature control Soot blowing pressure control and temperature control Local pneumatic pressure control for aux. steam to coal unloading. Local pneumatic temperature controls for fuel oil tank suction heating. Turbine integral controls Boiler Integral controls Other controls as per system requirements.

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DESEIN

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Above list of controls are indicative and same shall be provided as per plant safe control & operational requirements. Control system shall be complete and be designed to prevent abnormal swings due to loss of control power or instruments air pressure, failure of any control system components, Open/short circuits. On any of these failures, the final control drive shall either remain in the last position prior to failure or shall be moved to fully open/close position as required for safety of main plant. Bidder shall ensure necessary configuration and hardware to fully satisfy this safety objective. The power supply and associated hardware for the Auto manual stations shall be separate and independent of controller to provide an element of control of the final drive even in the absence of power supply to controller or controller availability. As for the water flow/steam flow measurements, necessary flow elements/transmitters are chosen in the process line and supplied such that their algebric summation shall be mass balanced for calculating the system efficiency. 4.04.01 The C&I system sub-supplier / manufacturer shall prepare the logic & loop diagrams based on the recommendations of the main equipment manufacturer (eg. Boiler, Turbine and other Major equipment manufacturer, as applicable) keeping in view latest engineering practices. The respective main equipment manufacturer shall vet these loop and logic diagrams including the set values. This shall be applicable to the system including the BMS, Turbine Protection, Turbine Stress Control System, Feed Water Flow Control, SH & RH temperature Control, Co-ordinated Master Control etc. Burner Management System (a) The BMS shall be provided with automatic self-monitoring facility. All modules to be used in this system shall be of fail safe design. Any single fault in primary sensor, I/O modules, multifunction controllers, etc. should not result in loss of safety function. All faults should be annunciated to the operator right at the time of its occurrence and also for alarm annunciation facia. The BMS shall meet all applicable relevant safety requirements including those stipulated in latest editions of VDE 0116, Section 8.7, VDE 0160, NFPA 8502/ 8503 etc. Bidder shall furnish compliance for already implemented MFT similar to that proposed for this project to VDE 0116, Section 8.7, VDE 0160 safety standards from recognized/ authorized third party certifying agencies. (b) The MFT functions shall be implemented in a fault tolerant 2 out of 3 triple redundant configuration. Each of the three independent channels shall have its own dedicated processors, multifunction controllers, communication controllers, I/O modules, interface etc. All safety related process inputs shall be fed to each of the 3 channels. All the primary sensors for unit/boiler protection shall be triple redundant. Additional signal for each trip input shall be made available for 1ms resolution SERS (Sequence of Event Recording System) at the input level itself, without any processing so as to enable analysis in sequence of event, the exact cause of trip. Limiter Technique from the transmitter signals shall not be employed for MFT of BMS. The process switches are to be employed in independent impulse lines from the process for 2 out of 3 logic trips

4.04.02

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System shall have an integrated sequence of event recording facility with a time resolution of 1 msec for all digital input signals as a part of DDCMIS. In case of separate DCS system for MFT, the recorded SOE signals shall be transferred to DDCMIS SOE system through Hardwired signals with a time resolution of 1 msec. (c) The acquisition and conditioning of binary and analog protection criteria signals for MFT shall be carried out in each of the three triple redundant channels. Each channel shall compute the 2 out of 3 voting logic and issue a trip command. The trip signals of the three channels shall be fed to a fail safe 2 out of 3 relay tripping unit for each drive. The protection criteria for tripping shall be executed by a program which shall be identical in each of the triple redundant channel. The check back contact signals of each relay of the 2 out of 3 relay tripping unit shall be fed back to each of the triple redundant channels and shall be continuously monitored for equivalence in each of them. In case one of the independent channels or any of the triple redundant sensors is faulty, the same shall be alarmed and the balance two channels/sensors shall operated in one out of the two modes. In addition to redundant software communication of 2 out of 3 MFT trip signals to all other processors (fuel and coal elevations), hard wired trip from each MFT processor to each drive of coal/fuel shall be provided to ensure the safety of boiler incase of failure of digital communication. (d) The BMS shall be designed to: Prevent any fuel firing unless a satisfactory purge sequence has first been completed. Prevent start-up of individual fuel firing equipment unless permissive interlocks have first been satisfied. Monitor and control proper equipment sequencing during its start-up and shutdown. Provide equipment status feedback and annunciation indication to the unit operator. Provide flame monitoring when fuel-firing equipment is in service and effect a burner trip or master fuel trip upon warranted firing conditions. Continually monitor boiler conditions and actuate a master fuel trip (MFT) during adverse operating conditions which could be hazardous to equipment and personnel. Reliably operates and minimize the number of false trips. Provide a master fuel trip relay independent of processors and I/O modules to provide a completely independent trip path. Provide all logic and safety interlocks in accordance with National Fire Protection Association (NFPA). Include a first out feature in all controllers to identify the cause of any burner trip or boiler trip. Provide a complete BMS diagnostic system to immediately identify to the operator any system module failure. Allow burners and igniters to be started, stopped and tripped on a burner basis.

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DESEIN -

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Allow the automatic start and stop of burners based on boiler load. The sequence of which burner will be started or stopped will be selected by the operator from a OWS/LVS display. Provide compulsory hardwiring of signals as required by other control systems for process interlocks & protections. For operation of the fuel oil corner nozzle valves, fuel oil trip valves etc., double coil solenoid valve ( latch coil & relatch coil) shall be adopted, As Single coil usage requires always power and loss of power leads to closure of above valves resulting the unit trip or loss of generation. Two separate DO cards are to be used to de_energies the solenoid coil by relatching for high reliability on safety of system. Loss of air pressure leads to closure of fuel oil trips valves resulting unit trip, hence to avoid air lock relays are preferred. To enhance the protection, emergency trip push buttons shall be wired directly to MFT contactors, which shall generate hardwired MFT irrespective of the controllers availability.

e)

f)

For operating burner tilt mechanism individual I to P converter shall be provided at each corners (Totally 4 Nos. of I to P converter) instead of laying the pneumatic control line covering all the corners with single I to P converter.

4.04.02.01

Typical minimum requirement of Boiler Interlock and Protection has been stated below: a. Boiler Starting Interlock After ID and FD fans have been started, following conditions should be fulfilled for light up of boiler: i. ii. iii. b. Purging of Boiler at a pre determined air flow for a pre-determined time. Resetting of MFT Permissive for starting Igniter

For purging the following conditions to be satisfied: i. ii. iii. iv. v. vi. vii. viii. Either or both I.D. Fans running Either or both F.D. Fans running MFR in tripped position Air registers in purge position Air flow between 25% to 30 % MCR No flame condition is true All fuel closed Boiler Tripping

4.04.02.02

Boiler shall trip automatically through Master Fuel Trip Relay (MFT) if any one of the following emergencies occurs (the list is indicative only). All initiating contact shall be configured in 2 out of 3 configurations a. Furnace Pressure Very High

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DESEIN b. c. d. e. f. g. h. i. j.

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k. 4.04.02.03

Furnace Pressure Very Low All ID Fans off All FD Fans off Combustion air flow low Total flame failure Loss of all fuel All air pre heaters off Boiler circulation water flow is not correct Loss of reheater protection i. Turbine trip, HP bypass valve closed and Boiler in service ii. Generator circuit breaker open, HP bypass valve closed and Boiler in service Control power failed

MFT operated will initiate the following as minimum: i. ii. iii. iv. Tripping of all oil burners Tripping of all pulverizers and coal feeders HT Supply to ESP Turbine trip

4.04.03

Steam Turbine Protection System (TPS) (a) The Turbine Protection system shall meet all applicable relevant safety requirements including those stipulated in latest editions of IEC 61508, IEC 61511, VDE 0116, Section 8.7, VDE 0160etc. The system design shall be such that safety function of the total system must not be jeopardized on occurrence of fault. Turbine Protection system initiates turbine trip in case of abnormal operating conditions for Turbine set and its auxiliary system. Any single fault in primary sensor, input/ output modules, controller modules etc. shall in no way jeopardize the safety of the turbine. All modules to be used in this system shall be of failsafe design. Bidder shall provide three independent trip/protection channels, each having its dedicated processing module & I/O cards. Two out of three voting logic will be implemented in each of the channels and the output of each channel to be fed to each of the three turbine trip relays. Turbine shall be tripped when either of the above three trip relays operates. The exact implementation shall be subject to Owner's approval during detailed engineering. All the input signals (trip signals etc. from the field devices) shall be fed in parallel to all the three/both the redundant channels of protection system as mentioned above via signal conditioning cards designed for such application. Further, the computation of field input voting logics i.e. 2 out of 3 etc. shall also be performed in the controllers of all the three/two channels of protection system which will then perform the computation of 2 out of 3 voting logic independently. Additional signal for each trip input shall be made available to 1ms resolution SERS at the input level itself, without any processing, so as to enable analysis in SOE list, the exact cause of trip.

(b)

(c)

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DESEIN (d)

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Bidder shall provide all the required primary sensors etc. required for protection system as per his standard and proven practices. All trip signal inputs required for the safety of the turbine shall be based on 2 out of 3 logics. The system shall include turbine lock-out relays, redundant turbine trip solenoids and necessary hardware required for testing. The tripping devices shall be designed to operate on DC supply. The trip coils shall be monitored continuously for healthiness and failure shall be alarmed. Following minimum Turbine Protection circuits shall be provided by bidder i. ii. iii. iv. v. vi. a. b. c. d. e. f. Bearing Temperature Protection (with 2 out of 3 logic) Bearing Casing Vibration protection (with 2 out of 3 logic) Condenser Pressure Protection (with 2 out of 3 logic) LP Exhaust Temperature Protection (with 2 out of 3 logic) Main Oil tank level Protection (with 2 out of 3 logic) Lube oil Pressure Protection (with 2 out of 3 logic) Axial Bearing Displacement Protection (with 2 out of 3 logic) HP Exhaust Temperature Protection (with 2 out of 3 logic) IP wet steam Protection(with 2 out of 3 logic) HP ratio pressure Protection(with 2 out of 3 logic) Over Speed Protection (with 2 out of 3 logic) Additional signal to Steam Turbine Protection System are as below:(1.) (2.) (3.) (4.) (5.) (6.) (7.) (8.) Control Fluid supply to Turbine valves Emergency Off Control Fluid supply to Turbine valves Protection Off ATRS Steam Turbine Shut Down Boiler Protection Tripped. Fire Protection push buttons operated Emergency Turbine trip push buttons operated Generator Protection operated. Reverse power relay operated.

(e)

(f)

4.04.04 4.04.04.01

Turbine Control System (TCS) Function The Turbine Control System shall consist of Turbine Governing System, Turbine Stress Control System and BFP turbine Electrohydraulic Governing System, HP/LP Bypass system & Automatic Turbine testing (ATT) system. In addition to the specific requirements indicated in subsequent clauses, the requirements of OLCS & CLCS as specified above shall also be applicable for TCS. Turbine control system (TCS) functions preferably shall be part of DDCMIS. However, bidder can also offer separate DCS Control System for DEH / EHGC and the turbine control system shall be interfaced through redundant bidirectional OPC connectivity with DDC MIS in addition to Hardwired signals. DEHC (Digital Electro Hydraulic Control) Turbine Governing System: The DEHC Turbine Governing system shall be provided with Triple modular redundancy i.e. the system shall consist of three independent channels right from sensors, transmitters, other field mounted devices, input modules, controller modules, output

4.04.04.02

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devices etc. of the Electro hydraulic converter. Further, each of these channels shall be fed from independent power supplies. DEHC Turbine Governing system shall meet the following functional requirements. The controls covered in this system shall basically consist of speed controller, load controller, valve-lift controller, inlet steam pressure controller and output frequency droop characteristic controller. The speed controller shall ensure controlled acceleration of the turbine generator and shall prevent over-speed without tripping of the unit under any operating condition or in the event of full load throw-off. The speed controller shall limit the over-speed of the turbine on loss of full load to a value less than 8% of rated speed. The governing system shall be equipped with speed/load changer to control the speed or power output of the steam turbine within the limits. The speed/load changer provided shall be capable of adjusting the speed of the turbo set to any value in the range of 94% to 106% of rated speed for manual/auto synchronisation of the generator with the bus. It shall be capable of varying the load on the machine from no load to full load. Two set of three speed sensors and one spare speed sensor shall be provided for speed measurement. In case of working speed sensor failure, the spare sensor shall be utilized immediately for vital signal of speed/ frequency. Main Steam Pressure Control: The pressure controller shall control the turbine load with respect to the pressure deviations and shall prevent, during a quick load increase, a pressure loop. Two operational modes- initial pressure control and limit pressure control shall be permitted. In initial pressure control mode, the pressure controller reduces a pressure difference between the reference pressure value and the actual pressure value to zero. In limit pressure control (load control) mode, the pressure controller influences the main steam control value to support steam generator pressure control, if a preset, main steam pressure deviation is exceeded. The other details, if any, shall be as per manufacturers practice. For remote control, suitable motor drive shall be provided. Indication of the speed/load changer position shall be provided on the OWS and console panel insert. The governing system shall be equipped with a load limiting device capable of being operated both locally as well as remotely from unit control room for the purpose of limiting the amount of opening of the governor controlled valves to set the load at a predetermined limit, while the turbine is in operation. A remote position indicator shall be provided on the console panel insert for indication of the setting of the load limit. Contacts shall also be provided on the load limiter for signaling load limited operation in Unit Control Room. Note - Since Honble CERC is insisting to implement the operation of 660 MW Turbine on RFGMO mode for enhancing the safety of electrical grid due to frequency disturbances. Necessary hardware and software for running the 660 MW Turbine on RFGMO mode shall be supplied in Turbine Control System based on the latest

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DESEIN guidelines given by project. 4.04.04.03 Honble

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CERC and available at the time of implementation of

Turbine Stress Control System (TSCS): Bidder shall provide a proven Turbine Stress Control System which will work in conjunction with turbine governing system and ATRS and achieve the following functional requirements. (a) Continuous on-line monitoring of thermal stress levels in all critical parts of the turbine such as main stop valves, control valves, HP casing, HP shaft and IP shaft etc. Continuous on line computation of stress margins available for the abovementioned critical components of the turbine during various regimes of operation i.e. run-up, synchronisation, loading, load maneuvering, normal operation, run backs, unloading, shutdown etc. Computation of the limits of speed and load changes allowable at any particular instant before synchronisation and after synchronisation respectively. The system shall be designed to inhibit further operation like speed/steam temperature raising or lowering wherever upper and lower temperature margins are not available (during periods prior to synchronisation) and load/steam temperature raising or lowering whenever upper/lower load/temperature margins are not available (after synchronisation) within allowable limits. Carry out a fatigue analysis for all affected components of the turbine and also to compute the percentage service life consumption of the turbine. Display the stress margins etc. on a separate dedicated colour Operating station/Printer as well as on OWS for operator guidance and storage of necessary data such as percentage service life consumption etc. Store long term data & carry out Residual Life Analysis.

(b)

(c)

(d)

(e)

(f)

The system shall be complete including measuring transducers for generator load and wall temperature, measured value processing modules, microprocessor based controllers for stress calculations and turbine life calculations etc., dedicated colour Operating station and Engineering station with 24 industrial type LED monitors & A4 B/W LJP etc. 4.04.04.04 HP/LP Bypass System: (a) LP Bypass Control System The LP Bypass control system shall consists of steam pressure control loop and steam temperature control loop. The LP Bypass control shall be implemented through a set of redundant controller modules, I/O modules etc. The system shall be supplied with triple redundant primary sensor and shall suitably interface with other TG control like HP Bypass, EHG etc. Further condenser exhaust hood spray valve shall be interlocked to open whenever LP Bypass comes into operation.

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(b)

HP Bypass control system The system shall consists of steam pressure control loop & steam temperature control loop. HP Bypass system shall be implemented through a set of redundant controller modules, I/O modules etc. The system shall be supplied with triple redundant primary sensor & suitably interface with other TG C&I controls like LP Bypass, EHG etc.

c.

Following parameters of the oil units shall be monitored in DDCMIS/DCS. i. ii. iii. iv. Oil level in tanks indication and alarm. Oil pump discharge pressure indication Oil temperature indication and alarm Group fault alarm

4.04.04.05

Automatic On Line Turbine Testing (ATT) System: The Bidder shall provide ATT system for on load testing of turbine protective equipment automatically in a sequential manner without disturbing normal operation and keeping all protective functions operative during the test. The ATT facility shall include but not be limited to the following. 1) 2) 3) 4) 5) 6) 7) 8) Opening and closing of Emergency stop and control valves reheat stop and interceptor valve. Over speed trips. Low vacuum trip. Thrust bearing trip. Electrical remote trip. Control Oil Trip Channel Vibration Trip Channel Axial Shift Trip Channel

ATT mentioned with item (2), (3), (4) & (5) above shall be possible to be carried out on 100% load. 4.04.04.06 Automatic Turbine Run-up System (ATRS): ATRS shall run the turbine automatically from zero speed to synchronising speed and then load the machine upto block loading and continuously check the operation upto 100% MCR without impairing the life of the turbine. The automatic turbine run up system shall be designed to provide for the following functions: (a) (b) Automatic start up/shut down sequence. Stress/temperature margin controlled acceleration as per the pre selected mode i.e. slow, normal and fast.

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DESEIN (c) (d) (e)

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Stress/temperature margin controlled loading/unloading Automatic synchronisation and loading upto 100% MCR. Unloading and shut down of the machine.

The functional group turbine shall include sequence control, interlock & protection, of all valves, drives, equipment/devices related to turbine drains, gland steam supply, turbine run up / shut down, auto synchronizer, AVR, etc. ATRS shall include the turbine sub group controls such as condensate evacuation system Turbine oil supply system, sub loop controls such as Turbine Startup, Shut down, turbine drain system. All modules to be used in this system shall be dual redundant and the field sensors shall be 2 out of 3 configurations. The sub-group control for condensate and evacuation system accomplishes its task which comprises of keeping at least on of the condensate pumps in operation, evacuating the non-condensate gases from the system, maintaining desired level of condenser pressure when turbine is in operation and breaking the vacuum and when required by the mechanical process. The sub group control for oil system performs its task comprising starting relevant oil pumps, ensuring turning of the turbine as and when demanded by the process and ensuring the lubricating oil at pre-defined temperature under circumstances. This subgroup controls include sub loop controls for auxiliary oil pumps, emergency oil pumps, jacking oil pumps, turning gear, oil temperature control, etc. The sub-group control turbine during Start-up executes the tasks which comprises of warming the turbine, speed increase, synchronisation and subsequent block loading. This sub-group also shuts down the turbine which comprises unloading, closure of steam supply to turbine, isolation from grid and bringing the turbine drains to desired position. This sub-group control executes in coordination with turbine governing system. The turbine drain system controls shall include the drain valves after HP control valves, HP casing drain valve, drain valves near interceptor valves, Drain valves in extraction lines, etc. The features indicated for OLCS is also applicable for ATRS. Two Set of Push buttons for Fire protection shall be provided near Main Oil tank to isolate the Oil system in the event of fire or any emergency. These fire push buttons shall be wired directly to the Turbine shut down logic. Emergency trip push buttons with front red cover/flap, one for each turbine shall be provided near the turbine. 4.04.04.07 Turbine Supervisory System The Turbine supervisory system shall be integrated as a part of DDCMISs TG-C&I system as a functional group.

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DESEIN (a)

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The turbine supervisory equipment shall be complete including sensors, transmitters, converters, limit value monitors, measuring and amplifier modules, power supplies etc. with the required accessories including twisted and shielded instrumentation cables, Ext./compensating cables, junction boxes etc. for TG & TD BFP. Operating Temp. for sensors and extension cables shall be 0-177 deg. C. Following measurements shall be provided as minimum. i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) (xiii) (xiv) (xv) (xvi) Shaft eccentricity detection. Absolute as well as relative shaft vibration measurement, of each bearing in both X & Y direction( both for Turbine and Generator bearing). Differential expansion of rotor and cylinder for HPT, IPT and LPT. Overall expansion of HPT and IPT. Absolute bearing vibration measurement of each bearing in both X & Y directions (both for turbine and generator bearings). Stator winding vibration measurement in radial and tangential directions. Axial shift of the rotor, (three sensors). Turbine speed (Two set of Three working speed sensors and one spare speed sensor). Emergency stop and Control valve position (with redundant position feedback sensors) Main steam and hot reheat steam inlet temperature and pressure. Turbine metal temperature. In case of vibration, shaft mounted reference detectors, Key Phasor and required supervisory instrument circuitry shall also be provided. HP, IP, LP casing temperatures at different zones. Bearing metal and oil temperature Bearing drain oil temperature. Any other measurements recommended by the Turbine manufacturer or required for the safe and reliable operation.

(b)

(c)

The system shall be provided with suitable hardware for necessary signal processing. The system should be capable of signal distribution and interfacing with other Control Systems & OCAMMS. The system should suitably HW interfaced with DDCMIS system supplied by Bidder. For all vibration measurements indicated above, a Microprocessor/computer based system (dedicated colour Operating work station with 24 industrial type LED monitor & A4 B/W LJP) for TSI shall also be provided to achieve the functions described under following items . This system shall also have the feature to accept 60 nos. minimum per unit buffered raw input from the vibration monitors of the auxiliary drives & motors and provide the following functionality for these machines as well. i) ii) On-line spectrum/harmonic analysis. Identification of the exact nature of failure resulting in increase in bearing vibration and direct message on the OS indicating the exact nature of fault e.g. mal-alignment, shaft crack, bearing looseness etc through use of intelligent software packages. Storage and comparative analysis of vibrations

(d)

iii)

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DESEIN iv) v)

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Generation / analysis of Bode Plot/ Orbit Plot and time waveform/ Nvquist plot/ shaft centre line plot/ cascade and water fall plot. All the vibration parameters as well as Turbine supervisory parameters shall also be fed to the Turbine Control System through hardwiring required for interlock /protection and through suitable redundant link so that all these parameters are suitably displayed on the TG control OSs. All required I/O cards and other processing modules etc. shall be provided for this purpose. Further, necessary redundant interface for hooking up these signals to DDCMIS System shall also be provided.

(e)

Test calibration jigs for site calibration of all sensors of TSS shall be provided. Telephone jacks shall be incorporated in all the TSS cubicles for communication during site calibration etc. The Turbine Supervisory Instrumentation monitoring system shall meet the requirement of API-670-1994 (Latest edition) and BS: 4675, Part-2. The TSI system shall be fed from UPS 240 V AC, 50 Hz supply. All the necessary power supply packs and other devices required to convert the above supply to the levels required by monitors / transducers / other electronics shall be redundant & shall be provided by the Bidder. Complete TSI shall be time synchronized from Master clock system. All the sensors shall be provided with max 5 % sensitivity tolerance. 2 relay modules shall be provided separate for vibration & position measurements. Each point shall be provided with min. 2 outputs one each for alarm & trip. Two (2) nos. buffer outputs shall also be provided with TSI / TSS system. Following feature shall be incorporated by Bidder for TSI/VMS as per API 670, 4th Edition, Cl. no. 5.4.1.5 & 5.4.1.6. i. Vibration Monitor front face status indication shall be available for indication of health conditions of pickup circuit, monitor circuit and power supply. Also set point indication with set point adjustment facility for setting alarm & trip levels shall be provided. The facility shall be available from front of mounting rack for functional checking of monitors with inhibition of alarm of alarm and trip contact outputs during test.

(f)

(g)

h) (i) j)

k) l).

ii.

m) 4.04.04.08

Redundant connectivity shall be provided between TSI/TSS rack & TSI/TSS OWS and between TSI/TSS OWS & DDCMIS/DCS respectively.

Boiler Feed Pumps Instrumentation Each BFP turbine shall be equipped with a redundant DDCMIS microprocessor based electro hydraulic governing (EHG) system, and Turbo supervisory Instruments (TSI). The

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speed demand signal is fed from the feedwater control loop to the speed controller of the EHG systems. This signal, in turn, is fed to the valve lift controller which modulates the opening of the valve admitting steam into the turbine. For the purpose of BFP turbine supervision, Turbo supervisory Instruments for measuring eccentricity, axial shift, differential axial expansion, overall expansion, bearing pedestal vibration, speed, Absolute & relative shaft vibration measurement of each bearing, turbine and stop valve metal temperature shall be provided as per above cl. No. 4.04.04.07. Controls of Electro-hydraulic governing system, Turbine Protection, TDBFP auxiliaries like drain valves, EOP, JOP etc. and Turbovisory Instruments (TSI) shall be implemented in DDCMIS. Control of MDBFP shall also be totally from DDCMIS. 4.04.04.08.1 a. The BFP Turbine speed shall be controlled by Electro-Hydraulic Governor, stable and satisfactory speed control over full speed range from 0% to 100%. The Electro-Hydaculic governing system hardware shall be microprocessor based with hot backup. When the Governing system is in auto mode, it will receive speed demand signal from FW control loop and in manual mode shall be fed either from OWS or through Auto/manual stations. The actual speed of the turbine should be measured by three independent speed sensors and three independent speed measurement channels. These three signals shall be fed to the speed controller. The speed controller output shall be fed to the valve lift controller. The output of valve lift controller shall be fed to the electro-hydraulic convertor which shall vary the position of the control valve admitting steam into the turbine. The Electro hydraulic controller shall be designed such that the transfer between different steam sources should be bumpless: A 220 V Split-series field, reversible, totally enclosed DC motor along with an electronic controller, shall be provided for remote speed changing operation. In addition to specification requirement and bidders recommended instruments following instruments shall be provided for remote monitoring of parameters in DDCMIS. i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) Pump recirculation flow & balance leak off pressure & flow. Lube oil tank level. Lube oil temperature & pressure at strainer outlet. DP across lube oil strainer and feed pump suction strainer Differential temperature across pump suction & discharge Seal water inlet & outlet pressure Cooling water pressure at inlet & outlet of lube oil cooler. Cooling water & lube oil flow at outlet of lube oil cooler. All bearing oil pressure & temperature. Lube oil temperature at inlet & outlet of lube oil cooler. Open & close indication of all manual isolating valves related to feed water, seal water, DM cooling water. Lube flow elements and transmitters for lube oil, cooling water, or any other auxiliary system as required. Bidder may consider turbine type flow

b.

c.

d.

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xiii)

xiv)

xv) xvi)

meter as cooling water and oil flow measurements. Flow nozzle for feed water flow measurement. Feed pump recirculation valves of suitable size and capacity and having proven background for BFP recirculation flow service for similar operating condition with pneumatic (0.2-1 kg/cm2 full stroke) actuators. Duplex RTDs/Thermocouples for bearing temperature, thrust bearing of main and booster pumps, journal bearing of main and booster pumps , suction & discharge of main & booster pumps and differential temperature, bearing drain oil, bearing temperature of driven & non-driven end of pumps and motor, seal water outlet at driven and non-driven end. Steam pressure, temperature, and flow to each BFP steam turbine. Provision of motorized isolation valves at inlet of each TDBFP from CRH, PRDS & HPH.

4.04.04.08.2 BOILER FEED PUMP (MD BFP) i. ii. iii. Boiler Feed pumps Motor driven shall be controlled & monitored from the DDCMIS operators station at central control room. Feed pump shall have start permissive and trip interlocks configured in DDCMIS. All critical instruments shall be configured in 2 of 3 voting philosophy. Conventional temperature switches have not been envisaged. Temperature switch function for pump and process safety shall be derived in DCS as software switch from RTD/Thermocouples. Boiler feed Pump system shall generally include but not be limited to the following: Smart type pneumatic actuators for hydraulic coupling system with all mounting accessories. Standard 4-20mA DC signal input for I/P converter (with stay-put feature) and position transmitter signal interface to be embedded in the smart positioned with HART protocol. Separate moisture separator unit for ensuring The quality of air entering the I/P convertor shall be supplied. Pump and motor bearing vibrations, axial play, speed both at local and remote and key phasor for complete machine monitoring & protection with required signal exchange with DDCMIS, Pump and motor bearing temperatures shall also be used for monitoring, interlocks and protective functions. All pressure & temperature stubs, thermo wells, root valves, impulse lines, gauges, manometers, thermometers, analyzers, sample retrieval system and other instruments for performance guarantee test measurements. Stubs and take off points for performance guarantee test measurement shall be separate and shall not be shared with online measuring instruments. Pressure and temperature gauges, RTDs, Transmitters and switches for lube oil, working oil, cooling water and heat exchangers and other important systems and auxiliaries related to basic system performance and safety and for the purpose of monitoring critical parameters in DDCMIS. In addition to local gauge board, necessary remote reading in DDCMIS are to be provided for following local gauges and instruments ensuring safety of BFP pump i) Oil supply pressure and drain oil temperature gauges of each bearing.

iv.

a)

b)

c)

d)

e)

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DESEIN ii)

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iii) iv) v) vi)

(vii) (viii) (ix) (f)

Differential pressure across feed water suction strainers, discharge pressure of main and booster pump, suction pressure of the booster pump, balance leak-off pressure. Lube oil and cooling water temperature at the inlet and outlet of coolers. Inlet and outlet temperature of seal water and its cooling water. Suction and discharge temperature of feed water pump. Pressure switches for main & booster pump suction and discharge, balance leak-off, lube oil-permissive & trip, aux oil pump cut-in and cutout. All bearing temperatures. Lube oil/working oil level. Working oil temperature.

Local start-stop facility for feed pump, auxiliary oil pumps, open & close operation facility of cooling water discharge valve, feed water discharge valve, re-circulating valve.

4.04.04.09

Steam Turbine Water Induction Prevention (TWIP) Logic The turbine water induction prevention logic detects the presence of potential water admission sources, disposes of accumulated water, and isolates the turbine from the water source as required. The turbine water induction prevention logic shall be designed in accordance with ASME Standard TDP-1. For detection of leakage of various drain valve, drain pipes and turbine, metal temp. thermocouple shall be provided to meet ASME TDP-1 standard. The TWIP logic serves four major functions: a) Prevents water accumulations by inhibiting the use of attemperating sprays at low loads. Prevents the carry-over of water from sources such as the boiler and deaerators. Disposes of accumulations of water in low point drains by forcing drain valves open during low load operations and prior to turbine startup. High level in heaters resulting water ingress inclusion of gland seal condenser.

b) c)

d)

The TWIP logic shall be implemented in the unit protection processors. The logic shall be implemented in two trains, with each train receiving process status information through separate input cards. In addition, process status information shall be transmitted to the unit protection processors via the data highway. The DDCMIS outputs which act to trip the steam turbine via its proprietary control system shall also be from separate cards and shall be configured in a two-out-of-two de-energize to trip scheme. Bidder to ensure that Motorized isolating valves shall be provided at extraction lines, condensate lines & extraction drain lines as per the protection criteria of ASME Standard TDP-1 Recommended Practices for the Prevention of Water Damage to Steam Turbines used for Electric Power Generation.

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DESEIN 4.04.05 4.04.05.01 SADC, AUX. PRDS, SBC System Secondary Air Damper Control System (a)

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SADC system shall be provided to achieve the following functions : 1. Control of fuel air flow. 2. Control of auxiliary air flow at the oil elevations. 3. Control of wind box/furnace differential pressure. 4. Limit NOX content in the flue gas by modulating overfire dampers, if provided. In case of tangentially fired boiler, SADC shall modulate fuel air dampers of each elevations based on the signal that is representative of the coal feed rate. Further, the auxiliary air dampers at the oil elevations shall be modulated on fuel oil pressure signal whereas the auxiliary air dampers at all other elevations shall be modulated to maintain the windbox to furnace differential pressure. In order to limit the NOX content in flue gas, SADC shall also include the control of overfire dampers (if provided). The secondary air damper controls and necessary interlocks to modulate or to open/close shall be incorporated as per the requirements of the boiler design. The secondary air damper control system shall also be provided even in case front or front and rear fired boiler is offered. All requirements indicated above shall be met by the Bidder. Further Bidder shall provide required secondary air flow devices for measurement of compartmental windbox air flow for each elevation etc. The I to P converters used for operating the SADC power cylinders shall retain the pneumatic signal (last value) even in failure of control signal and shall have self volume boosters. Necessary air lock devices and pressure switches for air pressure low alarming shall be provided.

(b)

(c)

(d)

(e)

4.04.05.02

Auxiliary pressure Reducing And Desuperheating Station (AUX PRDS) Control System (a) Auxiliary PRDS control system shall be provided to control the low capacity PRDS (with steam tapping off from CRH line) and the high capacity PRDS (with steam tapping off from MS line) and coordinate their operation under all regimes of unit/plant operation. Each of the aux. PRDS units (i.e. low capacity PRDS and high capacity PRDS) shall be provided with automatic control loops for steam pressure control, steam temperature control and spray water pressure control. However, facility for remote manual control shall also exist in case the automatic control fails. The signals for steam pressure and temperature control shall be taken from the downstreams of pressure reducing valve and desuperheating station respectively and their set points shall be adjustable. The spray water pressure control shall regulate the pressure upstreams to the temperature control valve and also based on feed forward signal from steam temperature control.

(b)

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DESEIN 4.04.05.03 Soot Blower Control System (SBCS)

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Soot Blower Control (SBC) system complete with provision for individual operation of any soot blower and facility to bypass any soot blower shall be provided with following : i. ii. iii. iv. v. vi. vii. viii. ix. x. Automatic starting of each soot blower in the system. Canceling the operation of any soot blower in the system when required. Indication of the soot blower-selected to operate. Capability to monitor all the essentials of the soot blowing system. Capability of prevent continued soot blower operation if the system is not functioning properly. The ability to operate two soot blowers located in opposite walls simultaneously. Manual over-riding of the automatic operations. To prevent automatic blowing when the parameters of soot blowing system are beyond permissible limits. Indications of soot blower which has malfunctioned. Control circuit for the retractable blowers shall be so designed as to prevent insertion of the blowers into the combustion chamber unless the blowing medium is available. Limit switches and Torque switches are to be connected to DDCMIS and command termination shall be done in DDCMIS only for each of the blowers. Soot Blower control system shall also provide controls for : a. b. c. xiii Pressure control of steam Warm up control of the complete piping system which shall include flow control, drain temperature control etc. Steam temperature control

xi.

xii.

Intelligent system deciding the required soot blower operation by considering the temperature measurements of boiler surfaces is to be provided. Extra thermal sensors if required for optimizing soot blower action shall be provided. Refer Cl. No. 4.11.10. Thermal imaging devices with IR technology ( 4 Nos. One (1) No.. located on each side of boiler) are to be provided.The data from this thermal imaging devices giving temperature profile of boiler walls shall also be utilized for effective optimistic operation of Soot blower. Soot Blower control system shall be smart type & redundant microprocessor based control system. Separate and independent hardware shall be provided for soot Blower controls mentioned above. Separate and independent hard ware of same DDCMIS family shall be provided for soot blower controls mentioned above in DDCMIS network.

xiv

xv.

Soot blowing system shall operate without loss of efficiency, loss of MW hr generation. Capacity or forced outage due to ash deposit, slagging or fouling. The soot blowing system shall maintain the furnace heat absorption optimally all the time resulting in efficient boiler performance keeping RH/SH temperature and

xvi.

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sprays under control. This is done by removal of deposit in the furnace by selective wall blowing. Objective: 1. 2. 3. 4. 5. 6. 7. 4.04.06 Improve boiler efficiency. Reduce steam/water consumption Reduce soot blowing induced boiler outages/tube erosion Reduce clinker formation Increase the range of burnable coals Reduce emission Provide optimization.

Coordinated Master control Co-ordinated master control system receives unit load demand signal from the Owner's automatic load dispatch centre or through the unit master control station and translates this signal into feed forward signals to the boiler and turbine control systems. The main objective is to enhance the response of the boiler and turbine control system in the over all operating condition while maintaining the outputs of the turbine, boiler and major plant auxiliaries, within their safe operating limits. The co-ordinated control system shall ensure that boiler generates that much steam as required by turbine and the turbine utilises as much steam as generated by the boiler. The Co-ordinated system shall provide for the operator the capability of manually producing a unit load demand signal from the work station. The unit load demand signal shall be limited by the following :Maximum unit load limit This limit sets the maximum load that the unit can support Minimum unit load limit This limit sets the minimum load that the unit can support Unit load rate of change limit This limit shall prevent the unit load demand signal from increasing at rate which may exceed the unit's ability to respond. Runback limits The runback limits shall provide automatic run back of the unit load demand at loss of critical auxiliary equipment and sudden load rejection. The limits and rate of runback shall be determined according to the individual capacity of each piece of auxiliary equipments. As a minimum, runback functions shall be provided for operation of unit with single boiler feed pump, single condensate extraction pumps, single induced draft fan, single forced draft fan, and primary air fan, single air heater and fuel feed system, single Circulating Water pumps,

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Auxiliary Bearing Cooling Water Pumps and other suitable criteria. Load demands to turbine shall follow this reduced capability. Directional block for increase in demand Further increase of load demand shall be prevented in the event: a) b) c) d) Fuel equipment at maximum Air equipment at maximum Feed water equipment at maximum When actual process values exceeds by preset amount in case of i) ii) iii) iv) v) vi) Throttle steam pressure Fuel flow Air flow Feed water flow P A flow and Operator adjusted maximum limit.

Directional block for decrease in demand Further decrease of load demand shall be prevented in the event : i) Fuel equipment at minimum ii) Feed water equipment at minimum When actual process value is higher than demand by predefined limits in case of i) ii) iii) iv) v) Throttle steam pressure Fuel flow/input Feed water flow P A flow and Operator set minimum limit

The unit load demands shall also be corrected by the deviations in the system frequency. This correction provides a change in unit load demand equivalent to the expected change in MW output due to any deviation in system frequency. The purpose is to prevent the unit load demand signal from canceling the effect of action of the turbine speed governor. System frequency/error signal shall be made available from other systems. Requisite interface shall be provided by vendor. Under steady state operating condition, system shall utilize the unit load demand signal to produce feed forward action on the boiler and turbine controls incorporating the following functions. i) MW Error Correction

It is expected that the feed forward action 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. However, the relationship may change due to changes in system

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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. The system shall also utilise performance calculations output and other optimising programme to reduce steady megawatt error to zero. Actual MW generated signal shall be provided from other systems to be used for control and rejecting the control configuration to either boiler or turbine follow mode upon failure of signal in use. Necessary interfacing requirements shall be provided by vendor. ii) Throttle Pressure Error Correction

Throttle pressure shall be controlled at a set point value to ensure that there is no mismatch between the outputs of the boiler and the turbine. The throttle pressure will be used to modify the demand signal to the boiler and turbine controls. Triple redundant transmitters shall be provided on each side of main steam line. Provision shall be made for selecting either of the two transmitters to be used for control and for automatically rejecting the system to manual upon failure of the transmitter in use. Under transient operating conditions, the demand signals shall also be modified to change the turbine output by utilizing the storage capacity of the boiler and to raise or lower the energy level in the boiler by over or under firing. The steady state corrections of megawatt and throttle pressure errors shall be suppressed under transient conditions to avoid any undesirable interaction between the boiler and turbine control system. For operator guidance, necessary indications (preferably digital indicators) shall be provided as part of the console. These shall include but not limited to. Gross MW generated, demand, frequency deviations, unit master demand, Boiler master signal, boiler demand, throttle pressure deviation, unit load set point etc. Status of directional block, run up, run down, emergency run back, auto transfer of mode of operation shall also be provided for operator guidance. Complete work station operation/indication for all above functions and any other related to safe and proper operation of the coordinated master control shall be provided. Interlock and Runback Logic Interlock and runback logic shall be provided to coordinate the unit response to auxiliary equipment upsets. The logic shall attempt to maintain a balance between steam production and steam consumption within the operable ranges of the equipment in service. Equipment to be considered in the development of interlock and runback logic shall include the following:i. ii. iii. iv. v. vi. Condensate pumps. Feed water pumps. Circulating water pumps. Pulverizers/ Mills Steam turbine (load rejections). Combustion air fans.

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DESEIN vii. viii. ix. ID Fan. FD Fan. PA Fan.

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Unit trip logic shall also be provided to allow the simultaneous tripping of the steam generator and steam turbine within a unit. The interlock and runback logic shall be implemented in the unit protection processors. 4.04.06.01 Operation in boiler following mode: In the boiler following mode, the megawatt load control shall be the responsibility of the turbine control system with boiler controls responsible for throttle pressure control. Boiler following mode shall automatically selected during startup when turbine control system is on manual. In the boiler following mode, all boiler inputs and turbine pressure limits are initiated through turbine limiting action. If runback occurs in this mode, the system shall automatically transfer to turbine following mode when turbine governing is on automatic. 4.04.06.02 Operation in turbine following mode: In the turbine following mode the megawatt control shall be 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., When turbine following mode is in automatic, all runbacks, run-ups limits and rate of change shall be automatic. 4.04.06.03 Operation in manual mode: In this mode the turbine governor shall be capable of being operated manually. 4.04.06.04 Master fuel control: Fuel flow control shall change feeder speeds in a defined manner based on the demand signal for fuel and air. The fuel demand signal shall be distributed among available coal feeders. Total fuel flow will be computed by adding coal flow of all mills and weighted value of oil flow. 4.04.06.05 Transfer of control: During operation of the turbo-set one of these above controllers shall be in the control. 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. The other details shall be governed by manufacturer. 4.04.06.06 Load shedding: In case of load shedding, the output signal of the load controller is immediately reduced below the output signal of the based controller. The speed controller assumes control and returns the turbine back to the set reference speed. The details shall be as per manufacturer.

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4.05.00 4.05.01

Design Criteria for BOP packages Control System Design Criteria for Programmable Logic Controller (PLC) System The PLC for BOP packages shall have following features: i. The PLC system shall fulfill and demands emanating from the domains Automation Monitoring Process control Management Engineering Uniform operator machine interface Reliable user guidance Comprehensive redundancy concept Modern object oriented software structure Shall be able to communicate with external system and intelligent field equipment Simple central project planning and configuration aids Integrated documentation system Integrated diagnosis and service Commissioning support The Control System shall have on-line simulation & testing facility. The system shall have the flexibility to easily reconfigure any controller at any time without requiring additional hardware or system wiring changes and without disabling other devices from their normal operation mode. Modifications shall not require switching off power to any part of the system. Fault Diagnostics Complete software for microprocessor based system including the communication software between systems, MIS system etc., shall be supplied and implemented. The software shall be also included for equipment performance test, life evaluation, equipment capability curve and alarm analysis, Management information system, etc. General I/O requirements of PLC based system shall be as per cl. No. 4.02.08.02, 4.03.11 and Annexure B. Bidder to note that all PLC system shall be from same manufacturer only. PLC system supplied & engineered through system house shall not be acceptable. It should be supplied & engineered directly from PLC manufacturer only. It is preferred to have each PLC system with hardwares from same family of Plant DDCMIS. Design & Functional Requirements as per the cl. No. 4.02.00 detailed for DDCMIS/DCS system shall be applicable for each PLC based control systems. PLC shall be provided with necessary redundant ports & complete hardwares for Auto time synchronization from Master clock time by bidder.

ii. iii. iv. v. vi. vii. viii. ix. x. xii.

xiii.

xiv xv

xvi. xvii. 4.05.02 4.05.02.1

Technical specification for PLC The latest proven PLC system shall be provided. PLC should be sourced from original manufacturers; PLC from system house shall not be acceptable. PLC system shall be complete with hot standby redundant CPU of word length of 32bits minimum, Input /

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Output modules, dual serial link interface module for connecting Input / Output Modules, dual Communication Processors, dual Memory modules and redundant Power supply units. Power supply unit shall be redundant for each CPU & I/O rack. PLC system will be interfaced with DDCMIS through OPC dual redundant communication interfacing (to be provided at PLC & DDCMIS end) for important process parameters. PLC shall confirm to IEC 61131. 4.05.02.2 Redundant CPUs in hot standby mode shall operate on fault tolerant mode with continuous self and cross monitoring facility. Redundant CPU/controllers shall be placed separately and shall not share the same motherboard. Failure of the active CPU shall not adversely affect the operation of the plant in any perceptible way. Failure of the active CPU will lead to transfer of the tasks being performed to the other healthy CPU within fastest possible transfer time (i.e. < 50 m sec.) without causing any output to drop during the Transfer period. In the Event of the both the CPU failure, the system shall revert to the Fail-safe mode. The CPUs shall not be loaded over 60% of the Individual capacity even under worst data loading conditions. It shall be possible to switch from the active to the back-up CPU and vice versa from Operating station as well from the CPU front panel. (The worst data condition of PLC means all modules in active mode, printer in operation, OLCS&CLCS logics active and process in running condition). Data bus loading shall not be more than 50%. This configuration shall be applicable for each type of PLC based control system. Engineered solutions for redundancy in CPU & I/O cards are not acceptable. The system shall be of modular construction and expandable by adding hardware modules and incorporating them in the address register. Bidder shall provide at least 20% overall with minimum two no. spare channels as hot-on-rail spares in each configured cards / Modules. In addition to this 10% or minimum one no. extra assigned complete spare cards mounted on rails in sub-racks for each type of I/O modules shall also to be provided. The spare channel and cards shall be fully wired up to termination cabinets. Spare Philosophy a s detailed i n c l . N o . 4 . 0 3 . 1 1 for D D C M I S / DCS system shall be applicable for each PLC based control systems. The memory unit of the CPU shall be field expandable. The memory capacity shall be sufficient (min. 8 MB per CPU) for system operation and shall have the capability for future expansion at least to the tune of 40%. The application program / sequence logic etc. shall be stored in non-volatile memory (EPROM). However all the dynamic memories shall be provided with battery back up with at least for 96 hours. Lithium or Ni-cd battery shall be used. The quantities of Hot standby redundant CPU/controllers for each PLC system shall be finalized during detailed engineering by owner depending upon CPU/controllers worst data loading conditions and CPU/controllers functional distribution. The max number of Input / Output points per card shall be 32 for digital and 16 for Analog / Thermocouple / RTD. No. of channels may also reduced to meet the I/O cards feature specified in NIT. Individual input channels shall have galvanic isolation. Output points shall also have optical / galvanic isolation. Merely fusing of individual or a group of channels is not acceptable. The I/O cards shall be rack mounted. Failure of Analogue I/O cards, binary cards / modules shall also be displayed on the Engineering cum diagnostic station.

4.05.02.3

4.05.02.4

4.05.02.5

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DESEIN 4.05.02.6

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The data communication system of the PLC including that of its redundant system bus with hot back up and other allied buses such us I/O bus, local bus etc., shall fulfill the following minimum features. The bidder shall furnish all the calculation details of CPU utilization and Bus loading. Bidder shall also furnish communication protocol used for the offered PLC. i. Communication links (I/O bus) between CPU and individual Input & Output (I/O) modules rack shall be dual redundant with 10 Mbps speed and 16 bit CRC data protection feature. In no case failure of a link shall affect the control of the plant. The communication system design shall ensure that any single point failure on the system bus / media shall not disrupt not more than single message and disrupted message shall be automatically retransmitted after the standby communication link takes over control. Failure of physical removal of any station / modules connected on the system bus shall not lead to any loss of communication. Diagnostics display both at operating workstation and module front end shall be provided for easy fault detection. Bus change over from active bus to stand by bus, during failure of active bus shall be performed automatically and bumpless. Such event shall be suitably logged or alarmed. The system communication between PLC controllers and the operators stations shall be conducted at high speed minimum 100 Mbps with Ethernet based open protocol with no collision feature to avoid data jamming / overloading of the system. The communication bus, serial link etc. shall have adequate protection against electrical noise and mechanical damage. System should have open bus structure and should allow further extension facility and connection with any third party system. PLC Network shall also be provided with external surge protection system and industrial firewall.

ii.

iii.

iv.

v.

vi.

vii.

h.

4.05.02.7

Man Machine Interface (MMI) shall be industrially ruggedised Operators station based on latest window based market available software along with its peripherals like LED monitor, printer, mouse. Engineering functions shall normally be carried out from dedicated workstation or operating station as per annexure-A control system for BOP. In case a dedicated engineering station is provided, EWS shall also be worked as operating station through password / Hardware lock. The monitor refresh time i.e. latency time should be < 2 second. The Operators station shall perform the following minimum requirements. a. b. Selection of Auto / Manual, Open / Close operation, sequence auto, start / stop operation etc. Dynamic Mimic display detecting the entire process for control monitoring purpose.

4.05.02.8

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DESEIN c. d. 4.05.02.9

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Alarm monitoring, report generation, logs, calculations and printing of logs, reports, trends etc. Online / historical trending, historical storage and retrieval of data.

Software provided shall be latest, modular, upgradable and industrially proven. It shall have capability for multi tasking, multi programming, multi user operation in real time environment and support for third party system. Bidder shall provide the following minimum requirements: 1. Required software for fulfilling the complete implementation of the control logics, operation displays, logs, data storage, retrieval, diagnostic and other functional requirements as indicated in this specification. Detail documentation on all programming softwares and this shall be part of the O & M manual. Supply of Licensed version of all software both in edit and run mode with multi user license. All the third party softwares should be latest and market available. Bidder shall provide and connect suitable communication hardware / software/ cables and other accessories required for connecting all numerical relays as per IEC 61850 of auxiliary in PLC / SCADA where PLC with OWS. Bidder shall provide firewall (hardware) in various layers to protect PLC from other network as per ISA SP 99. Communication to any third party system shall be via industrial grade anti spam, anti virus Firewall only. Bidder shall provide redundant software/hardware link with online in Motion Bridge computer and other belt weight system with CHP PLC system to calculate coal flow to indicate following status: i. ii. iii. iv. d. Daily and cumulative coal unloaded by track hopper. Daily and cumulative coal sent to stockpile. Daily and cumulative coal sent to boiler bunker. Amount of coal available in stockpile.

2. 3.

4.05.02.10

a.

b.

c.

Remote indication in centralized control room (DDCMIS) for total coal unloaded in 24 hours from ECHS shall be provided. A pneumatic control valve shall be provided at the interconnection line between service air header and instrument air header before air dryer unit. When instrument air header pressure falls below set value, the control valve will start opening and maintain the instrument header pressure at specified level in line with plant requirement. Again when instrument air header pressure goes above specified level in line with plant requirement the control valve will fully close automatically. Complete system shall be in bidder scope.

e.

4.05.02.11

PLC shall specifically meet the following requirements: (a) (b) PLC shall have extensive self-diagnostic capability. Self diagnostics shall include both module level diagnostics as well as channel level diagnostics PLC shall have h o t st an db y redundant processors/controllers. This shal l mean t h e fulfillment of the following requirements:

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DESEIN (i) (ii) (c) (d)

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Automatic synchronisation of primary processor/controller of PLC with secondary processor/controller Bumpless switchover to secondary processor/controller of PLC when the primary fails.

Automatic program and data equalisation in the event of any on-line program / edit executed in the primary processor/controller of PLC. Automatic Forcing Bit update in the secondary processor/ controller of PLC when any Forcing is applied in the primary processor/controller of PLC.

4.05.03 4.05.03.1

SYSTEM REQUIREMENT & SPECIFICATION The system shall have high MTBF and shall be hot maintainable. The system hardware shall be designed to be fault avoidant by selecting high grade components of proven quality and properly thermally de-rated design. The system shall have extensive fault monitoring, self surveillance & on-line self diagnostic capability so that failure up to module / card level is immediately detected. Each of the modules shall have its self diagnostic system. The operator station located at the area control room shall be used for fault data presentation and monitoring purpose. The system shall have capability to automatically check & correct gain & drift for ADCs on-line. All data exchanged in a bus shall be fully monitored & checked for validity. Loop Cycle time in PLC shall be equal to or less than. a. b. OLCS : 100 ms or less CLCS : 250ms or less

4.05.03.2

4.05.03.3 4.05.03.4

4.05.03.5

Following operations will be performed on I/Os, as required: 1. 2. 3. 4. 5. Square root extraction Pressure & Temperature compensation Responsibility check of all inputs (analog specially), validate and quality tagging like good, bad, suspects etc Channel wise engineering unit conversion. Contact bounce filtering with adjustable time constant.

4.05.03.6

All controllers shall be freely configurable with respect to requisite control algorithms. An extensive library of macros shall be included for the purpose adequate software capability shall be provided to implement closed loop control functions as follows: i) ii) iii) iv) P, PI, PD and PID control and their variations. Open loop (On- Off, sequence control) Cascade control Ratio control

4.05.03.7

For open Loop Controls, the system shall have, as a minimum, the following features:

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a) b)

c) d)

Logic functions like AND/OR/NOT gates, timers (on-delay, off-delay), shift registers, counters, latches, flip-flops, mono shots, tantalizers etc. The automatic sequence control to ensure sequential start up and shut down of auxiliaries / equipment. Sequence control shall be performed in 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, and it shall output an action on the process. System shall have the capability to by pass one step if desired by the operating personnel by forcing an input or output from the operators station. Such action however will be registered as an exception or alarm. Increase the reliability and availability of the plant as a whole, for example, by timely and correct switchover to standby drives etc. Basic interlock and protection logic related to safety of individual drive and plant equipment. All inputs required for protection system shall be on high priority basis. 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.

4.05.03.8

Interface of the PLC system with AC Solenoids & DC Solenoids shall be in the form of potential free contacts via interposing relay modules mounted in the interposing relay cabinet. 20% additional interposing relay modules shall be provided as installed spare. For AC solenoids and contactors directly driven from output cards, arc suppressors & MCB shall be provide across the coil. Displays The operators station shall be responsible for handling all commands as well as in generating desired displays, logs, reports, alarms and printouts. Security in different levels shall be provided to prevent unauthorized access to the system. Programming shall also be permissible by drawing Ladder or Boolean diagram or through any easily understandable language. 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 standby CPU programs shall equalize automatically, once the new program is permitted to RUN. Updating time and reaction time (systems response to an operators command) shall be provided for operator station as follows: a. Calling up a mimic b. Updating status signal in mimic : 1 sec or better : 1 sec or better

4.05.03.9 4.05.03.9.1

4.05.03.9.2

4.05.03.9.3

c. Updating variables in a mimic : 1 sec or better. d. Issuance of command to output : 2 sec. or better (without considering travel time and process lag) 4.05.03.9.4 Programmable Controller shall be responsible for real time process Parameter monitoring, storage and display. Basic requirements are (i) Operator Interface, (ii) Basic

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Calculation, (iii) Alarm Monitoring & Reporting, (iv) Display generation, (v) Logs, (vi) Trend Recording & (vii) Historical Storage & Retrieval. 4.05.03.9.5 The displays at the operator console shall be classified into overview Display, group display, point display, alarm display and trend display. a) Overview display This display is to enable the operator to set an overview of the entire plant section. Group display The group display page shall display several sub-sections & present status information. Point display Along with the specified parameter value, this page should indicate historical trend of the parameter. Trend display This display include real time/historical trend display facility including Dynamic Graphic Display & Bar Graph Display. Alarm Message Display It shall be possible to display process as well as system and diagnostic alarms for operators attention and action. Alarm shall appear immediately on the operator station as and when they occur on priority basis. In addition to alarms appearing on displays, the system shall also be able to display alarm summary and alarm history listing the date and time of occurrence, tag number, point description, type of alarm (absolute value or deviation), serial number of alarm in the sequence of occurrence etc. Alarm shall disappear from display only when they are acknowledged and cleared. Any abnormal condition in any sub-system or any other function devices shall be displayed as system alarm message on the operator console irrespective of display selected.

b)

c)

d)

e)

4.05.03.9.6

The system shall print the following logs as minimum as defined in the Following clauses. The printing of these logs shall be initiated automatically at prescribed time intervals, or initiated on demand by the occurrence of predefined events. Shift/Daily Log A Shift/daily log shall be provided to furnish data for routine analysis of plant performance. This log shall be automatically printed at specified time each day and on demand at any time.

4.05.04

Salient hardware / software features of the PLC system The salient hardware / software features of the PLC system for I/O handling shall be as follows. 1. 2. 3. 4. 5. 6. 7. 8. Input filters to attenuate noise. SWC of 500v DC common mode and 500V AC peak to peak Comm. Mode Noise rejection for analog inputs of 120dB at 50 HZ Normal mode noise rejection for analog inputs of 60 dB at 50 HZ LED indicators on each card to show status of input All the outputs shall be with individual fuse. K type thermocouple mV input where applicable. Pt-100 three wire resistance thermometer input where applicable.

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DESEIN 9. 4.05.04.1

Vol-V : Instrumentation & Control Works

24 V DC power supply to field mounted two wires transmitters.

The salient hardware / software features of the CPUs as follows: a) b) c) d) e) f) g) h) i) Watch dog timer Max. Scan time for I/Ps Maximum Scan Rate Memory Capacity Comm. Processor Power Supply Control Processor Battery back up for RAM Diagnostic feature : : : : : : : : : Periodical reset, Alarm and interruption, if not reset within stipulated time. 1 sec. max. for measurments 2.5 ms (per k word) 40% spare capacity after full utilization Expandable in multiples of 16K. Integral / Separate Dual redundant at each CPU rack 32 bit processor , RISC based. Ni-Cd / lithium type, at least for 96 hrs continuous Operations during power failure. Periodic, automatic, self-diagnostic. Result available at the Operators Station.

4.05.04.2

Input / Output Modules: Bidder to note that All I/O cards shall be sourced from their original manufacturers/Principal. Indigenous cards shall not be accepted. No. of channels per I/O card may reduced to meet the I/O cards features specified in NIT. The salient features of the Input / Output modules are as follows: a) All I/O Cards 1. 2. 3. b) Ambient temp. Surge withstand capability Power Supply : 0-50 degree C : IEC-255.4 : Dual redundant at each I/O rack

Digital General 1. 2. 3. 4. 5. No. of channels / card Interrogation voltage Status Indicator Isolation Electrical Isolation : 32 max : 24/48 VDC : LED Type./channel : Optical (channel to channel) : between system and field

c)

Digital Input Module 1. 2. Contact bounces filtering Self Diagnostic : Adjustable time constant of 15m.sec. : Wire break, Short Circuit

d)

Digital Output Module 1. Output protection : Short ckt protected and individual fuse

e)

Analog General

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1. 2. 3. 4. f)

No. of channels/card Isolation Status Indicator Fuse protection for failure

: : : :

Input /output 16 channel Galvanic/Optical (channel to channel) LED Type./channel Individual for each signal

Hi-Level Analog Input Module 1. 2. 3. 4. 5. Type of input A/D Converter Accuracy Diagnostic Power of transmitter : : : : : 4-20mA DC & 1-5VDC 14 bits + Sign (or better) 0.1% or better A to D / Channel fault, Short circuit, wire break 24 V DC 2W type

g)

Low Level Analog input Module 1. 2. 3. 4. 5. Type of output : PT-100; T/C (As required) C-J-C : On Module Accuracy : 0.1% or better A/D converter : 14 bits + sign (or better) Diagnostic : A to D / Channel fault, short circuit, wire break Analog Output Module 1. 2. 3. 4. Type of output : 4-20mA DC Accuracy : 0.1% or better Load : 600 OHM Diagnostic : Channel fault

h)

i)

The maximum number of channels with LEDs indications that can be provided in a single module shall be: (i) (ii) (iii) Digital input module/ Digital output module 4-20mA input/output modules - 16 Thermocouple / RTD input module - 16 - 32

j.

Input/Output modules shall have the following features: The functions performed on digital inputs shall include: (i) (ii) (iii) (iii) (iv) (v) (vi) (vii) (viii) Signal isolation (optical) Fuse protection & monitoring Short circuit protection Contact bounce protection Contact monitoring for trip and causes of trip inputs Contact interrogation at 24/48 V DC Configurable as status input, latched input or pulse input Direct or reverse sense Alarming of abnormal state

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Digital outputs shall have the following characteristics: i) ii) iii) iv) v) vi) Individually fused Individual contact suppression Configurable as momentary, latched or pulse- width modulated Outputs Individually definable default state Output read back verification Short circuit protection

l.

Analog inputs can be 4-20 mA DC, RTD, thermocouple. A/D converter shall have a minimum resolution of 14 bits. Functions performed on analog inputs shall include i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) Signal isolation (Galvanic/opto coupling) Fuse protection and fuse failure detection Transmitter power supply at 24 V DC Input filtering for noise level Cold junction compensation for thermocouples Transmitter monitoring for parity, wire break, live zero and end limit values Monitoring of A/D conversion Test for substituted value Conversion to engineering units Test for normal or extended range Detection of open circuit for thermocouples Alarm limit testing for high, low, high high and low low substituted values Rate of change - positive and negative dead band All analog signals fed to the control system shall be acquired and validated.

m.

Analog outputs shall be 4-20 mA DC with the following characteristics: i) ii) iii) iv) v) vi) Direct or reverse operation D/A per output and power regulator per output Loop check back of output Default options upon failure 5-segment output characterization Go to zero current

4.05.05

PLC Configuration: The PLC configuration will have a hierarchy of industrial grade open system architecture for management information system (MIS) and closed system architecture for plant operation and control system. The specification of Peripherals for Operator Station, Engg Station & printers for PLC/microprocessor based system shall be as same as specified at cl. no. 4.03.03.04.

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The complete MIS system including hardware, software, cables etc, as required shall be provided. This shall acquire dynamic pre configured points and mimics as required by Owner. The closed system architecture for plant operation and control system is secure and deterministic system for real time operations of the plant. Industrial grade managed type Ethernet switches shall be provided with features as same as specified at cl. no. 4.03.03.07. PLC Network shall also be provided with external surge protection system and firewall. "The Bus systems (like Profibus/ Modbus etc) or the Serial Port Systems (like RS-232/ RS-485 etc) shall be protected with suitable surge protection devices, confirming to the latest IEC-61643-21 guidelines. The surge handling capacity of device shall at least be 10 KA, 8/20 Sec between core-core and 20 KA, 8/20 Sec between core-ground. The device shall be pluggable & on-site testable". All the operator stations will be work stations grade as same as specified at cl. no. 4.03.03.04 and are required to reside on the main redundant bus running on IEEE 802.4 or IEEE 802.5 to facilitate determinism. 4.05.06 Redundancy Criteria (For details also refer chapter no. 2) i. Redundancy of components and systems shall be dictated by availability criteria to ensure the system availability target as well as safety considerations in critical applications. Dual/Triple redundancy for sensors and transmitters will be used for critical and semi critical applications i.e for interlocks/trip/protection conditions (as decided by Owner). The Wiring Scheme for inputs/outputs to/from PLC control system shall be as same specified at Vol. V, cl. No. 4.02.08.02.1. Sensor redundancy (1 out of 2 or 2 out of 3 ) requirement shall be indicated in the respective control system. The CPU / Controllers, communication modules, data highway, power supply modules, etc for all PLCs shall be 100% hot standby redundant. All drive input/output modules redundancy shall be as per Annexure B. All input/output of SCADA from/ to breaker & isolators shall be redundant. Redundant Cooling fans with fire retarded filter for panels/cabinets

ii.

iii. iv. v. vi. vii. viii. 4.05.07

CONTROL PANEL AND OPERATOR INTERFACE (For details also refer chapter no. 6) i. Operating console desks for OPERATING STATION's and KB shall be provided by bidder along with their printers in AC control room. OPERATING STATION/KBD shall generally be used for control and monitoring. Complete industrial grade Furniture for mounting Operating stations, Swivel Chairs, Printers, Keyboards, Computer etc. shall be furnished by bidder.

ii. iii.

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In the Back up Control desk and relay based system following operator interface devices shall be provided as per Annexure A. a) b) c) d) Control station (illuminated P.B. stations, Desk P.B., control switches etc). Hardwired Annunciator with push buttons. Coloured Mimic with LEDs for Drive status (ON, OFF, & trip) and level (Low & High) of tanks. Process recorders, indicators & Ammeters as decided during detailed engineering.

v.

Control panels housing the control cards/equipment marshalling cabinets shall be located in a control room; and shall have IP-32 min. degree of protection as per IS-13947 offering dust and vermin protections, 2 mm thick steel sheets (CRCA) shall be adopted for fabrication, consistent with weight of devices, control equipment to be mounted. UPS panels shall be with 2 mm thick steel sheet (CRCA). Cable gland plate thickness size shall be 3mm. Mimic shall be made of Acrylic sheet with thickness of minimum 6/7 mm. Panels shall be furnished complete with requisite accessories such as transformers, regulators, switch fuse units, MCB, MCCB and other power supply equipment to adopt the sources of power supply to requirements of panel mounted instruments and devices. All panels, cabinets and enclosures shall be furnished, fully, wired with necessary provisions for convenience outlets, internal lighting, grounding, ventilation, space heating, and vibration isolation pads, double compression cable glands, integral piping and other accessories as per IS: 5039- 1969. The sealing of panels/cabinets/enclosures bottom with bottom plate. Double compression cable glands and suitable sealing material to prevent entry of dust shall be in the Bidder's scope. Suitable arrangement for preventing fire propagation through cable entry points like fire seals etc. shall also be provided at cable entry points. Fire/Smoke Detector, Neoprene/silicon Gasket, Exhaust Fans with louvers & filters shall be provided in all consoles and panels. All the panels shall be equipped with Anti vibration pad of 15 mm size. PLC with OWS a. b. c. d. All winding/Bearing Thermocouple/ RTD shall be connected to PLC. All analog inputs i.e. Temperature, Pressure, flow, level, vibration etc. shall be connected to PLC. Only important parameters shall be display on desk / Panel. Bidder shall provide Ammeter on panel for all HT Motor current & > 15 KW LT Motor and very important LT drives as decided during detail engineering.

vi.

vii.

viii.

xi.

x. xi.

xii.

PLC without OWS or Relay based control System a. All winding/ bearing Temperature, T/C, RTD shall be connected to 16

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b. c.

point microprocessor based Temperature Scanner and mounted on panel for every HT motor / pump / auxiliaries. Illuminated PB shall be provided for Start / Stop, ON / OFF indication on the Desk / Panel. Panel mounted Indicator/ Recorder shall be provided for flow, Temperature, Pressure, Level, vibration etc. for all analog points.

xiii. 4.05.08

Bidder shall provide Ammeters on control panel/desk for all HT motor current and LT motor current > 15 KW & other important critical LT drives.

RELAY BASED LOCAL CONTROL PANEL/DESK Local control panel shall be of 2.5 mm steel construction, free standing type, totally enclosed dust and vermin proof with enclosure protection class of IP-55 as per IS: 13947 and colour shall be as per shade no. RAL 7032/7035. Panel shall be mounted on vibration dampers secured to steel frame on to the floor. Equipment and relays mounted on the panel shall be easily accessible. The panel shall be supplied completely wired upto terminal blocks for connecting external cables entering the panel from the bottom. Blank removable gland plate shall be provided with double compression type cable glands/conduits knockout along with the panel. Terminal block shall be rated 600 volts minimum and shall have strap cage clamp type screw less terminals suitable for connection with 2x2.5 sq mm copper conductors on each side. Terminal block shall be provided with white marking strips. Fuses shall not be mounted on terminal blocks. At least 20 percent spare unused terminals shall be provided on terminal block. Contactors, Relays, timers and other devices mounted on the panel shall have clearly visible identification marking. Separate contactors shall be provided for start & stop command. Common contactor for start & stop command are not acceptable. All fuses shall be HRC semiconductor type of AC supply. HRC link & fuse shall be of removable type having 45 kA rupturing capacity (min) for protection of various circuits. The panel shall be provided with a 50x6 mm tinned copper earthing strip running throughout the length of the panel at the bottom. Panel shall be provided with space heaters with isolating DPN MCB, and thermostats. LED based illuminating lamps, complete with door switches; and 1 no. 6 pin 5/15amps sockets with DPN MCB. Panel shall be provided with LED illuminating lamps with door switch and 6 point 5/15A, 240V AC socket with switch for maintenance purposes. Panel shall have removable lifting eye bolts for safe lifting from top during handling. Control power supply shall be provided from dual redundant feeders with auto change over scheme, surge protection devices and Power/Volt/AM meter. The panel shall be provided with push buttons, indicating lamps, annunciators, indicating instruments, interlock/ deinterlock switches etc., required for the complete system. General details as specified in chapter 6 shall also be referred for engineering and design of relay panel/desk. Coloured Mimic with 6mm thickness sheet for respective plant lay out shall be provided as specified in Annexure A, control system philosophy.

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20% spare relays of each type and rating shall be mounted and wired in relays control panel/Desk. All contacts of relays shall be terminated in terminal blocks of relay control panel/Desk, Additionally in the relay control panel/Desk, 20% spare terminal blocks shall be 'provided so that additional relays can be mounted and wired. The annunciation system shall consist of panel mounted audio-visual windows of 50x75 mm provided with plug-in-type solid-state logic 16 nos. high intensity LEDs in parallel. EACH relay based control panel shall be provided with 30 nos min. facia windows. Initiating contacts may be either NO or NC; a jumper or switch shall be provided in each card to make it suitable for either type of contact. A set of acknowledge, reset and test push buttons shall be provided on the panel. All printed circuit boards shall be of epoxy fibre glass construction. The sequence of annunciation shall be as follows: Condition Normal Alarm Acknowledge Return to Normal: a. b. Reset: a. b. 4.06.00 Alarm condition Return to normal No change OFF No change OFF Before acknowledge After acknowledge Flashing Steady ON OFF Visual OFF Flashing Steady Audible OFF ON OFF

Online Computer Aided Microprocessor based Machinery Maintenance Management System (OCAMMMS) One no. Microprocessor based standalone online vibration/machinery monitoring and analysis system for each unit shall be used for condition monitoring, analysis & diagnostic of STG and HT drives/motors with fans / pumps, air compressor, and any other HT drives envisaged for subject plant. OCAMMMS shall take care of predictive maintenance of machine/equipment. And shall be compatible and of same family of turbine vibration monitoring system/HT drives vibrations system. For OCAMMMS a dedicated colour Operating station with 24 industrial type LED monitor & A4 color LJP and separate OCAMMMS redundant server (Server shall be capable to store bulk data for 5 years duration with facility for retrieval of same) shall also be provided to achieve the functions described under following items. General Description The bidder shall furnish a programmable On-line Machinery Management System that automatically acquires processes and displays vibration and process data for critical

4.06.01

4.06.02

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machinery. The monitoring system shall interface via redundant bidirectional (Ethernet / RS 485 Modbus) links to one or more plant process computers or controllers/VMS as well as provide input to a Windows NT based Machinery Management System for trending vibration and process data for on-line machinery diagnostics. The system shall have the capability to be networked (single or multiple client/server) using Windows NT-compatible protocols on both LANs and WANs. It shall also have the capability to be accessed remotely through a telephone line and to interface via Modbus serial or Ethernet link to one or more plant process computers or controllers, as well as to interface with network devices to obtain process data. Any signal required for interlock/trip/protection from TSI/VMS shall be hard wired to DDCMIS. Redundant connectivity shall be provided between TSI/TSS/VMS rack & OCAMMMS OWS. 4.06.03 Online Machinery Protection & Monitoring System Latest monitoring system should be supplied. The monitoring/protection system should be compliant to API670 (Latest edition) and must meet the detailed specifications placed below. 4.06.04 High Speed Multi-channel Online Data Acquisition Communication Processors (CPs) Fully online and continuous Data Acquisition (Communication) Processors shall be supplied for all channels. For dynamic channels, sufficient sampler cards shall be supplied. The Data Acquisition CPs must comply or be better than detailed specifications placed below. 4.06.05 Data Acquisition, Data Management and Machinery/Process Data Display System The bidder shall supply latest machinery data management software, which runs on Windows NT software with data acquisition, configuration and display software. As a minimum, this system must be able to accept all the condition/process data necessary to fully monitor all the critical machinery in a Plant. The same system must also be capable of taking process data from the DDCMIS or directly from field (via the monitors). Such process data, once input into the Data Manager System, should also be available to Performance Analysis and Management Software provided by the same vendor. Together, using machinery condition and process data, this system should be able to provide data in formats fully suitable for analysis of machine problems related to both, the machinery defects as well as process upsets. 4.06.06 Process Data Interface For correlation of Mechanical behaviour with Process Data All the process parameters requisite for effective and complete machinery behaviour understanding will be imported Machinery Management Software either digitally from Machine Control System/DDCMIS (preferably) or through proportional value/recorder outputs from field devices through a suitable hardware for acquisition of such field based inputs. The DDCMIS in each plant shall have capability/provision to provide required process data through redundant bidirectional Modbus/OPC to main control room in which the Machinery Management Software will be installed. The interfacing will be designed and executed by the specialist Machinery Management System vendor. 4.06.07 Advanced Automated Machinery Diagnostics System

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Latest Automated Machinery Diagnostics software shall be supplied. 4.06.08 Transducer System & other inputs Proximity transducers compliant with API670 requirements shall be supplied for all fluid film/sleeve bearings. Refer clause No. 4.06.10 below for details of monitoring points/process inputs to be supplied for each machine type. 4.06.09 Scope of Work & Supply for Plant-Wide Machinery Protection Monitoring & Management System covering all Critical and Essential Plant Machinery a) The bidder shall ensure that the machinery OEMs abide by best practices and overall machinery management plant for the Plant-wide Machinery Management System. Such adherence to specifications shall include provision for each machine. The OEMs are however free to recommend and provide any additional measurements into the Machinery Management System, if the same will provide more capability to the machinery management system. No measurements should however, be deleted from the ones listed; without concurrence from the machinery monitoring system vendor and a written OK from the owner. Bidder will be required to hire the single point specialist services from the Machinery Monitoring System supplier for design, detail engineering, supply of all components needed, installation & commissioning.

b)

4.06.10

Detailed Specifications, Capabilities & Functionality of Online condition Monitoring/ Protection & Diagnostic System The monitoring system shall be fully in accordance with API670. The system should be fully software programmable, should measure multi-channels continuously (more than 40 channels per rack) in a fully online fashion and also provides monitoring, annunciation and protection for critical machinery. The monitoring system shall have the capability to interface via a dual-redundant Modbus and/or Ethernet link to one or more plant process computers or controllers so as to provide monitoring and recording facility for the measured data. The system must provide a separate input to an online dynamic and transient data acquisition system for trending and advanced machinery diagnostics. The system configuration software must operate on both Windows 95/98 and WindowsTM NT platform. Monitoring System: The Monitoring System shall consist of a rack chassis, fully dualredundant (low/hi ac or dc voltages) power supplies, interface module, monitoring modules, logic programmable relay modules, and configuration software. All hardware components of the system shall be capable of operation between 30C to 65C. Rack: The rack shall have the following mounting options: 19 EIA rack mount, panel mount, or bulkhead mount. Option for internal as well as external terminations configuration should be a standard feature. Power Supplies: Dual Redundant. Fully floating as standby mode operation of both power supplies on a rack. When used in a redundant fashion, failure of one power supply shall not affect monitoring functions. Power regulation within the system shall be at the monitor level

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rather than at the power supply so that in the event of regulator failure, only the failed monitor will be affected. It used in a redundant fashion, hot-removal (of a faulty power supply) and hot-insertion (of repaired/replacement) power supply should be possible, without any problem to the rack. Rack Interface Module: The interface module shall provide means for programming the components of the system using the Host Computer. The interface module shall provide a means of connecting the monitoring system to an online machinery management data acquisition system. This module shall store an alarm event list, up to 1000 entries, which shall be date and time stamped, in non-volatile memory. This module shall store a system event list, up to 500 entries, which also shall be date and time stamped, in non-volatile memory. This module shall allow remote access via an internal modem connection. Modem access shall allow configuration changes and access to system and alarm event lists. Such modem access shall make possible remote diagnostics to be carried out on the system. Monitoring Modules: Monitoring modules shall allow hot insertion or removal. All dynamic monitoring modules shall have each channels buffered transducer signal available on the front of the monitor through BNC connectors. This will enable the buffered output to be used for connecting portable test and diagnostic equipment. All vibration monitors shall have four channel input capability and be fully software configurable for the any of the following measurement parameters; radial vibration, thrust position, acceleration, velocity, differential expansion, or eccentricity. When configured for radial vibration measurement; the monitor should return direct, gap, 1X amplitude and phase, 2X amplitude and phase, not 1X, and Smax data. For radial vibration measurement, in addition to Shaft Relative, Shaft Absolute and Bearing Absolute measurements shall also be configurable within the same monitor. Gap alarms must be available on the monitor. Relay Modules: Relay modules shall have 4 relay outputs. Programming of relay logic shall be performed via the configuration software. Logic programming shall be performed with Boolean operators (AND and OR). It should be possible to programme these relays in double redundant and triple redundant mode. Configuration Software: The monitoring system shall be software configurable using any standard WindowsTM 95/98 and WindowsTM NT host computer. The configuration software shall provide a list that establishes the Modbus register locations of all data exportable from the monitoring system. The optional display software shall provide displays including Bargraph displays, trend information, machine train diagrams with real-time values of measurements tagged on the diagram, as well as access to the system events and alarm events lists. 4.06.11 Specifications/Functionality/Capabilities of the High Speed, Multi-Channel and fully Online Data Acquisition/Communication Processors Communication Processor: The communication processor should collect static as well as dynamic machinery data under steady state as well as start-up & shutdown conditions from the interface module within the machinery protection system. The communication interface unit shall store this information and then download to the Condition Monitoring System Computer running the Condition Monitoring Windows NT software. CP will provide TCP/IP Ethernet link for data transfer to condition monitoring software & support RS 485 communication link to DDCMIS. This unit shall also have the ability to communicate the

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monitor values directly to DDCMIS. The communications to the Condition Monitoring System shall utilize a high speed redundant Ethernet network communications link. This shall enable high speed data download to the Condition Monitoring host computer. Data collection methodology/requirements: The processor shall collect data either through delta-time samples or delta-RPM samples These sampling methods shall be determined when the processor collects steady state and or transient data from the monitors. (not in channel after channel scan mode), and fully online from all monitor channels connected to the Communication Interface Unit. Each delta-time and delta-RPM data set shall hold 320 vector and 32 waveform records, the system must automatically preserve the 40 most recent delta-time vector records and 4 most recent delta-time waveform records once delta-RPM sampling is enabled. Vector records must contain the direct and gap amplitudes, and phase information for each dynamic monitor. Waveform records contain 1024 samples each of synchronous and asynchronous waveform data. The processor shall be capable of collecting data for any set of increasing or decreasing rpm values. Specifically; Startup mode shall collect data when RPM has increased a user specified amount since the last sampling point. This mode shall provide for observation of machine startup characteristics. Shutdown mode shall collect data when RPM has increased a user specified amount since the last sampling point. This mode shall provide for observation of machine shutdown characteristics. Dual mode shall combine the capabilities of startup and shutdown modes by collecting data samples as RPM both increased and decreases. Specifications/Capabilities/Functionality of Machinery Management System Condition Monitoring/Machinery Management Software: The condition monitoring software shall run on the Windows NT platform. It shall be capable of collecting data both asynchronously and synchronously (with a Keyphasor signal) and store the data in the original time domain format. From the stored time domain sample, it shall be possible to reproduce a spectrum in addition to other time domain data formats at any time for review of data saved in historical trend files. To accommodate acquisition of non-protection system monitored parameters, there shall be provision for import of data from other systems, (e.g.) DDCMIS, using either OPC, a serial link using Modbus/DDE protocol. The software shall collect and store data from the monitor racks and communication processors or process information from the digital links connected to it. The software shall allow the display of all collected data from the one or more other data acquisition computers when networked together. The software shall have the capability to

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take process data directly from DDCMIS and correlate this data with vibration data. The software must integrate with thermodynamic performance management without including another software. The software shall display at least the following plots: Plot display formats: Must have the ability to select and store transit or steady state data, from stored Alarm Event Data, or from Baseline Data. This must include current data, in which case, the computer requests a sample of the current signal(s) from the associated monitor channel: Steady state plots: Transient data (during start-up/shutdown conditions) plots: Virtual probe rotation Bode plots for 1X & 2X vectors during startups & coast-downs Current values Polar plots for 1X & 2X vectors during start-ups & coast-downs Alarm event and system event Cascade / Full cascade plots listing Bargraph of current values Machine train diagrams Fast trend Trend Multivariable trend Acceptance region Time-base Orbit & timebase Shaft centerline Both spectrum and full spectrum X versus Y (any variables)plot Waterfall / Full waterfall Plot orbits & plus Spectrums Quick-view

Alarm data acquisition and storage: Condition Monitoring Software shall provide computerized machinery management with continuous, online data acquisition, archiving, and display capabilities. Static and dynamic data shall be collected, the data acquisition modes can be both automatically and manually initiated, based on alarm conditions, startups/shutdowns, and other events. Software alarms can be implemented in the software as a proactive maintenance tool, these alarms are usually set below the protection system hardware alarm set points (used for machine shutdowns). The information provided by typical software plot format in form of an Acceptance Region information provides a machinery user, a valuable indicator of an impending machine malfunction. 4.06.12 Specifications/Capabilities/Functionality of the Knowledge-based, Fully Automated Machinery Health Diagnostic and Advisory System The Advanced Automated Diagnostic System (AADS) shall utilize both vibration and process information from the Data Acquisition software plus programmed rules to provide

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clear analysis and recommendations for effective machinery management. It shall be an extensive and accurate knowledge base to enable quick determination of the condition of a machine by providing alarm notification or advisories of the machinery malfunction. It shall have the capability to send advisories through pagers and e-mails. Types of malfunctions: The AADS shall be able to specifically evaluate the available data while checking for the presence of the most frequently occurring machine malfunctions like High synchronous vibration Shaft bow Fluid induced instability (Whirl and Whip) Radial pre-load forces (including misalignment) Vector change Rotor rub Loose rotating parts Compressor surge Electric motor non-uniform air gap Gear mesh problems, pump cavitations Machine types: The AADs shall specifically support at least Industrial Steam turbines Generators Exciters Pumps Centrifugal and axial compressors Electric motors Gearboxes, and Plant air compressors.

Custom Rules for Machinery behavior/Performance Management and Advisories to the right people: The AADS system must be equipped with a Desktop based system that can be used to create rules related to acceptable (or non-acceptable) machinery behavior. Creation of such rules should have possibility to involving any of the parameters (process related or condition related) that have been mapped/measured into the Online data manager system. Moreover, the system must also allow changes being made to the definition of Machine Defect Severity as and when such changes are required to be made by the owners machinery experts. The system must have in-built capability to use a host of Advisory services like e-mail, paging messages, etc in a customization manner, so as to allow the plant personnel to distribute a varied set of Advisories to different people in the plant (or outside by e-mail) at different times under differing conditions of machine malfunction severity. 4.06.13 Critical Measurement Parameters for Online Monitoring, Protection and Management of Critical Machinery Transducer Systems a) Steam Turbine: The following parameters shall be measured on Steam Turbine directly by the machine monitoring, protection & management systems:-

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X&Y radial shaft vibration at each bearing Absolute bearing vibration using solid-state velocity transducers Dual thrust Eccentricity Differential expansion Case expansion Zero speed Over speed protection Valve position Keyphasor Bearing metal temperatures The following process parameters shall be integrated in to machine monitoring, protection & management systems through DDCMIS (or proportional value outputs from various field devices): 1. 2. 3. b) Turbine inlet pressure & temperature Turbine exhaust pressure & temperature Bearing oil temperatures

HT Motors, Fans, Pumps and any HT drive X&Y radial shaft vibration at each bearing/or Absolute bearing vibration using solidstate velocity transducers (based on the type of bearings) Keyphasor Bearing metal temperatures Speed measurements for drives with hydraulic coupling and VFD Drives. Reverse Rotation Measurments.

c)

Generators X&Y radial shaft vibration at each bearing Absolute bearing vibration using solid-state velocity transducers Temperature - Two bearing metal temperature sensors installed at each radial journal bearing (1 in use and 1 spare), plus winding temperature sensors, one active, one spare, to be installed per winding.

d)

Compressors X&Y radial shaft vibration at each bearing Dual thrust Overspeed protection Keyphasor Bearing metal temperatures

4.06.14

Training The bidder shall provide training on the proper application and maintenance of the system. The bidder shall be responsible for hiring specialist help from vendor for training of the

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plant management and engineers. Such training shall be as specified under General Technical Requirements in Volume-II of Specification. 4.07.00 Large Video Screen ( LVS) The Large Screen Graphics Wall will primarily be used for: (a) (b) (c) 4 nos. LVS (size 84/80 inch) per unit for plant operations and monitoring in CCR. 2 nos. LVS (size 84/80 inch) per unit interfaced with Turbine Control System (DEHGC) in CCR. 2 no. common (size 80/84 diagonal) with their own display controller connected to both unit DDCMIS on common redundant OPC network common to both 2 X 660 MW units and shall be located in CCR. In case bidder provide separate Turbine control system & Boiler control system from DDCMIS. Then configuration of LVS shall be 4 no. LVS with Display controller as part of DDCMIS package, 1 no. LVS with display controller as part of Turbine control system and 1 no. LVS with display controller as part of Boiler control (MFT) system. The LVS supplied with TG & SG control system shall be same to the other 4 nos. LVS supplied with DDCMIS because of Uniformity & Asthetics. LVS for BOP packages & Electrical Packages. The quantities of LVS for BOP/Offsite packages & electrical packages shall be same as specified in Vol. IV & Vol. V, Annexure A respectively. LVS provided anywhere in plant shall comply all the features & technical requirements as stipulated below.

(d).

(e)

(f)

4.07.01

Functions of LVS a) Display of important data, graphics coming from the PC, Workstation, Video, SCADA, images from CCTV, IP camera etc in real time. To provide real time clear luminous view to share information to operators and visitors. The 6 nos. Large Screen Graphics Wall of 84/80 diagonal size shall be installed in the Control Room. The overall screen size shall be approx. 10000 mm (W) x 1500 mm (H). Design of LVS shall be in such a manner, that it can be installed in linear or curvature setup. The overall resolution of the 6 nos. graphics wall shall be min. 8400 x 1050 pixels or better. The whole screen of the Large Screen Graphics Wall should behave as a single logical screen and the control of the same should be from a dedicated Graphical Control Unit (Controller) having a Keyboard & mouse. However it should be possible to control & monitor the each Graphics Wall from the WORK STATIONS on DDCMIS/DCS/PLC System LAN having Windows NT/2000 OS/or windows latest OS. DDCMIS/DCS/PLC software shall be compatible to display the two graphics simultaneously i.e one on OWS monitor and other on LVS.

b)

c)

d)

e)

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DESEIN f)

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The complete system shall be interfaced on 10/100/1000 MBPS redundant LAN. Also LVS shall be integrated with the RGB, Video signals available in the Control Room by providing extra input cards. Complete cards shall be provided by bidder. The Large Screen System should have the functionality to pre configure and save various display layouts to be accessed at any given point of time with a simple mouse click. The system should be possible to show the mirror images of operator workstations running on WINDOWS NT / 2000/XP/7 & sitting on data highway. The system should be able to show the applications running on UNIX complying to X-Windows protocol. The system should be configured such that any of the operators sitting on the same Ethernet should be able to work on the Large Screen sitting at his own position with his local keyboard & mouse using the industrial grade managed type Ethernet switch connection with individual LVS. The offered system should be able to work in 24/7 days environment and is of industrial nature. LVS system shall be provided with UPS redundant power supply.

g)

h)

i)

j)

k) 4.07.02

The Rear Projection Module shall have the following specifications: 1. 2. The Graphics Wall in CCR should be made up of 6 nos. of rear projection modules placed in a single row depending upon DDCMIS/DCS scope. The rear projection modules must be based on Single Chip DLP Rear Projection technology 3 separate colour (Red, Green & Blue) LED lit, without any colour wheel. The light source should be LEDs of 3 different primary colours; Red, Green & Blue and not a single lamp using the LED as a light source. Should have the scalability and upgradeability to be made up of multiple rear projection modules stacked up in rows and columns to achieve a display wall for better viewing ability in linear or curved configuration. The each Rear Projection Module shall be with a native resolution of 1400 X 1050 pixels or higher and should offer 16.7 million colors. It should be rear serviceable to avoid the operator distraction. The Visual Display Unit / Rear Projection Modules should have in-built redundancy in LEDs, LED driver (power supply) and ensures redundancy at the light source level without any mechanical movement. In case an LED shorts or LED driver (power supply) fails, system should ensure the image without any primary colour loss. The life of LED > 60,000 hrs. In case of LED failure or wear out, the LED's shall be field replaceable within reasonable time without affecting the plant operation without engine removal. The brightness uniformity should not be less than 95% ANSI 9. The contrast ratio shall be min. 1,750:1 or higher. The Aspect Ratio of each of projection module should be 4:3. The projector brightness should be 700 ANSI Lumens. The luminance on each rear projection module is 250 cd/m2 with DNP FXS screens having 1/5 gain angle of 46o horizontal and 45o vertical.

3. 4.

5.

6.

7. 8. a) b) c) d) e)

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DESEIN f) g)

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h)

i)

j) k)

l) m)

n)

The screen should have low inter screen gap to give seamless viewing experience. It should be <0.2 mm using the stitched screen technology. During the useful lifetime of the illumination unit, there shall be real-time automatic color and brightness alignment of different projectors to a common target, resulting in a uniform display wall. The auto calibration system shall measure the hue of the color and adjust by the use of an internal spectrometer to measure the complete spectrum of each primary color, in order to derive the chromaticities with the highest accuracy. The real-time automatic color (brightness of color as well as hue) and brightness alignment shall be done in the background, without any downtime or temporary loss of content and need of external calibration devices. The Projector should support 2x Duallink DVI in and 2x Dual link DVI out to have a flicker free image on the Large Screen Graphics Wall and support content redundancy. The pixel clock shall be > 162 MHz on both the inputs. Each cube shall have its own IP address to have the access from a standard web page from any WORK STATIONS over the Ethernet and shall communicate to a viewer via ethernet and it's IP address in star architecture to prevent communication loss. It shall have it's own webpage with status, health and configuration. Power consumption for each Visual Display Unit / Rear Projection Modules should be 170 watts in the economy mode. As the LED lifetime drops by 50% if the LED junction temperature increases with 10C, The LED cube should have suitable and proven cooling Technology in order to guarantee the advertised lifetime. To avoid visible color break up each LED shall be pulsed at 24x speed, meaning 24 pulses per frame

4.07.03

The Display Controller of LVS shall have the following specifications: 1. In an industrial 19 rack mounted casing based on processor/controller configuration same as specified for server with latest processor at the time of supply as per NIT, vol. V, cl. No. 4.03.03.06. Should have dual 10/100/1000 Mbps Ethernet port for redundant LAN connection and redundant hot swappable power supply. Supplied with a Keyboard and mouse with min. 20 m cable extension. Based on Windows 2000 OS XP Prof/NTOS/7. Min. 1 to 8 Graphics Output to be connected to 6-rear projection modules. The system should have future expansion possibilities. As no full hardwired backup has been envisaged, the plant LVS should ensure control/operation of the plant in case of total failure of all operator stations. Hence Complete DDCMIS/DCS HMI & Operation software shall also be loaded on display controller. There should be possibility of connecting the various type of analog and digital sources using single multistandard input card in freely scalable and moveable windows on the graphics wall. It should support : - SDTV analog PAL, NTSC, SECAM (Composite, S-Video, Component) - HDTV 720p, 1080i, 1080p (Component) - RGB analog up to 1920x1200 (up to 165 MHz pixel clock) - DVI up to 1920x1200 (up to 165 MHz pixel clock) Should have full range scaling capability from finger print size to full wall size.

2. 3. 4. 5. 6. 7.

8.

9.

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DESEIN 10.

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11. 12. 13. 14. 15. 4.07.04

The controller shall provide integrated hardware accelerated streaming video decoding using streaming video decoder cards. The Display controller shall be capable of supporting integrated streaming video input cards to achieve a seamless integration between potential future IP networks and the display wall. The streaming video card shall provide IP interfacing and hardware decoding of the streaming video input locally on the card, and shall not require any additional processing power from the CPU of the main base unit for this task. The integrated hardware decoding shall be independent from a large set of current encoder suppliers. The manufacturer shall publish his encoder interoperability list. The decoder card shall have a dual 10/100 Base-T failover Ethernet interface. The decoder card shall support IGMP multicasting. The decoder card shall support MPEG-2, MPEG-4, MJPEG & H.264 compression protocols. The decoder card shall allow implementing other compression protocols via a firmware upgrade. The decoder card shall decode up to four (4) channels simultaneously.

Display controller shall have suitable cards for interfacing with Video signals, to receive & project pictures from CCTV, Employer's live camera, VCP/VCD player/DVD player, SCADA, Input signals like DVI D, DVI-I, Video input (PAL, NTSC, SECAM), HD signals & DDCMIS. The system shall also accept IP stream from CCTV camera with suitable IP input cards. The Remote unit for switching between video signal & MMI signal, selecting the video signal channel (live camera no./location typically) shall be provided. LVS shall be designed for continuous viewing (24 hours in a day) under normal room ambient lighting without any need to darken the room. Suitable darkening of the projection screen for light absorption shall be provided for this purpose. The LVS and its accessories shall be designed in such a way that the brightness in the centre of the screen and the edges of the screen is uniform and there is no perceivable difference in the quality of the picture on the centre and on the edges of the screen. If any extra hardware has to be provided for achieving the above feature, same shall be provided by the bidder at no extra cost. The LVS Software should have the following specifications: g. h. The software should be able pre configure various display layouts and access them at any time with a simple mouse click or based on the timer. The software should enable the users to see the desktop of the graphics display wall remotely on the any work station connected with the Display Controller over the Ethernet and change the size and position of the various windows being shown. The software should enable various operators to access the display wall from the local keyboard and mouse of their workstation connected with the Display Controller on the Ethernet. The software should copy the screen content of the workstations connected on the Ethernet with the Display Controller to be shown on the Display wall in scalable and moveable windows in real time environment. The LVS software shall allow switching the video streams. The LVS software shall allow display of video/data windows inside other graphic windows and it should be possible to configure the video/data windows to always

4.07.05

4.07.06.

4.07.07

i.

j.

k. l.

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m. n.

remain on top while the operator works on the windows below. The LVS software should support open APIs to enable system integrators to integrate it with their Software. The LVS Diagnostic software shall perform health monitoring that allows timely detection of faults. i) Wall health ii) Cube health iii) Cube IP-address iv) LED hours worked v) Native Brightness target & actual brightness vi) Native Color (white, red, green, blue) & actual color vii) Selected inputs and presence of sources on either input LVS Diagnostic Software shall allow commands on wall level or cube level or a selection of cubes : i) ii) Switching the entire display wall on or off. Setting all projection modules to a common brightness target, which can be either static (fixed) or dynamic to always achieve maximum (or minimum) common brightness between projection modules. Switching to either Eco or Normal operation mode. Changing the active input (of the two present DVI inputs). Finetune color of each cube records all events can record full status at given time intervals can be exported to excel/html Show internal patterns

o.

iii) iv) v) p. i) ii) iii) iv) 4.07.08

The integrated view shall provide a database that

LVS Annunciation Following indicates the guidelines for implementing LVS annunciation functionalities. 1) The LVS annunciation will emulate salient features of the conventional hardware annunciations while presenting more flexibility. The annunciation points will be presented on topmost area of LVS screens. This annunciation area will be reserved for soft-annunciations only and no process graphics/system window/application windows will occupy this area. The annunciation area will be divided in multiple LVS alarm bands. There will be 3 nos. of LVS alarm bands in each LVS screens. The height of this band will be typically 42 pixels (the size of LVS screen has been considered as 1400x1050 pixels). Light horizontal lines will be provided to separate the bands on screen. In alarm window alarm text will be displayed when point is in alarm. There will be one alarm for each alarm window. The font type and size of message text shall be such that it is legible to operator. However typically this can be selected as Arial 10 Bold.

2)

3)

4)

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DESEIN 5)

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Annunciation points shall be distributed on various LVS screens based on process area. That is, each annunciation point will be assigned LVS no. and alarm band no. on which it will be displayed. First three (3) rows of LVS will be used for critical alarm display. First row will be kept reserved for fixed alarm and the other two rows will be used for other alarm display for which location of window may vary. Number of LVS alarm will be decided during detailed engineering stage.

6)

Each band will show up to 9-12 alarm windows depending upon visibility for operators. The alarm popping up sequence is from left to right. No fixed space will be reserved for any alarm on any of the band. Alarms as and when occur shall be displayed on the bands one after other (from left to right) on each LVS screen and will persist until returned to normal and reset by operator. In case alarm band described above is full (9-12 nos.) and new alarm(s) is/are reported, new alarm(s) will be presented sequentially on corresponding band by automatically scrolling older alarm(s) and left side of band, one by one until all latest alarms have been displayed. Suitable scroll bar facility on both sides of each band shall be provided, which will appear only when there are more alarms than the designated display capacity (9-12 nos.) of LVS band. The scroll button(s) will flash (slow or fast) as per the state of alarm(s) in their band. For each LVS annunciations, a menu based options to acknowledge, reset, configuration etc. is to be provided. Through configuration utility operator can view and edit alarm list, tag nos. etc. of all points in all LVS. The configuration utility shall be password protected for any modifications. However, with one acknowledge/reset action, all alarm point(s) of all band(s) of that LVS will be acknowledged/rest. The hooter sounds will be different for each of the unit of power plant, when there is common control room for multiple units. Shift/Unit in-charge can call alarm area of any LVS of that unit on his OWS.

7)

8)

9) 4.08.00

COMPUTERISED MAINTENANCE & INVENTORY MANAGEMENT SYSTEM CMIM system will consist of different application modules specific to the maintenance tasks normally encountered in Thermal Power Station; system will have capabilities to document maintenance related functions and will streamline the entire maintenance activities. Features like generation of work order, preventive maintenance schedule, inventory control, storing of equipment information, job planning, purchase modules and report generation will be available with the CMIMS system. CMIMS system shall be integral part of ERP system as specified in chapter 18.

4.09.00

PERFORMANCE CALCULATIONS, ANALYSIS, DIAGNOSTIC AND OPTIMIZATION PACKAGE PADO system have 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.

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The system shall combine the thermodynamic models of the plant components with cost and revenue related parameters like electricity sales, amortization, variable and fixed cost. 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 offline manual (what - if) analysis tool that will enable the user to conduct the model based analysis of the plant operation. 4.09.00.01 Integrated performance calculations package for a coal fired boiler and steam turbine generators will be furnished with a). 1 no of Operating Station for performance calculations & optimization for Unit in charge (shift supervisor) with 1 LJP A4 B/W. 1 no. of Operating Station for performance calculations & optimization at the Office of Executive Engineer/ Efficiency with 1 LJP A3 B/W. 1 no. of Operating Station for water chemistry parameters connected with performance calculations & optimization at the SWAS / Chemical Express lab room with 1 LJP A4 B/W. 1 no. Engineering Work Station for performance calculation & optimization with 1 LJP Heavy Duty Industrial grade A3 Color Performance Calculation & Optimization redundant server

b).

c).

d).

e)

In case standalone Performance calculation & Optimization package is provided, same shall be provided with above servers, OWS, EWS & printers and the complete configuration of PADO shall be connected through redundant bidirectional OPC connection with DDCMIS network (Refer Drg no. 114-01-0110). This package should use relevant ASME Performance Test Codes and ASME Steam Tables: Steam Generators and ASME PTC 6S for Simplified Procedures for Routine Performance Tests of Steam Turbines. In this package the data validation efficiencies, heat rates and controllable losses are computed. Data Validation There should be a data validation package to check for the correctness of the measurements. The package should use the following types of checks: a) b) c) Sensor/measurement range check Neutral Network/Statistical checks Model based checks for consistency of data

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In case of violations in range, reasonability or consistency are discovered, the package should be able to create reconciled data for substituting the actual plant measurement. All the instruments required for performance calculation & Optimisation including Thermo Couples required for measurement of metal temperature at 50% and 100% depth of thick wall equipments such as Super heater & Reheater, Boiler, Y-Piece, etc. shall be supplied by bidder. Features: i) The performance calculation system shall include calculations of flow, enthalpies, efficiencies, heat rates, deviations in heat rates, deviations in efficiencies, saturation temperatures etc. The performance calculation shall be done using sub/routine based calculations on latest ASME steam turbine tables applicable to the particular plant cycle. The prime objectives of plant performance calculation is to provide the plant operator, on a continuous basis, with controllable losses in a tabular form indicating deviations in heat rate and efficiencies to determine the optimised operating conditions of the boiler and turbine. It shall facilitate in brief the following functions:a. Monitor controllable losses and calculate fuel cost penalty when operating at less than optimum conditions. Improve unit heat rate by identifying and minimising controllable losses. Develop unit heat rate versus generation curves for economic load dispatching. Develop an online continuous unit-monitoring programmed to enable the operator to minimise controllable losses and to optimize the operation of SG and ST.

ii)

b. c.

d.

iii)

The performance calculations shall run on a nominal 10-minute period cycle except class 1 calculations, which shall be performed at a much faster rate. The calculated results shall be available for use in displays, performance logs and historical data collection.

(iv)

Initiate/cancel class II performance and optimization calculations Display/print class II performance and optimization results Display/change the periodicity of class II performance and optimization calculations Display / print class II performance and optimization calculation input list. Calculation functions to be performed by IS as a minimum (class I and Class II)

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Use of high level software language for performance calculations; and Basing steam property subroutines on 1967 ASME steam tables. The performance calculation shall be broadly sub divided into two classes: Class I : Equipment protection calculations and Class II : Plant equipment efficiency calculations. The class I calculations are generally for the purpose of detecting and alarming unit malfunctions. The following lists typical Class-I calculations that shall be required. i. ii. iii. iv. v. vi. vii. viii. 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 Feed water heater temperature deviation from standard Boiler separator water saturation temperature rate of change. Metal temperature difference for SH & RH etc.

The class - II performance calculations shall be performed to determine the performance of individual items of equipment and the overall unit. The periodicity of this calculation shall be selectable from 10 minutes to 60 minutes in increments of 10 minutes. The calculated results shall be available for use in displays, performance logs and historical data collection. Class-II calculations shall include but shall not be limited to the following : i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii. xiv. xv. Boiler efficiency (Input/Output & Heat loss) Turbine Generator 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 performance terminal difference Heat rate from Accumulated Heat input & MWH Plant load factor from accumulated MW hour. Feed water heater performance drain cooler approach Condenser performance Economizer performance Air heater performance Desecrator performance. Turbine Generator heat rate (Gross)

Apart from Class I & Class II calculations, this sub-system shall also perform the following functions. 1. Running hour computation of different rotating machineries. 2. Cumulative time the TG runs below or above alarm level of steam temperature.

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DESEIN 3. SH / RH tube creep life calculation.

Vol-V : Instrumentation & Control Works

4. Cumulative time of any bearing running above alarm level of vibration. 5. Number of Start & Stop of various drives 6. Number of hot, warm and cold starts of the turbine 7. Plant life calculation 8. Variable Alarm Limit Calculation. 9. Heat rate deviations. 10. Revenue calculation 11. Frequency excursion time beyond limit. 12. Plant availability and load factor calculation 13. Operating cost and cost of generation calculation 14. Merit order rating calculation 15. Monitor and analyse plant emissions such as SO 2, NOx, Co and CO 2 in real time. 16. Monitor and analyze ESP and stack conditions such as temperature, humidity, gas flow rate and opacity. v) Measured Performance values (Output, Cycle Efficiency and Compressor efficiency etc.) shall be corrected to the design conditions and compared with the base performance data of the plant. Performance Guarantee Test results shall be used as base data. The performance monitoring system shall be designed to apportion loss in performance (output and heat rate) to major causes like compressor fouling, air intake differential pressure, ambient conditions, frequency, change in fuel heating value, condenser vacuum, higher stack exit temperature etc. Display of On-Line Heat Balance and Performance calculation shall be available to Plant Operator in Central Control Room. Display of Trend Graphs of measured and calculated / corrected process of performance variables shall be available to plant operator in central control room. On line optimization system shall combine thermodynamic models of the plant components with economic parameters. On line optimization system shall suggest the optimal setting of controllable parameters e.g. Load set point, cooling tower fan operation, CW inlet temperature etc. in order to maximise plant efficiency and profitability under the prevailing operating conditions. Performing the detailed analysis of each component including calculation of key performance indicators such as efficiency, heat transfer coefficient, TTD, DCA and fouling factor.

vii)

viii)

ix) x)

xi)

xii)

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DESEIN xiii) 4.09.01 What if analysis at system and component level. Performance Calculations

Vol-V : Instrumentation & Control Works

The important performance calculations for thermal power plant has been broadly classified into following groups:Steam Generator Performance 1. 2. Effectiveness of SG Effectiveness of Low pressure economizer, Low pressure evaporator, High pressure economizer, High pressure evaporator, High pressure superheater, etc.

Steam Turbine Generator Heat Rate 1. 2. 3. Steam Turbine Isentropic Efficiency Net and Gross Heat Rate Steam Turbine Heat Rate deviation

Condenser Performance 1. 2. 3. Terminal Temperature Difference in Condenser Heat load in condenser Condenser efficiency

Gross and Net unit heat rate Operating hours. Plant load / availability factors, Unit availability calculations, Auxiliary power consumption calculation, Operating cost calculation, Actual operating hours logged by STG. Equivalent operating hours logged by STG. Deviation from expected values for each critical parameter. As for the water flow/steam flow measurements, necessary flow elements/transmitters are chosen in the process line and supplied such that their algebric summation shall be mass balanced for calculating the system efficiency. 4.09.02 OPTIMIZATION PACKAGE The Optimization Package will determine the optimum distribution of the load.

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The Optimization Package will also identify if soot blowing is required in the SGs. If SGs are equipped with additional firing, the Optimization Package should also compute if additional firing is required. The Optimization Package should monitor the actual operation of the entire process and should compare it continuously to its current optimum. Specifically, the operation of the steam turbine, the condenser and the feed water preheaters should be included in the Optimization Package evaluation. The impact of the relevant components on the economics of the current operation should be clearly identified. The operator should be informed whether any of the components is operating below its respective optimum value and how much this deviation costs in terms of additional fuel consumption. 4.09.03 BOILER PERFORMANCE OPTIMISATION SYSTEM A. The Bidder shall provide a WORK STATIONS based on line Boiler Performance Optimization System (BPOS) for each steam generator. The BPOS shall incorporate the complete thermal design model of the boiler capable of both forward and backward calculation of complete boiler thermal performance. The model shall be calibrated and made Site Specific based on series of field trials of thermal performance of the boiler during start-up and prior to Trial Operation. The input for the BPOS shall be based on accurate and continuous on line grid measurement of the following:a. b. c. d. e. f. Flue gas temperature at Economiser inlet and outlet using Acoustic pyrometer/thermocouples. Flue gas oxygen. Other fluid temperature(s) entering and exiting various heat transfer banks. Coal characteristics. Unburnt carbon in Fly ash. Coal mass flow rate/Air fuel ratio in each PF pipe for each coal pulversior.

The BPOS shall be capable for continuous on-line calculation of the thermal performance of the boiler for the operating conditions indicating performance prediction zonal absorption, metal temperature and shall have necessarily the following features:i. ii. iii. iv. Fuel switching capability. WHAT IF capability. Selective soot blowing of Furnace / Super heater based on trends of zonal absorption. Expert system diagnostics for quick identification of the Root Cause of deviations from the predicted parameters. The computer modeling and arriving at factors to make it Site Specific shall be to the approval of the Owner. The BPOS shall be furnished complete with the appropriate computer hardware to the approval of the Owner. Boiler Tube life fraction and stress calculation feature. Boiler startup optimization facility.

v. vi. B.

Soot Blowing Optimization Module

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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. The data from instruments mentioned in cl. No. 4.11.10, 4.11,11 & 4.11.12 & 4.11.12.1 shall be utilized in the boiler performance optimization system. Bidder shall provide Boiler start up optimization facility also. 4.09.04 Boiler Stress analyzer and service life monitoring. This module shall determine the maximum allowable load change gradient in MW/min. and monitor thermal stresses and assesses residual life in thick walled components like separator, final superheater outlet header and reheater outlet header. The software shall compute the thermal stress value and estimate the expended life due to low cycle fatigue and creep, SH outlet header temperature, Saturated steam temperature, Riser steam temperature, SH spray water flow, Combustion air flow and Main steam flow. During the boiler startup and shutdown, 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. 4.09.05 Emission Analysis and Monitoring and Interactive Chemistry control i. Monitor, track and analyse plant emissions such as SO2, Nox, CO and CO2 in real time. Monitor and analyse ESP and stack conditions such as temperature, humidity, gas flow rate and opacity. Facilitate obtaining lowest emission for CO and unburnt Carbon while maintaining combustion efficiency. Facility to set alarms to highlight conditions that violate predefined limits. Optimal Damper position to minimize the Nox level at the stack.

ii.

iii.

iv. v. 4.09.06

SYSTEM AND PERFORMANCE Optimization & DIAGNOSIS i. Evaluate system and component performance degradation to detect worn plant equipment. Expert system diagnostics using neutral and Bayesian belief networks and historical data for quick identification of problem pinpointing down to within the component. Identify degradation of measuring instruments.

ii.

iii.

The module shall have the following objectives: a. Heat rate improvement

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Reduced auxiliary power consumption. Reduction CO and NOx levels. Cleaner furnace walls and convective pass. Avoid possible trip. Maintain process parameters within the safe limit thus enhancing the life of equipments.

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 subsystems optimization in the framework of Rankine cycle optimization. The package shall cover optimization of Turbine, Condensor, 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. 4.09.07 Regenerative cycle performance optimization. This module shall consist of the following. a. The deviation of performance of the turbine cycle. b. Actual efficiency of individual stages of turbine. c. Evaluation of LPH and HPH performance by comparing current values to the reference values. d. Heater level evaluation. 4.09.08 Water Chemistry Management 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, oxyginated water treatment and carry out further investigation 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 two diagnose variations in controlled parameters, in order to 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. 4.09.09 Merit order Rating System Merit Order Rating System facilitates scheduling of optimal load of the individual units of a poer plant with minimum total generation cost.

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The salient features of this module shall be as follows: a. b. c. 4.09.10 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.

Miscellaneous Calculations a. b. c. d. e. f. g. h. i. j. k. l. m. Number of start & stops of various drives. Running hour computation of various rotating machines. Cumulative time the TG runs bellow/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 turbineperformed. Plant life calculation. Revenue calculation. Frequency excursion time beyond limit. 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 resettings.

4.09.11

In order to achieve the maximum results from the PADO, any special type/Conventional instruments in addition to the signals designed by DDCMIS on process information shall be identified and provided by bidder as per PADOs supplier recommendation. PADO System Implementation System shall be delivered fully implemented and shall be user tested at site. It is the bidders responsibility to demonstrate the proper functioning of the system to Owner Personnel.

4.09.12

4.10.00

VIBRATION MONITORING SYSTEM FOR HT DRIVES Bidder shall furnish microprocessor based vibration monitoring system for all HT motors and its associated pumps, fans, drives etc. for X, Y & Key Phasor directions, in BTG & BOP packages including CW, ACW system; Air Compressor, Coal Crusher, Coal Conveyor etc which shall consist of the following items as a minimum: a. b. c. d. e. f. Vibration transducers (including pre-amplifiers / drives). Vibration monitors Redundant Power supplies 19 Vibration Monitor Racks Cables, conduits & junction boxes Mounting Pads for transducers

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The system shall interface with the main plant vibration analysis system via suitable redundant communication network link like modbus / Ethernet to provide analysis & recording facility for the acquired data. Two (2) nos. Buffer outputs shall also be provided by Bidder required for Vibration analysis & diagnostic system. VMS shall be connected to DDCMIS thru suitable redundant communication network link like modbus / Ethernet. Any signal required for interlock/trip/protection from TSI/VMS shall be hard wired to DDCMIS.

h.

Bidder to note that the above items are only indicative and the vibration monitoring system shall be supplied on a complete system basis to meet the requirement of the subsequent clauses and relevant standards. All other accessories as required to make the system complete shall be furnished by the Bidder even if it is not specifically indicated in this specification. The vibration monitoring system shall meet the requirement of API-670-1994 (Latest edition) and BS: 4675, Part-2. 4.10.01 Vibration Transducers a) Vibration transducers shall be velocity coil type, piezoelectric accelerometer type or proximity type. The incremental scale factor of sensor (proximity probes) shall not be more than + 5% of 7.87 mV/micrometer within the testing range temperature. The sensitivity of sensor (accelerometer) shall not be more than 100 mV/g + 5% within the temperature testing range. The selection of transducer shall depend on each specific application. Bidder shall review the equipment to be monitored and furnish his recommendation regarding selection of transducer for Owners approval. Two vibration transducers shall be provided for each bearing measurement location (one for horizontal (X) & one for vertical (Y) direction). One no. Key phasor transducer with complete hardware & system shall also be provided for vibration analysis for steam turbine & each HT drive. Vibration transducer shall be complete with all required pre-amplifier / driver / charge amplifier as necessary for proper operation of the entire vibration monitoring system. The electronics shall be housed in a separate field mounted box located near the bearing housing. The transducer and the housing for the field mounted electronics shall have protection class of IP-65 and shall be suitable for operating in the environmental conditions specified elsewhere. Operating Temp. for sensors and extension cables shall be 0-125 deg. C.

b)

c)

4.10.02

Vibration Monitors i) The vibration monitors shall be micro-processor based with extensive self diagnostic facility, which will include monitoring health of the monitor as well as the transducer and continuity of cables. Test switch, test indication etc. shall also be provided at the monitor front. The trip / alarm outputs shall be inhibited during the testing. Status indication showing the health of monitor and transducer, availability of power supply etc. shall be provided on monitor front.

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ii)

A separate four-channel vibration monitor shall be provided for each bearing location point (which means one channel for monitoring of vibration in horizontal (X) and one channel for vertical (Y) direction). For each of the vibration monitor channels, separate bargraph type LCD displays or dot-matrix graphic display shall be provided. The displays shall be calibrated in velocity unit. However, field programmable integration facility shall be available to have the display in displacement unit also. One normally open relay contact for alarm and one changeover type contact for trip shall be provided, common for both the channels. The contact ratings shall be compatible for connection with Bidders Annunciation System and Protection Systems. The monitor shall have inbuilt capability like voting logic, time delay etc. to prevent nuisance alarm or trip. It shall also have provisions to bypass the alarm during equipment start-up. Tamper proof facility for adjustment of the set point for alarm & trip shall be provided. The set points shall be adjustable from 5 percent to 100 percent scale range. Programmable high pass and low pass filtering facility shall be available to improve the frequency response. Alarm indication lamp / display along with alarm acknowledge/reset facility shall be available on the monitor front. Start-up attenuation lamp shall also be provided. All the calibration of the monitors and transducers shall be possible from the front panel. All incoming and outgoing signals shall be connected through a terminal block or connection mounted at the back of the monitor. In addition to the above, the monitor shall contain all other required signal conditioning devices and accessories required for proper functioning. Reverse rotation monitor system shall also be provided from VMS supplier for CW pumps by bidder.

iii)

iv)

v)

vi)

vii)

viii)

ix)

x) 4.10.03

Power Supplies i. The vibration monitoring system shall be fed from UPS 240 V AC, 50 Hz supply. All the necessary power supply packs and other devices required to convert the above supply to the levels required by monitors / transducers / other electronics shall be redundant & shall be provided by the Bidder. The power supply for the transducers and the field mounted electronics shall be fed through the monitor to whom these are connected. The power supply for the monitors can be separate or in-built with the monitors. However, in case the power supply is external to the monitor then not more than two monitors (i.e. 4 channels) shall be fed from one redundant power supply.

ii.

iii.

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iv.

Power supply monitoring feature with suitable indication and external alarm shall be provided. Power supply failure shall inhibit the trip output.

v. 4.10.04

Vibration Monitor Racks 1. 2. 3. Vibration monitors shall be mounted in 19 racks. These 19 racks shall be suitable for flush panel mounting. The number of monitors to be mounted in one rack shall be as per Bidders standard practice. However, in case there is any common hardware like power supply, or other system module, then not more than two (2) nos. of monitors shall be mounted in rack. Each rack and each monitor on the rack shall have a nameplate.

4. 4.10.05

Test calibration instruments/jigs for site calibration of all sensors of VMS shall be provided by Bidder. This shall be in addition to provided with TSS/TSI system. SG Related Control & Instrumentation System/ Equipments Flame Monitoring System The purpose of the system is to detect the individual flame and to enhance the boiler/furnace safety, to avoid spurious and unwarranted trips and to increase operational reliability, availability and efficiency of the Steam Generator such that the consumption of fuel oil shall be reduced to optimal minimum. Fail safe easily mountable Microprocessor based digital flame monitoring system shall be provided, which shall include flame detectors of proven design for the type of fuel, environmental condition and other conditions, of established reliability at all loads of the Steam Generator. It shall be designed to work under all adverse conditions such as wide variation in fuel/air input ratio, wide variation in fuel characteristics, variation in operating temperature, maximum temperature under interruption of cooling air supply and shall be immune to Electro-Magnetic Interference (EMI). The system shall conform to NFPA recommendation and location of detectors as per NEC requirements. The Selection and location of the flame detectors/scanners shall be decided by the Boiler manufacturer. The Bidder shall furnish the justification of selection of flame detector locations for Owners review. Flame detector shall be working on the dynamic and static properties of primary combustion zone of each type of fuel and flicker frequency of flame. It shall be p based visual scan system for discretization of flames. It shall pick up only the flame to which it is assigned and shall not respond to the adjacent and background flame or other radiation generated in the furnace. The design shall also take into account the absorption by a coal shroud, recirculated dust or other deposition on the flame detector head. The complete system shall provide the discrimination between oil and coal flame. Intensity indicators for main flame shall be provided along with galvanically isolated 4-20 mA DC signals and hooked to DDCMIS.

4.11.00 4.11.01

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The system should be easily maintainable and include automatic self test facility at regular interval. The sensor fault, alarmimg, diagnostic and pre historised flame intensity value of flame monitoring system shall be hooked up to integral OWS with suitable software. Specification of OWS shall be same as specified elsewhere in the Specification. In case of tangentially fired boiler, the Bidder shall arrange flame detectors in such a manner that coal flame detectors are available both above and below each coal burner and separate oil flame detectors are provided for each oil burner. In case Bidder has discriminating type flame detectors capable of detecting and discriminating both oil and coal flame, with the help of a single scanner, the same can also be utilised for monitoring both oil and coal flame per burner. For any other type of firing i.e. non-tangential type the flame detectors shall be provided for each coal and oil burner responding only to the flame of its associated burner. Bidder shall furnish the details of the flame detector locations and justification for the same. The Bidder shall demonstrate the complete performance of flame detectors in cold start up test and load condition test. In cold start up test, capability of detectors to detect oil flame under varying oil pressure shall be checked. In load test, the detector shall be able to detect when only oil is present, only coal is present and both coal and oil are present. It shall be ensured that the detectors are able to detect the proven flame at very low load with oil guns withdrawn. The above tests shall be performed for every coal and oil elevation. Provision of scanner air for cooling the flame detectors by 100% redundant Scanner Air Fans, shall be provided. The dampers associated with scanner air fans shall be pneumatically operated with DC solenoid valves. Pneumatically operated scanner emergency damper shall be erected to safeguard all the flame scanners even in case of failure of both FDs and both scanner air fans. Flame Monitoring System shall have dual redundant modbus/OPC bidirectional interface connectivity with DDCMIS in addition to hardwired signals. FLAME DETECTOR TESTING KIT The Bidder shall also provide a portable flame detector testing kit with built in stabiliser, capable of simulating both oil and coal flame, and testing of flame detector head unit at field. The testing kit shall also have facility for testing all type of electronic cards as being used in the flame monitoring system. 4.11.02 Coal Feeders Control and Instrumentation Bidder shall provide a microprocessor based coal Feeder C&I system having the following feature. It is preferable to use the same family of hardware as that of CLCS for implementation. Remote/Local operation selection shall be implemented in DDCMIS.

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Bidder shall provide a minimum of two independent speed sensors, 2 nos. of load cell, pulsar units and associated amplifiers, etc. for each of the coal feeders. Output from the speed sensors will be used to provide at least four number isolated 4-20 mA DC analog signals corresponding to coal flow rate in tons per hour and any other signals that may be required for the control of the coal feeder. Each coal feeder shall receive signals from DDCMIS for feeder speed control. The signal to be provided for the same shall be in the form of galvanically isolated 4-20 mA DC. All required power amplifier units/interface devices to accept this 4-20 mA signal shall be included. Accuracy class shall be + 1 %. All associated electronics like buffer amplifiers, frequency to current converters etc. shall be provided for each RC feeder with local speed indicators. The speed sensors shall be totally enclosed, fire, dust and weather proof, suitable for the service conditions. The control cabinet shall be provided with Reset push buttons and individual lights to signal the individual Internal trip conditions. Motor and Speed sensing system of RC feeder must be totally enclosed with no chance of dust and water ingress. Each feeder shall be provided with a four position switch located at the feeder for remote off, local run (when there is no coal on conveyor) and calibration purpose. If there is any electronic modules mounted local to the feeder body then these shall be suitable for operating in a non-air-conditioned area in a suitable enclosure to combat the effect of noise, vibration, entry of dust etc. All necessary paddle switches and other detectors to monitor coal on belt, feeder discharge plugged, coal motion monitor etc. should be provided to ensure safe operation of the feeders. If the system does not measure coal flow on loss of any signal, alarm has to be given to DDCMIS and initiating the feeder to run on volumetric mode from the gravimetric mode. Provision for changing the coal density by end user to run the volumetric mode with higher accuracy shall be provided as inbuilt feature with system. 4.11.03 Electromatic Relief (Safety) Valves The Electromatic safety valve shall be an automatic, electrically actuated pressure relief valve. It shall be possible to set the value for one percent or less differential between opening and closing pressure. The Electromatic safety valve shall be provided complete with all accessories like pressure measuring devices, controller units, local PB station, solenoid assembly, impulse piping etc. Provision shall also be kept to operate the Electromatic relief valves from the DDCMIS OWS and miniature PB stations on the UCP. The operation of the valve shall be accomplished by operator command or by means of pressure sensitive element which shall precisely and automatically relieve the pressures within very close limits. 4.11.04 Furnace Temperature Probe

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Furnace gas temperature probes on each side of furnace shall be provided for monitoring of gas temperature at the furnace outlet. The probes shall be movable type. For above purpose, Bidder shall provide furnace temperature probes before platen super heater and/or before reheater regions and shall be electrically operated, fully retractable type. The furnace temperature probes shall be furnished with complete actuating mechanism and all the logics required for the actuating mechanism. The probe shall be provided with position transmitters, limit switch & indicator for remote indication. Each temperature probe shall have a duplex thermocouple suitable for the measurement range. Bidder shall furnish complete details of the temperature probe along with all the technical catalogues including the details of the actuating mechanism, position transmitters and limit switch which shall be subject to Owner's approval. The logics for furnace temp. probe shall be implemented in the SG C&I part of DDCMIS. 4.11.05 Acoustic Pyrometers Acoustic Pyrometers are to be provided to determine the average flue gas temperatures and complete flue gas temperature profile Furnace Exit plane (for FEGT measurements) and at Economiser outlet. For each temperature measurement plan/section, A system complete with all required software, comprising of minimum eight nos. of acoustic transreceivers or two nos. acoustic transmitters & twelve nos. acoustic receivers, signal processors/controllers, interface unit, Operating WORK STATION & A4 sized Colour LaserJet Printer shall be provided. The minimum specification of the WORK STATIONS & printer shall be as specified in specification. The system shall be able to eliminate the varying high noise environment both in and out of an operating boiler The transit time of each of the associated transmitters/receivers shall be transmitted to the central processing unit (to be located at CER) for storage and analysis through suitable interface device. A temperature profile shall then be determined and displayed by analyzing the mean temperature across every transit section using deconvolution technique. The time interval to make a complete cycle of eight nos. of acoustic transreceivers or two nos. acoustic transmitters & twelve nos. acoustic receivers should be less than one minute. The measuring range should be sufficient to cover the entire regime of boiler operation and shall not be less than 1900C. The mean temperature and profile temperature accuracy shall be 2%, & 4% of reading respectively or better. Full colour display and colour printer output shall be provided. The system shall provide 4-20mA DC outputs for SG C&I and BOP C&I part of DDCMIS and Ethernet TCP/IP or Ethernet Modbus connectivity for Operating work station. The transducers shall not be placed directly in the hot gas stream. The system shall be of proven design and it's performance must be proven for at least two 500 MW rating boilers or higher rating using similar type of fuel for a period of two years. The components to be located at Boiler Area shall be able to withstand the stringent environmental condition expected at such locations with operating Boiler. System shall be provided with high speed technology, so that system can collect minimum 16 paths simultaneously. The system shall be capable to measure every path

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in both directions simultaneously. Every path shall be measured two times (back and forth) after the transmit cycle (each transceiver has transmitted once). 4.11.06 Furnace and Flame Viewing and Analysis System Bidder shall provide a Furnace and flame viewing & analysis system. The flame cameras shall be suitable for direct online continuous viewing in the central control room of the coal and oil flame and condition of the furnace internals including slogging of the water walls and any other deterioration in the furnace condition. The minimum nos. of such flame cameras to be included in the proposal shall be selected by the Bidder appropriate to his boiler design subject to minimum of four (4) numbers. The system shall comply to NFPA requirements. The flame camera system will consist of the following facilities/ components as a minimum: i) -OWS with redundant server, 40 High resolution color LED monitor & A4 sized b/w LaserJet Printer & bulk data storage retrieval facility. 40 LED monitor shall be roof hanging with complete mounting hardware. The location shall be finalized during detailed enginnering considering asthetic view and monitoring for all the operators. The LED monitor shall be capable of showing multiple windows from all the cameras simultaneously. Facility for zooming and adjustment of iris from the monitor Proper cooling arrangement (preferably air) and protection against cooling medium failure. Weatherproof local control box for mounting of electronics. All necessary remote/ local programming tool. All interconnecting cable and termination device. Automatic camera extraction system from the furnace in case of camera cooling arrangement fails. Flame Analysis software with all relevant users licences. Redundant OPC communication link with necessary hardware and software. Any other accessory like armored video cables, Remote control unit, Video signal distributors etc. to make the system completely operational.

ii) iii) iv) v) vi) vii) viii) ix) x)

The cameras and the total system shall be suitable for the furnace design as being offered by the main boiler vendor, the firing arrangement (corner, front/ wall fired), the fuel being fired considering the ash content of worst coal. The cameras should be expected to withstand the temperature expected in the furnace of the offered boiler but shall not be less than 1600 deg C. The viewing angle of the camera shall be commensurate with the furnace size, the camera location and the positioning of the burners. The offered flame camera system shall have a record of trouble free performance of minimum one (1) year in a coal-fired boiler of size 500 MW or above where the firing arrangement is similar to the offered boiler. The system shall be capable of transmitting the image to the Bidders DDCMIS system where it should be possible to display the same on the monitors of Operator workstation

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and the Large video screen. Also the data from thermal imaging camera shall be used for soot blowers in order to improve the efficiency. 4.11.07 Conductivity Type Level Switching System For Separator (for Boilers provided with separator), drip legs level, etc. used for alarm & protection purposes, conductivity type level probes shall be provided. Each of the switching systems shall be furnished complete with upto 2 nos. conductivity probes for drip legs (Eight nos. for separator level application), column for mounting the conductivity probes, isolating valves, drain valves, vent valves, electronic units & racks for mounting the electronic hardware, twisted & shielded pair interconnecting cables. The conductivity probes & the column for mounting these probes shall be designed for the respective pressure and temperature conditions. The system shall be proven & approved by factory mutual USA or equivalent, IBR etc. 4.11.08 Mill and Airheater Fire Detection System Adequate number of thermocouples type fire detection system for each Mill and Airheater shall be provided as a composite & complete units with all required signals & accessories with adequate redundancy shall be provided. The controls & protection required for the Mill detection system fire detection system shall be implemented in the SG-C&I part of DDCMIS and Air-heater fire detection system shall be implemented in the DDCMIS using rate-of-rise algorithm taking care of manufacturer's recommendation. For measurement of pulveriser outlet temperature tungsten carbide block thermowells abrasion resistant of tungsten carbide coated thermowells shall be used. The terminals of temperature sensors shall not be at the top of mills itself. The temperature sensors wires are to be laid up to JB though SS tube of required diameter and the head shall be placed nearer to the JB. Compensating cable exposed to atmosphere in the conventional method melts away due to high temperature at the top of mill or due to coal burning. 4.11.09 Boiler Tube leak detection System For acoustic leak detection based Boiler Tube leak detection System, A system complete with all required software, comprising of signal processor, interface unit, OWS & A4 sized colored LaserJet Printer and separate redundant server with A4 sized B/W LJP shall be provided. Boiler Tube Leak Detection system shall monitor steam tube conditions for any possible tube leakages by monitoring various tube zones in the boiler on continuous on line basis and provide necessary feedback to plant operation personnel regarding the occurrence of, location & extent of tube leakage at the initial stage itself, to enable the plant personnel to take necessary remedial measures early. The system shall perform the following functions :i. Able to detect the tube leakage at the earliest so as to minimize the secondary damage caused to furnace internals due to steam leakage.

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Capable of Real time detecting and pinpoint the steam tube leakage anywhere in the boiler. Monitor tube leakage continuously and showing the leak frequency spectrum. Following the leak growing trends Real time monitoring noise in the boiler Recording the trend of the leak history Watching operation condition of ash blowers & Soot blowers Self detection of device Judging ash blocked condition of the conductive tubes Having mechanical blowing and electric ash cleaning ways in the conductive tubes. Digital Filtering of sound signals, Frequency spectrum analysis, trends analysis, bar graph and mimic. Automatic air purge system Alarms to DDCMIS in case of system failure. Display likes Bargraphs, trends, group trends, history, mimics etc shall be provided on Boiler Tube leak detection Systems OWS & DDCMIS OWS.

To achieve the above functions, the whole system shall be divided into two parts:i) Sensing System The system shall be based on monitoring the secondary acoustic noises generated out of tube leakage by using acoustic sensors. System shall be suitable for use with a mixture of both airborne & structure borne sensors. Sensors to be fixed to the boiler wall as following a. b. Through bypass of the soot blowing tubes for airborne sensors. By welded wave guides for structure borne sensors.

Sensors shall be preferably with integrated pre-amplifier thereby eliminating the need of external pre-amplifier. However if the additional external pre-amplifiers if required, the same shall be provided. Sensor shall be either of SS316 or ceramic type depending on the temperature & other applicable requirements. Sensors shall be preferably be of piezo-electric type with a measuring audio frequency range of 300 Hz to 10kHz. Sensor shall be capable to absorb severe thermal shocks (550 deg. F/sec) Number of sensors to be provided shall be on as required basis, covering all boiler tube zones (Furnace, Radiation, Economiser and Convective) However minimum 30 no. sensors shall be provided. Each sensor channel including the wave guide shall have the accuracy of +/- 2 dB.

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Wave guides and sensors shall be mounted in such a manner that, there is no leakage from the furnace to the atmosphere and vice-versa. Necessary stubs, proper sealing and other hardware shall be provided. Sealing of the sensors shall conform to IP 65. Sensors shall be air purged to prevent blocking of the sensors and remove dust from the wave guide and ensure sensor response. The air purging arrangement shall be such that acoustic signal shall not be masked or distorted. Complete purging system (isolation valves, tubing, solenoid valves etc.) as required shall be provided by bidder. The purging operation shall be possible both periodically on Auto mode or remote manually from control room. Provision of local purging also to b e provided. Provision and necessary facilities required for isolation of each sensor for maintenance shall be provided by bidder. Also it shall be possible to perform routine calibration of sensors without disconnecting the sensors. If any sensor hood is required to block undesirable noise pick up the same shall be provided..

ii)

Signal Processing, Analysis & Monitoring System Sensor data to be processed in terms of amplitude, frequency , time period, RMS value, Average signal level (ASL), partial discharge etc for which the signal persist and shall analyze the same for distinction between the steam leakage and normal background noise due to fuel firing of oil & coal burners and soot blowing. Signal processing & analysis shall be able to filter out atmospheric and other background noise associated with steam leakage such as valve gland steam leakage noise and combustion noise etc. so as to avoid false steam leakage alarms. Both high pass & low pass filters shall be available for each channel to allow for selection of right frequency bandwidth for each channel individually. The system shall have audio, graphics and electrical alarms that can be connected to DDCMIS. System should have in built time delay feature to avoid false alarm. The system shall allow 2-8 channels of auxiliary signal inputs synchronized with BTLD leak detection channels. This will include soot blowing On and also the other process parameters such as Main steam pressure, Main steam temperature, Main steam flow as required with due consideration. These information shall be available on the BTLD VDU display. Necessary interfacing with DCS/Soot Blower control system for the above signals to be provided. System shall have the facility to set various alarm based on logical operations.

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BTLD system shall be designed to accommodate additional 25% sensors over the quantity of sensors installed initially. Audio signal by aid of head phone device or any other suitable method with a channel selection facility shall be provided for the operator in the signal processor rack/cabinet. MIMIC of overall boiler or in zones of the boiler where one or multiple sensors are located for each sensor shall be displayed on the Monitor of the user OWS. System shall also be able to display a 3D model of the furnace, location of each sensor, signal level, alarm status. Bar graph display shall be display for each sensor noise and frequency with respect to time. Trend graph for each individual channel with data and time stamped on single display. Simultaneous trend graph for each of the sensor in a group of 8 sensors. Displays shall be updated every 5 seconds. It shall be possible to display leak detection signal along with temperature, pressure and power output. It shall be possible to display simultaneously wave form and spectrum for each individual channel. Suitable displays to be provided for alarm set points. Air purging status, fault status of each sensor/amplifier, etc The system shall be able to provide 4-20mA DC type signal and alarm contact for each channel leakage and abnormal condition along with any system failure/unhealthy condition alarms for connecting to external system like plant DDCMIS. System shall be capable of retaining the parameters setting after power loss. Parameter setting shall be under key lock/password protection. System shall have electro-magnetic compatibility (EMC/EMI) as per EN 50081/82

History Function BTLD system shall have facility for storing and displaying the historical data on demand regarding the history of each sensor signal amplitude and frequency. The historical data shall be displayed in bargraph and trend form. The data storage shall be with adjustable duration of 1 minute to 1 hour. The data display shall be selectable with a resolution of 1 minute to 1 hour for displaying the history upto 1 year. It shall be possible to retrieve and display historical data concurrently with real time monitoring.

Diagnostic facility Following diagnostic information shall be available:

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a) The system shall have an automatic self diagnostic feature for periodically testing each channel including the sensor, amplifier & signal processing card through an internal sound generator. Also it shall be possible to initiate manually any channel system test. b) Self Diagnostics of the system (server & user PC) and software with any abnormalities alarmed. c) Power supply monitoring & alarm BTLD Other Features All Documentation of the BTLD system shall be stored in the system in the system itself. All displays shall include mandatory information like unit name & number, data, time etc. Opeator adjistable parameters shall be through suitable password protection & each such setting change shall be logged & printed automatically. Facility/software to be provided in the system to modify/add any display/mimics/bar graphs/trends/set points/time delays to allow user function at site. All I/O cards shall have quick disconnected connections allowing card replacement without disconnection of external wiring. Also, it shall be possible any card replacement with power on condition. The system shall have facility to store bulk data for 5 years duration with facility for retrival of the same. The system shall have facility to share bulk data for 5 years duration with facility for retrival of the same. The system shall have facility to share all the data in the harddisk/back up media and provide user friendly utilities to retrive and analyze stored data. The system shall be operable with redundant UPS power supply. The power supply provision shall be such that on failure of one power supply the other power supply shall cater to the requirement of the equipment so as never to hinder the functioning of the system in any manner due to power supply failure.

BTLD Hardware/SOFTWARE/INTERFACING REQUIREMENT Each BTLD system shall include all hardware and software as required for proper functioning of the system including but not limited to the following unit. a. Sensors (both airborne & structure borne type ) as required but minimum 30 Nos.

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b. Waveguides as required c. Air purging arrangement for each sensors d. Isolating valves, tubinmg, solenoid etc as required e. Junction box, cables, system cables, interconnecting LAN etc as required. f. Signal Processing, Analysis & Monitoring System 1 No. g) Necessary software with all relevant user's license h) Server & user OWSs Operating licenses. i) Bulk data storage and retrival facility as required j)Calibrator 1 No for each of sensor All software user licenses shall be valid for entire life of power plant. User should not have to pay any recurring license fee during the usage period of the system. License will be provided on permanent basis and for any up gradation of software in five years,it will be supported as per the agreement. It shall be possible to upgrade the installed system with the latest available version of the software model for up to 15 years after commissining. Boiler tube leak detection system to be interfaced with plant DDCMIS through suitable communication link and hardwaried cable.

BTLD System Implementation System shall be delivered fully implemented and shall be user tested at site. It is the contractor's responsibility to demonstrate the proper functioning of the system to user's personnel.

Monitoring System For Boiler Tube leak detection System, A system complete with all required software, comprising of signal processor, interface unit, WORK STATIONS & colored A4 sized LaserJet Printer and separate redundant server & bulk data storage and retrieval facility shall be provided. The specification of WORK STATIONS, servers & printer shall be as specified in NIT else where. The monitoring system shall also consist of system cabinet where the cables from different sensors shall be terminated along with necessary hardware & software to achieve the above functions. Redundant OPC interface shall also be provided with DDCMIS in addition to 4-20 mA signals for each channel. 4.11.10 Thermal imaging devices with IR technology located on each side of boiler are to be provided by bidder. Thermal imaging cameras with necessary air cooling shall be preferred. This will give temperature profile of the boiler wall. Also the data from thermal imaging camera shall be used for operating soot blowers in order to improve the efficiency. The data from this thermal imaging devices giving temperature profile of boiler walls shall also be utilized for effective optimistic operation of Soot blower. 4.11.11 On Line Carbon in Ash Analysers System

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The system shall utilize non sampling/extraction type microwave technology for online monitoring/measurement of the unburnt carbon in fly ash with minimum 4 nos. probes measurement to have complete profile per location. The system shall measure a fly ash at a representative location (The locations shall be decided & finalized by owner during detailed engineering). In order to maximize the reliability, the number of moving parts on the sensor shall be minimized. Accuracy shall be < 0.6 % minimum. The system shall also provide 4-20mA DC output for SG C&I and BOP C&I part of DDCMIS and thru redundant soft link also. Panel protection class shall be IP65. Panel shall be provided with industrial grade LCD display. System shall work on UPS power supply. On Line Carbon in Ash Analysers System shall be used in optimization package also. The offered system shall have a record of trouble free performance of minimum two (2) year in min 1 (one) nos. coal-fired boiler of size 500 MW or above where the firing arrangement is similar to the offered boiler. 4.11.12 Coal Mass Flow & Velocity Measurement System On line Fuel flow & velocity measurement facility in each Pulverized Fuel (PF) pipe for each coal pulveriser shall be provided by bidder for accurate, absolute and simultaneous measurement of coal velocity, coal density, coal mass flow rate and air-to-fuel ratio. The equipments shall compromise of sensors working on micro wave technology. The error in the measuring system shall not be more than 5%, which shall be demonstrated by comparisons with isokinetic measurements. The scope of each steam generator shall include two (02) nos or more of erosion free measurement sensors for each PF pipe from each coal conveyor as per system requirements, redundant control units (including processors, communication modules, power modules etc), visual display unit, connecting cables etc for making system complete. For the purpose of above fuel measurement each PF pipe shall be provided with two nos. or more of tapping points of suitable size, with necessary plugs/dust proof dummies etc as required. Automatic Motorised Adjustable valve/orifice of erosion resistant/ceramic coated material suitable for highly abrasive pulverized coal applications shall be provided on each PF pipe at pulveriser outlets and the system shall enable onload adjustment of coal flow in PF pipelines to achieve balanced coal flow. The system shall also provide 4-20mA DC output for SG C&I and BOP C&I part of DDCMIS and soft link also. Panel protection class shall be IP65. Panel shall be provided with inbuilt laptop for data analysis. Specification of Laptop shall be same as specified elsewhere in the Specification. System shall work on UPS power supply. The offered system shall have a record of trouble free performance of minimum two (2) year in min 1 (one) nos. coal-fired boiler of size 500 MW or above where the firing arrangement is similar to the offered boiler. 4.11.12.01 Secondary air flow measurement (Left & Right) In addition to the conventional triple DP measurement techniques involving venturi/Airfoil for secondary air flow measurement, One number Flow measurement system each on Left side and Right side shall be provided as redundant/checking measurement for secondary air flow which could be used in the optimization package.

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On line secondary air flow & velocity measurement facility in each on left side & right side shall be provided by bidder for accurate, absolute and simultaneous measurement of air velocity & flow rate. The equipments shall compromise of sensors working on triboelectric (Correlation technique) technology. The error in the measuring system shall not be more than 2 %.The scope of each steam generator shall include minimum two (02) nos of erosion free measurement sensors for each left & right side air line (Sensors quantities may also increase depending upon duct size), redundant control units (including processors, communication modules, power modules etc), visual display unit, connecting cables etc for making system complete. The system shall also provide 4-20mA DC output for SG C&I and BOP C&I part of DDCMIS and soft link also. Panel protection class shall be IP65. Panel shall be provided with inbuilt laptop for data analysis. System shall work on UPS power supply. The offered system shall have a record of trouble free performance of minimum two (2) year in min 1 (one) nos. coal-fired boiler of size 500 MW or above where the firing arrangement is similar to the offered boiler. 4.12.00 Master Clock System i) The Master clock system shall be provided based on Global Positioning system (GPS). Master clock shall have separate signal conditioner facilities to transmit clock pulses of specific formats, (such as IRIG-B, pulse, NTP/SNTP etc.) for time synchronizing other equipment in the power plant such as, DDCMIS system, PLCs, SOE & for all microprocessor based system like TSI, TSE, VMS, HMS, Flame monitoring & detector system, Bolier tube leak detection system, Plant performnce & Optimisation system, CCTV, ERP, MIS, simulator etc. All the PLC & Microprocessor based system in entire plant shall be time synchronized from Master Clock System. Master Clock System shall be common for all the system in complete plant. Spare 10 nos. port of each type of signal shall also be provided for future use. Redundant (dual or Triple) Time Synchronization signals shall be provided for DDCMIS, DCS, PLC and other control system, where redundant hardware configuration are envisaged, so that at failure of one signal, system shall not get affected. Separate signal conditioner cards shall be provided to generate redundant (dual or Triple) Time Synchronization signals. Complete hardware, cables equired for time synchronised at both end shall be provided by Bidder. Time synchronising signals shall be able to communicate to multiple protocols like IRIG-B, pulse, Mod-bus, NTP/SNTP, K bus, SPA protocol etc. ii) The receiving system of master clock shall consist of antenna, a low noise amplifer, a down converter combined as head unit, co-axial cable to carry the converted signal to indoor unit which consist of a demodulator and a decoder. The decoder time signal shall be employed for synchronisation of plant systems. The Clock system shall be dual redundant microprocessor controlled and fully automatic. Clock system shall employ highly stable crystal oscillator to ensure accurate time indication. The stability shall be better than 0.5 sec. per day. Oscillator shall have redundant standby unit. Provision for manual settimg of time

iii)

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shall be provided in the master clock. The master clock shall incorporate alarms for fault conditions thru pot free contacts, which shall be displayed locally on the unit and also in DDCMIS. iv) The UPS power supply shall be provided for Master clock system with redundant feeders. The clock display would get automatically time synchronised to IST in less than two minutes after power up (or interruption). It shall also have the provision of manual setting and can operate autonomously in absence of satellite reception. Battery shall be provided with teak wooden rack. The Master clock shall be housed in a suitable panel made of CRCA MS sheet of 2 mm thick and located at Central Control Room. The panel shall be vertical, floor mounted and provided with necessary illumination. The cable entry shall be from bottom shall be provided. All the control and monitoring devices and all switches for affecting the various controls shall be provided in front of the panel so as to provide easy accessibility and aesthetic look. All the Slave clocks shall derive impulse from the Master clock. Each Slave clock shall be connected to Master Clock by 2 pair copper wire with annealed, tinned, stranded Copper conductor, PVC insulated, PVC sheathed, GI round wire armoured, overall FRLS PVC sheathed. It shall be ensured that loss of any slave display unit does not affect the display of any other slave unit. Cable specification shall be as per NIT cl. no. 9.06.00. All slave clocks shall work in exact synchronism with Master Clock. They shall be weatherproof construction suitable for indoor or outdoor use. They shall be enclosed in a suitable hevy gauge sheet metal enclosure and fitted with protective antireflective glass face / cover. Slave Clocks shall be digital type with updates at every second. The display shall be of six digits for hours, minues and seconds. Display element shall be red LED and the digit size shall be 100 mm minimum for a viewing distance of 20 meter. Anti glare glass cover shall be provided. In control rooms wall / panel mounting type decorative slave clock shall be provided.The slave clock shall work on 240 V AC supply. Slave clocks shall be indoor 25 (twenty Five) nos. and outdoor 25 (twenty Five) nos. minimum distributed all over the power plant (each unit) . All required hardware like signal conditioners, signal booster etc shall be provided as on required basis.

v)

vi)

vii)

4.13.00

HART Management System The Bidder shall provide a dedicated and standalone WORK STATIONS based system for each of the generating units for centralized configuration, maintenance, diagnostics & record-keeping for all smart type electronic transmitters specified under clause 3.03.01, smart type analysers and any other HART based instrument/system. For this system, suitable HART interface modules, power supply modules etc. shall be provided, suitably mounted in cabinets for hooking up to a dedicated WORK STATIONS & a colored A4 sized LaserJet printer to be provided by the Bidder. The quantum of signal connected to HMS hardware shall be minimum of 1500 nos. in addition to this 1500 signals at least 20% spare wire slots shall be made available for future use.The Bidder to note that this WORK STATIONS & printer shall be over and above those

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specified under chapter 4 of this volume. This system shall meet following requirements as a minimum: i. Each of the transmitters/HART based instrument shall be terminated in marshalling cabinets through cage clamp type maxitermi connections on special twin terminal blocks to be provided by the Bidder. The transmitter/HART based instrument signals from each of the transmitters shall be wired in parallel to CLCS/OLCS/control system and to HART interface modules via these special twin terminal blocks. The CLCS/OLCS/control system will necessarily use 4-20 mA analog signals and superimposed digital signal shall be used in HART interface modules. The interconnection between twin terminal blocks and HART interface modules shall also be through prefabricated cables with plug-in connectors connected at both ends at manufacturers works. The multiplexed signal from HART interface modules shall be hooked upto a HART OWS 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 Bidders 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% spare smart type electronic transmitters, smart type analysers and any other HART based instrument/system shall be kept. A industrial grade RS-485 to RS-232 converter shall be provided for interfacing HART data of transmitters to a HART OWS station. This converter shall also provide proper isolation to ensure data integrity. The processor, Power supply, communication port shall be redundant. The configuration of HART OWS shall be fault tolerant. HART management system shall be time synchronized with station GPS based Master clock system. Any failure/short/open-circuit and/or removal of any of the cards/devices/cables in this centralised configuration, maintenance, diagnostics and record keeping system, including failure/removal of HART interface modules, communication modules, converter, etc. shall in no way affect the 4-20mA analog signals being used in CLCS/OLCS/control system. The HART interface modules and communication modules (if applicable) shall be suitably mounted in cabinets. Suitable parallel redundant 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 plant UPS system. All modules/cards/power supplies shall be mounted in cabinets to be located in Control Equipment Room. The WORK STATIONS and printer shall be located in Programmers room. All cables/links for connecting system described above shall be provided by the Bidder on as required basis within quoted price.

ii.

iii.

iv.

v.

vi.

vii.

viii.

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The bidder shall install suitable software in WORK STATIONS to achieve centralised configuration, maintenance, diagnostics and record keeping of smart type instruments. Following facilities shall be available as a minimum through software and the HMS software have to be licensed for 2500 tags. a. b. c. Constant scanning to monitor faults of changes to instrument configuration. Owner-defined and standard calibration and configuration procedures for all transmitters/smart type instruments. Constant signal data collection facilities to maintain continuously updated records in accordance with ISO 9000 quality standards this will include historic database records of all configuration changes, test and calibration details and additional service notes. 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. Event and log reports on screen as well as on printer. Any addition/deletion of transmitter will be reported on printer and logged in hard disk.

d.

e. f.

The Bidder shall enclose detailed bill of material and schemes alongwith the bid indicating how the requirements of centralised configuration, maintenance, diagnostics and record keeping facility for transmitters are being achieved. The makes of modules/devices and configuration scheme shall be subject to Owners approval during detailed engineering stage. 4.13.01 In case bidder DDCMIS has the facyility to acquire HART signals through analog Input cards and carry out the communication to HMS OWS through DCCMIS hardware, the same is also acceptable. In this case all above features & hardwares mentioned above cl.no. 4.13.00 shall be complied by integral HMS system. For easy handling of the various functions at HMS panel itself, and Control & Instrumentation Laboratory, One no laptop PC with necessary advanced configuration as listed in specification else where, HMS software, one no industrial grade RS 485 / RS 232 converter shall be provided for configuration, maintenance and diagnostic of all smart devices. All the functions mentioned in above at cl. no. 4.13.00 (ix) shall also be available in the laptop PC. STATION LAN General A plant wide Local Area Network (LAN) encompassing the different plant buildings shall be provided. The Station LAN shall interconnect the buildings together and shall facilitate the smooth transfer of Data from one building to the other. 4.14.02 Design and functional requirement A Plant Wide Network shall be provided, so that pre-selected plant graphics & data can be viewed on real time data basis at selected nodes and from remote locations. The LAN

4.13.02

4.14.00 4.14.01

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shall be redundant with redundant industrial grade Ethernet switches and of the industrial grade with 10 Gigabit speed and shall utilize standard IEEE 806.3 protocols such as Ethernet. Complete network shall be provided with External surge protection system and industrial grade fire wall. The Station LAN connection with necessary RJ-45 connectors and other accessories shall be provided at cabins of each occupants in service building, administrative building, fire station building, Time office, Stores, and other buildings. 4.14.03 The Station LAN shall connect following buildings: i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii. xiv. xv. xvi xvii xviii xix xx xxi. Station building Central Control Room Service building Coal Handling Plant Ash Handling Plant Water Treatment Plant DM plant/RO plant, Desal. plant Workshop Central Stores Switchyard Control Building Sea Water Intake Pump House Simulator Room. Admin Building Chief Engineer Room Conference Room Discussion Room Training Room Cooling water pump house ESP Control room Mill Plant Area Regeneration building (CPU) Any other plant area / building where STATION LAN need to be provided for the purpose of MIS.

4.14.04

The LAN network to be provided for all users points in all the rooms in the buildings and with in plant premises. Exact user points in each building and with in plant premises will be decided during detailed engineering stage. The various buildings shall be interconnected through the use of minimum 4 core single mode fibre and shall be connected to the main switch in the Service Building in a STAR topology. Each building shall be provided with a 12.U high wall-mountable communications cabinet complete with glass door, 6 way power distribution unit, 6 shelves and force ventilation. All units are to be supplied with cage nuts and bolts to house LAN switches. Industrial grade managed type Switches provided shall be minimum 4x fibre (10000 Base-SX) 10 Gbps uplink ports or 6.x STP (10000Base-T) 10 Gbps uplink ports Ethernet switch, configurable via browser interface and have a 50% spare capacity for future addition of LAN points. These switches shall also be provided with in built diagnostic features, inbuilt redundant 24 V DC power supply features and Integrated Security features (IPS, ACL, Firewall).

4.14.05

4.14.06

4.14.07

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The LAN shall be designed in a manner such that failure of an individual switch shall not hamper the failure of the entire system All provisions required for extending the Station LAN to Admin. Building shall be provided in main LAN switch. Inter building wiring shall be a minimum of Category 5E STP cable manufactured, tested and verified to ISO11801 EIA/TIA standard. Internal building wiring shall be of the structured cabling type and shall incorporate patch panels on every floor or as required. Communication cables shall be armoured and routed through GI conduit pipes or suitable grade permanently lubricated HDPE protection pipe as per IS 4984, IS 12235 & TEC.G/CDS-08/01 of suitable size @53% fill factor. A minimum of two RJ-45 ports shall be provided for each specified location Category 5E shuttered modules shall be used in pre-assembled faceplates to save installation time. Modules shall include a slide label system. All the locations availing the operating stations namely FOPH, CWPH, Boiler A elevation, Turbine 0 meter, ESP, Ash handling Control room, HT Switchgear room, SWAS / Chemical Express lab and DM Plant etc. are to be air conditioned. Intrusion Detection System (IDS) and Intrusion Prevention System (IPS) Features: In order to inspect all inbound and outbound network activity and identify suspicious patterns that may indicate a network or system attack from someone attempting to break into or compromise a system on the Station LAN Network, the recommended IDS/IPS should contain the following combined features. Any feature can be selected depending on whether it is to be configured as IPS or IDS. i. ii. iii. iv. v. vi. vii. viii. Able to analyze, detect and report on security related events. Able to inspect traffic and to drop malicious traffic based on the configuration of security policy. Able to inspect the content of network packets for unique sequences/signatures. Able to detect and prevent known types of attacks such as worm or Trojan infections and hacks. Able to prevent denial of service (DOS) and Distributed Denial of Service attacks. Able to prevent abnormal behaviors by monitoring and learning normal network behaviors. Keeps up-to-date on new threats and vulnerabilities. Should provide user friendly interface to queries and reports on threats and event data so that security administrators can gain a better understanding of their ability to protect their network. Should provide detailed activity logs for auditing. Able to detect known threats via deep-packet inspection. Able to defect unknown threats via anomaly scanning. Able to detect unknown threats via behavior pattern to protect from zero day attacks.

4.14.09

4.14.10.

4.14.11

4.14.12

4.14.13

ix. x. xi. xii.

4.14.14 4.14.14.1

Network Management Software (NMS): The network management software should contain the below mentioned features.

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i. ii. iii. iv. v.

vi. vii. viii. ix.

Graphical user interface (GUI) management. Automated discovery and display of Ethernet topology and devices. Real-Time SNMP Support Monitor traffic flow through the device View a device image indicating which ports are active and which modules are installed. It a particular network device is down, it should give the tools like ping/telnet options in the same screen to further diagnose the problem. Real-time activity and utilization statistics and graphical trends. Facility of providing pre-defined actions like e-mail, SMS etc. upon any event generated in the network. Facility of viewing logical graphs of devices like routers, web servers, according to the needs. The following parameters should be monitored. a. b. c. d. e. Device status Port Status CPU utilization Memory Utilization All port utilization including uplink ports.

4.15.00 4.15.01

Management Information system (MIS) MIS-GENERAL Any integrated management information system (MIS) shall be provided for the plant. System shall be able to provide information related to the following aspects to management personnel and pre-selected plant graphics & data can be viewed on real time data basis at selected nodes and from remote locations iii) iv) v) Plant operation information. Plant maintenance related information. Environmental information

4.15.02

FUNCTIONAL REQUIREMENT MIS will provide following plant information: 1. 2. 3. 4. 5. 6. 7. Environmental and hazard management. Equipment maintenance history. Fault cause analysis. On-job information report. Plant operation History. Plant performance details. Any other plant operation data/details.

4.15.03

DESIGN REQUIREMENTS MIS system shall be based on client server and rational database environment. The system shall operate on a commonly used hardware platform and network operating system.

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System shall be suitable for simultaneous use by multiple users. Presently, the system supplied shall be used by 72 nos. physical nodes including 50 nos. work stations, 05 nos. Laptop, 7 nos. LED TV users and 10 nos. printers as per details mentioned below. The system shall be expandable in future to accommodate additional 20 nos. users through additional client workstations and user licenses. All required physical nodes & software shall be provided by Bidder for these additional 20 nos. users. 10 nos. Digital LaserJet printer cum copier A3 sized shall be provided by bidder in service building on station LAN network at various locations. In addition to 10 Nos. A3 sized Digital LaserJet printer cum copier printer, 25 Nos. B/W laser jet printers A4 size shall also be provided. This 25 Nos. B/W laser jet printers A4 size need not be on network based and same shall be connected to individual user as decided during detailed enginnering. 3 Nos. of LED TVs having size of minimum 55 and above (one at TG Hall, one at 0th floor of service building, & one at 0th floor of Administrative building) shall be provided and the connectivity from MIS server shall be on MODBUS/PROFIBUS/RS485. Management information/production information using mimics/slides technique shall be displayed thru MIS server. 1 no. LED TV (size 55 inch) each with their own work station controller and a physical node with minimum configuration connected to MIS server on redundant connection to show the status/ conditions of various process parameters/equipments in process mimics, trends, logs etc with real time data shall be provided by bidder at station head/Chief Engineer room, at conference hall, Training room, and Discussion room-1. These Four nos, LED TV are common to both 2 X 660 MW units. 1 No. A3 sized Scanner copier cum printer shall also be provided in CEs Chamber/Office with LED TV work station. Operation/command shall not be executed from these local LED TV to start/stop the equipments. Software and Hardware security lock shall be provided for not using these local LED TV for any control/operations. Configuration of work station controller shall be same as specified for operating station in Vol. V, chapter 4. The system shall be password protected. It shall be possible to organize system users into groups and each group shall have a separate security profile. It shall be possible to provide additional personal security settings for individuals within a group. MIS processing shall be carried out in an independent server interfaced with different plant control systems like plant DDCMIS/DCS. All utility plant PLC control systems (e.g. plant common systems like CHP control systems, switchyard SCADA systems, Raw water and pre-treatment systems, DM plant control systems, Effluent treatment plant, H2 generation plant, Sea water intake system, Ash handling (Bottom Ash system), Ash handling (Fly Ash system) and unit specific DG set control, Fire protection system, etc.), Plant analysis, Diagnostics and optimization system.(PADO),for polling of plant operational and performance data and maintenance details and Plant environmental data shall be obtained from DDCMIS/DCS/AAQMS server thru OPC servers.

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The MIS system server will be connected with station LAN and all users WORK STATIONSs will be connected with the station LAN. ERP system servers shall also be connected with MIS servers with redundant industrial grade network. MIS users workstations will be located in different plant buildings and the same shall be connected to the MIS server through station redundant industrial grade LAN network. The system shall have facility to store bulk data for 5 years duration with facility for retrieval of the same. Memory size of servers shall be designed & provided by bidder accordingly. The system shall have facility to share all the data in the hard disk/back up media and provide user-friendly utilities to retrieve and analyze stored data. The system shall be provided with UPS power supply. The power supply provision shall be such that on failure of normal power supply the UPS power supply shall cater to the requirement of the equipment so as never to hinder the functioning of the system in any manner due to power supply failure. UPS Minimum 1 KVA industrial grade UPS with 60 minutes Ni Cd battery backup for WORK STATIONS. Minimum 2 KVA industrial grade UPS with 60 minutes NiCd battery backup for each server with Printer. One no. for each user One for each server

MIS system is illustrated in drawing no. 114-01-0100. 4.15.04 The Station LAN network to be provided for all users points in all the rooms in the buildings and with in plant premises. Exact user points for MIS in each building and with in plant premises will be decided during detailed engineering stage. MIS SYSTEM IMPLEMENTATION System shall be delivered fully implemented and shall be user tested at site. It is the bidders responsibility to demonstrate the proper functioning of the system to user personnel. It is preferred that bidders implementation team will involve ultimate users personnel during system implementation. 4.15.06 4.15.06.1 MIS HARDWARE/ SOFTWARE REQUIREMENT MIS shall include all hardware and software as required for proper functioning of the system including but not limited to the following: i. ii. iii. Redundant MIS server with one no. MIS work station, 24 LED monitor and 1 no. LJP A4 B/W. 55 nos. client workstations (50 Nos. each with WORK STATIONS, 24 LED display unit, keyboard/ mouse and 5 nos. shall be laptops of latest model.) 10 nos. Digital LaserJet printer cum copier A3 sized shall be provided by bidder in service building on LAN network at various locations.

4.15.05

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vi. vii. viii. ix. x. xi. xii. xiii.

25 Nos. B&W laserjet A4 sized printers. 3 nos. > 55 diagonal sized full HD LED TV of latest version with advanced features and minimum requirements mentioned in Vol. V, Chapter 13. 4 nos. > 55 diagonal sized full HD LED TV of latest version with advanced features and minimum requirements mentioned in Vol. V, Chapter 13 with own work station controller. 1 No. A3 sized Scanner copier cum printer shall also be provided in CEs Chamber/Office. DDCMIS software to be loaded on each MIS users work station for viewing the process mimics, trends, logs etc. 20 nos. spare physical nodes for aditional usesrs with complete client workstations and user licenses shall be distributed in different buildings/locations. MIS software with multiple users license. Bulk Data storage and retrieval facility Redundant OPC communication link with all necessary hardware and software. Server and User WORK STATIONSs with operating licenses. Industrial Grade Hardware like System cables, interconnecting cables to station LAN switch etc. All hardware like routers, bridges, switches etc shall be managed type industrial grade only.

4.15.06.2

All software user licenses shall be valid for entire life of power plant. User should not have to pay any recurring licenses fee during the usage period of the system. It shall be possible to upgrade the installed system with the latest available version of the software model during the plant life.

4.15.06.3

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Table 4.1

Performance Requirements for Closed Loop Control System


Sl no. Load/Rate of load Change (% of MCR per min.) Maximum Deviation Of Parameters from Set Point

Throttle pressure deviation (kg/cm 2 ) A. 1. 2. B. Steady state condition 90% to 100% 60% to 90% Ramp test (change for max. duration of five minutes) 30% to 50% 50% to 90% 90% to 100%

Flue gas oxygen deviation 2 (% O )

Furnace pressure deviation (mmwcl)

S.H. steam temperature deviation (Deg.C)

R.H. steam temperature deviation (Deg.C)

0 0

+3.0 +3.0

+0.5 +0.5

+3.0 +3.0

+4.0 +4.0

+6.0 +6.0

1. 2. 3. C. 1.

+3% +5% +10%

+3.0 +5.0 +-7.0

+0.6/-0.4 +0.8/-0.4 +1.0/-0.5

+7.0 +12.0 +12.0

+10.0 +10.0 +10.0

+ 10.0 +14.0 +14.0

Step load changes From 100% to 80% at the rate of 10% per minute +7.0 +1.5/-0.5 +20.0 +15.0 +20.0

Notes: a. Sufficient time shall be allowed as setting period between conducting the tests. b. Plant operating condition, i.e. main equipment status, availability of auxiliaries, operational and equipment constraints, which can influence the test, shall also be recorded.

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c. Control system shall be running in the coordinated master control (CMC) mode i.e. boiler master, fuel flow, air flow, feed water and turbine load control shall be in automatic mode. Load set point, maximum and minimum load set point, rate of raise / lower of load shall be set through the OWS, keyboard/conventional console. d. These tests will be conducted within 30 days of attaining 80% load.

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CHAPTER-5 STEAM AND WATER ANALYSIS SYSTEM AND FLUE GAS ANALYZERS 5.00.00 Design criteria for continuous on line analytical measurements of important plant media such as water, steam and flue gas shall be based on microprocessor based instruments only. General Requirements a) Separate Steam and Water Analysis System shall be furnished for continuous monitoring and control of water and steam purity in the plant cycle of each unit and at other important points as specified in this specification. The SWAS System and Analytical lab may preferably be located on the 0 M floor in TG building. The sampling system shall obtain samples from steam and water system, which shall be adequately conditioned and fed to analyzers for continuous analysis and provide parallel facility for grab sampling as specified. The analyzer outputs from SWAS shall be used for providing i) Continuous monitoring of various parameters using SWAS OS as specified herein with additional isolated analog outputs of 4-20mA, DC for each parameter for monitoring in plant monitoring system i.e DDCMIS. Alarm for all significant parameters measurements which exceed their permissible limits including those of sample conditioning system, with repeat facility in the Central Control Room in the form of potential free contacts and for hooking up to plant monitoring system.

5.01.00

b)

ii)

This will enable the plant chemist and operators either to make adjustments in the water and steam conditioning system or to modify plant-operating procedure so as to minimize equipment damage due to corrosion, scaling etc. c) The Bidder shall furnish all analyzers/monitors including sample conditioning components and other devices as specified in the sample stream detail table. The bidder shall furnish all required accessories for completeness of the analyzers furnished by him even though this may not be specifically stated in other clauses of this specification. The system shall be furnished complete with sample conditioning devices and monitoring instruments (for temperature, pressure, flow & sample), analyzers, transmitters, indicators, alarm initiating devices, interlocks, isolated 4-20 mA DC for plant monitoring system and all required accessories to provide a complete and integrated sampling and analysis system as per the intent and requirements of this specification. Sample line diagrams shall be used to implement the design at system level that shall be subject to Owner approval. All necessary piping, tubing, fittings and valves etc. shall be furnished.

d)

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The system shall be designed in accordance with the recommendations in ASME PTC 19.11 Part II, Water and Steam in Power Cycle, ASTM standards - 31 water and ASTM D1066-69 standard method of sampling steam. The Bidder shall be fully responsible on system basis, for proper engineering, selection of hardware, manufacture, testing, installation, commissioning and satisfactory functioning of complete and fully operational steam and water analysis system, meeting the intent of this specification. All system components and accessories required for completeness of this system shall be furnished by the Bidder although these may not be individually specified herein. The equipment shall be constructed to operate accurately and safely under the operating conditions described or implied in this specification, without undue heating, vibration, wear, corrosion or other operating troubles. All parts subject to high pressure or temperature or other severe duty shall be of materials suitable for the service. All piping, tubing, fittings, valves, filters and other wetted parts in the sampling and analyzing system shall be of type 316 stainless steel or other suitable material for the service approved by the Owner. No plastics or rubber shall be permitted except within analyzers as furnished by the manufacturer. All SWAS system components and accessories shall be from the latest proven product range of qualified manufacturers. The SWAS components and accessories shall be of specified makes and models or other owner approved makes and models, fully meeting the qualifying requirements. i) To ensure operation under adverse conditions the equipments mounted outside the Sampling and Analysis Room shall be designed for outdoor conditions. Sample room located instruments and electronic hardware will be required to operate normally in an air-conditioned area.

f)

g)

h)

i)

j)

ii)

However, they shall also be able to operate indefinitely with ambient room temperature between + 5 deg. C to + 55 deg. C and relative humidity upto 95%, during air conditioning failure. k) One WORK STATIONS-based operator station with A4 sized B&W LaserJet printer for water chemistry parameters as a part of performance calculations & optimization package (Hooked up to the DDC MIS through redundant OPC, MODBUS or DDCMIS TCP/IP network etc) and one no. SWAS OWS shall be kept in SWAS/Chemical Express lab room as specified in chapter 4. Specification for WORK STATIONS and printer shall be same as specified else where in the specification. All the analysers should work with sample temperature of 40-45 deg.C chilled water requirement. Alarm Annunciation: with out

l) m)

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HW Alarm annunciator shall have adequate/required points (80 or more which shall be finalized during detailed engineering. 5.02.00 Sample Conditioning System a) i) General Sample conditioning system shall be designed and constructed to receive and condition all samples (listed in the enclosed Sample Stream Specification) as required by the respective analyzers connected to the sample streams. This will include all conditioning as specified herein and shall cover the following: ii) Sample filtering Primary and final sample cooling and temperature control Pressure reduction and control as required Flow rate control Pressure & Temperature protection Other treatment as required by individual analyzers or specified herein.

The sample conditioning system shall provide samples at 25C or a preset temperature required by the analyzer within tolerance of + 1C, at a pressure of about 2 kg/cm2 and at flow rates as required by individual analyzers/streams. Sample line to analyzer elements shall incorporate an anti-syphon design to prevent possibility of running dry because of a broken or plugged sample line. Sample conditioning system shall be designed and constructed to fully meet the intent and requirements of this specification. Suitable arrangement shall be made by the bidder to condition the sample by way of providing chiller and isothermal bath.

iii)

iv)

v)

The cooling/chilled water header shall be provided with pressure gauge, temperature gauge and flow switch and isolating valves. Provision shall be made for heat exchanger shell drain which will be connected to drain header. Potential free contact shall be provided for annunciating loss of cooling/chilled water. Sample Filters Sample particulars removal shall be accomplished by passing all sample through cartridge filters with type sintered 316 stainless steel body. Removable type filter element shall be capable of retaining particles of 40 micron and larger. These elements shall be installed downstream of solenoid operated sample shut of valves at each branch of analyser sample stream.

vi)

b)

c)

Sample Cooler

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All samples having a temperature in excess of 45C shall be cooled by use of sample cooler. The sample cooler shall use DMCW water (softened water) as cooling water. This cooling water is tapped from DMCW water system whose temperature may vary from 20C to 40C. A maximum cooling water temperature of 40C shall be considered for design of sample cooling system. Capacity of cooler shall be adequate to cool the sample within 5C of cooling water inlet temperature considering the combined flow of each analyzer connected to sample cooler and one manual grab sample at flow rate of 500 cc per minute assuming adequate flowing factor. Cooler capacity calculations shall be submitted by bidder. Provision shall be made for adjusting the temp. of each sample individually at an optimum value. Sample cooler shall be of submerged Helical coil type of shell and tube design with removable shell. The sample tube shall be of seamless with no welds and other joint inside the cooling jacket. Unions shall be provided to facilitate removal of coils. All sample tubing and fittings, other components shall be constructed of type 316 stainless steel. Cooler design shall conform to requirements of ASTM D1192-64 (Equipment for sampling industrial water and steam). IBR certificate is required wherever applicable. The shell relief valve shall be built in type. d) Isothermal Bath In isothermal bath each sample stream shall be finally cooled to the required temperature as specified by the analyzer manufacturer and as approved during engineering within a variation +1 Deg. C before passing sample to the respective measuring cells. This shall be accomplished in isothermal bath by counter current heat exchange of each sample against the flow of chilled water at 20 Deg. C. The chilled water for isothermal bath shall be provided by package refrigeration unit (chillers). Sufficient heat exchange capacity shall be provided to obtain the required temperature at sample outlet for maximum flow rate required by the analyzers and grab samples requirements considering adequate fouling factor at both ends of the coils. Capacity calculations shall be furnished. Provision shall be made of adjusting each sample temperature individually. Temperature control shall be provided to maintain the isothermal bath temperature at the required value. Temperature control system shall be provided to maintain the isothermal bath temperature at the required value as mentioned below:i. A Temperature control system shall maintain the isothermal bath temperature at 20 drg C + 1 deg C and sufficient heat exchanger capacity shall be provded to maintain the temperature of all sample stream at 25

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ii.

iii.

deg C + 1 deg C under all operating conditions with adequate margin for future expansion. Isothermal bath temperature shall be maintained by a local Temperature controller modulating a three way mixing valve, which mix the chilled water from the chiller with the recirculed water from the isothermal bath. The chilled water isothermal bath shall include the following: Automatic water makeup Bath Temperature Gauge Bath water level Gauge Drain and overflow connection for bath Chilled water Recirculation System

iv.

Temperature Switch shall be provided to annunciate high chilled water Temperature on the Dry panel and in DDCMIS.

e)

Chiller Two (2) 100% capacity water cooled chillers shall be provided for the SWAS package. Each chiller unit shall be designed with sufficient refrigeration capacity to ensure each sample stream temperature to 25 deg. C 1 deg. C when all streams are simultaneously at maximum flow rate and maximum temperature. The chiller capacity shall have a provision of 25% spare capacity for future samples. Suitable temperature monitoring and control systems shall be provided for maintaining the chilled water temperature at chiller outlet at 20 deg. C or at a designed preset value and within the desired band. The compressor shall be readily accessible for service and shall include low noise hermetically sealed motors. Compressor assembly shall also include crank case heaters, suction and discharge valves, oil sight glasses, forced feed lubrication system and an integrated motor protection system alongwith the necessary instruments. The condenser shall be water cooled, cleanable shell and tube with water regulating valve. The cooling water shall be supplied from closed cooling water system. Chiller shall be of the direct expansion type with refrigerant tubes inside a shell, completely insulated and to be constructed in accordance with the ASME code for unfired pressure vessels. Refrigerant circuit shall be complete with a thermostatic expansion valve, liquid line solenoid valve, sight glasses, filter-dryer, refrigerant shut-off and charging valves. 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. Vibration dampeners shall be mounted between the packaged chiller and the channel base.

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DM Cooling water and chilled water piping shall be provided with block valves. The Bidder shall provide detailed calculation for chiller capacity and other technical particulars like foundation details/mounting etc. and the same shall be subject to Owner's approval. The chiller system shall be provided with 100% redundant chilled water pumps with suction and discharge pressure gauges and temperature gauges; Chilled water circulation pump with 100% standby facility; Storage tank automatic water make up with manual by-pass facility, temperature indicator, level gauge and drain and overflow connection, in addition to any other instruments/equipments required for smooth, convenient operation of the system, which shall also be furnished by the Bidder. f) Sample Pressure Conditioning The pressure reduction of samples shall be accomplished by using high pressure reducing element. All samples after high pressure reducing element shall be provided with back pressure regulating valves. Each sample line shall include a safety relief valve down stream of the control valve. For samples with pressure less than 2 kg/cm2, suitable field mounted pumps shall be provided by bidder as part of the sampling system. g) High Pressure reducing element Pressure reduction of samples shall be accomplished by means of a variable rodin-tube capillary capable of discharging low flow at low pressure into a sample stream as per requirement of analyzers. These pressures reducing element shall be conveniently located for removal and cleaning. h) Pressure regulating valves The pressure regulating valves shall be furnished for all samples to maintain constant sample flow at a pre-set sample pressure. Variation in sample flow to individual analyzer shall not exceed 5% when total sample flow is increased or decreased due to change in number of individual analyzers utilizing a particular sample. Valve shall be back pressure regulating type. i) Sample system thermal shutoff valve, temperature switches, pressure gauge, Flow switches and flow indicator The temperature gauge shall be 100 mm size, gas filled type thermometer with SS armoured capillary of suitable length required for installation in wet panel. It shall include contacts of adequate current rating. The contacts shall be multiplied by a relay and relay contacts to be used for alarm. Thermal shut-off valve shall be provided for shut down of high temp. sample and to protect the analysers.

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The pressure gauge shall be 100 mm dial size. Sample rate of flow indicator shall be purge type meter with 75 mm scale length, panel mounting bezel and SS float body. Flow switches shall be provided on the primary cooling water outlet and on the chilled water outlet as indicated in the drawings for SWAS. Accuracy/repeatability shall be 2 %. Make & model of flow switches shall be of Owners approved one. Temperature switches shall be provided on the sample lines as indicated in the drawings for SWAS. All switches shall be repeatable within 1.0% of full scale range. j) Grab samples Grab sample valves shall be arranged to allow grab sample flow to be directed to either a drain header or through a grab sample nozzles to samples trough. Enough flexible tubing shall be furnished to allow sample collection without splashing. k) Sample table All steam and water analyzers should be installed in a room. This arrangement would help better maintenance and better control of water chemistry. For measurement of conductivity of condensate water in the hotwell, direct mounting type conductivity cells shall be used. For all measurements other than conductivity of condensate water in hot well, sample shall be brought to the sample table, where sample shall be cooled and their pressure reduced and flow regulated before being led to the respective sensors for analysis of different parameters. For make up DM water sample stream, sample extraction pump shall be provided. The core of sampling system is the high pressure sample cooler. One or two high pressure shut off valve depending upon sample inlet pressure shall be provided in the sampling line at the inlet of the cooler. Another high pressure shut off valve for blowing down the sampling line shall be connected before sampling line shut off valves. An indicator shall be provided to measure the temperature of a sample after cooler. One signaling contact for alarm and protection (to operate solenoid valves) at high temperature shall be provided in this temperature gauge. The required contact multiplication shall be done through relays mounted inside the analyzer panel by bidder. This measurement point is to be followed by high pressure reducing element, pressure reducing valve, safety shut off valve and safety relief valve, pressure gauge and multi valve manifold. The multi valve manifold and fittings are liable to be subjected to high pressure in the line when the valves are closed. Thus the pressure rating of these valves and all associated fitting should be same as that of the root valve in the corresponding sample line. This multi valve manifold should have separate outlets leading to individual analyzers. The flow of sample to individual analyzers should be indicated by a flow meter. The flow, temperature and pressure indicators and needle valves should be mounted on the front of vertical portion of sample table for ease of operation as well as for proper layout.

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Two numbers of cation exchange columns (one working and one standby) should be provided with manual switching for each cation conductivity measurements. Bidder shall provide all equipment necessary for bringing cooling water to sample table from one common point of cooling water supply line. Flow switch shall be provided for signaling loss of cooling water flow at each cooler outlet. During collection of grab samples, flow of sample to analyzers shall not be affected. 5.03.00 Steam and Water Analysis System (SWAS) Panels a) Design Consideration for SWAS Panel and Accessories The SWAS Panels shall have two sections namely sample conditioning section and analyzer section . The first section shall be the wet section of SWAS panels which shall be called as the "Sample Table". The second section shall be the dry section housing the analytical transmitters, signal conditioning devices and other requisite accessories. All monitoring instruments and controls for sampling system shall be located on the front panel and shall be grouped accordingly to function in a logical and orderly fashion. There shall be a general progression of flow from top-to-bottom and left-to-right to minimize sample line length, purge times and material exposed to sample. Similarly, the conditioning components for each stream shall be grouped together wherever possible. Indicating instruments such as pressure, temperature and flow shall be arranged in a vertical line directly above the grab sample valve. Sufficient clearance shall be maintained between instruments banks of adjacent sample points so that there is no confusion in reading these instruments. b) Ease of Maintenance Sample conditioning, analyzer, panels shall be designed for ready access of components. Panel design shall ensure that:i) Parts subject to wear, corrosion or other deteriorations or requiring adjustments, inspection or repair are readily accessible and capable of convenient removal, when required. Individual components or groups of components mounted on sub-panels can be removed for replacement or repair without the need of prior removal of components of other healthy streams. Flow meters, pressure gauges and temperature indicators can be removed for repair or replacement from the front of the panel without disturbing any piping.

ii)

iii)

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Filter elements and pressure reducing elements can be easily disassembled for periodic cleaning.

The general arrangement drawings of panels as well as location and spacing of all instruments and equipment shall be subject to Owner approval. SWAS panels shall be designed based on human engineering considerations fully keeping in view the convenience of operation and maintenance personnel. Each sample inlet shall be provided with bulkhead type tubing connection and an isolation valve or block valve suitable for sample operating conditions. A blowdown connection and suitable blow down valve shall be furnished upstream of each isolating valve. Blow down valves shall be manifolded into a suitable blow down header. Strainers, filters, relief valves etc. shall be provided as specified and as required to properly protect the coolers, valves, analyzer elements etc. All drains shall be piped into two separate drain headers. One header shall be called "Waste Drain Header" and will receive all drains which contain substances not wanted in the plant heat cycle water. The other header shall be called "recoverable drain header" and will receive all other drains not containing unwanted substances. All drains shall be headered as indicated above. Vendor shall pipe the waste drain header to the building drain system. c) Constructional Features The SWAS panel (wet panel) shall be constructed of 3 mm thick steel plates except for the extreme top of the Sample Table and Analyzer Panel (Dry Panel) which shall be of 2 mm sheet steel. The counter top, sample sink and front section above the counter top shall be 2.5 mm type 316 stainless steel. The sample table shall be of free standing, totally enclosed panel whereas the Dry Panel shall be of free standing, totally enclosed construction with back doors. General constructional features described in chapter -6, Vol V of this specification shall apply. All SWAS panels shall be furnished with 100 mm base angle for bolting to 100 mm high concrete curb. The foundation details shall be as approved by the Owner during detailed engineering. Panel sections shall be reinforced to ensure true surfaces and adequate support for instruments and equipment. All equipment and piping shall be firmly anchored and supported from within the respective panel section to ensure vibration free operation. Doors and equipment arrangement shall be such that all items are readily accessible for maintenance and repair. The arrangement and spacing of the equipment shall be acceptable to the Owner.

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Doors shall have concealed type hinges and three point type latches to assure tight closing. Doors shall have turned back edges and additional bracing where required to assure rigidity. The SWAS panels and equipment shall be suitably braced to prevent damage during shipping and handling. These additional supports shall be removed after final installation. Exterior joints shall be continuous seam welded and ground smooth. Interior joints shall be neatly finished in a manner so as to eliminate hazards to personnel. All surfaces shall be free from waves, bellies, or other imperfections. All stainless steel surfaces shall have uniform finish. All exterior steel surfaces shall be sand blasted, ground smooth, filled, primed, sanded and finished with a smooth backed enamel. The final color shall be as specified in chapter 6. d) One teak wood laminated work tables 1x2 meters, two nos. industrial grade high adjustable wheeled swivel chairs, two vertical cabinets 1000 x 480 x 2000 mm made of sheet steel (18 gauge sheet thickness) and equipped with safety locks, one shelf 200 x 500 x 200 mm with partitions made of steel, Operating work station table & printer table shall also be provided by bidder. Thickness of steel almirah/cabinet sheet shall be 18 gauges. All items shall be placed in SWAS air conditioned room. SWAS panels shall be placed in separate SWAS room, SWAS room shall be divided in two part i.e one part shall be air conditioned for SWAS dry panel & Chemist and other part non air conditioned for wet pael & chiller unit. Necessary exhaust fans with louvers shall be provided by bidder in SWAS wet panel room.

e)

5.04.00

Piping, Tubing and Accessories a) All internal piping, tubing and system components required for making the system complete shall be shop installed and tested as per applicable codes, prior to shipment to project site. All tubing and wiring shall be located behind the face of the panel with projections allowed only for indicator faces, valve handles, manual grab sample lines etc. The physical arrangement of the tubing and wiring shall, in all cases, be so as to permit easy access for maintenance of all items of equipments. All piping and tubing materials, fabrication, erection and application of piping materials shall be in accordance with the latest applicable requirements of the code for pressure piping (ANSI B 31.1,B36.19) and all other applicable regulations. Unless otherwise specified, fittings used with pipe 50 mm and smaller shall be socket welding type, and fittings used with larger pipe shall be butt-welding type. All fittings shall be constructed of materials equivalent to the pipe with which they are used.

b)

c)

d)

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DESEIN e)

Vol-V : Instrumentation & Control Works

All piping and tubing shall be neatly installed and securely braced to ensure adequate mechanical rigidity. Routing and support of tubing shall be such that expansion and contraction of tubing or equipment mounted in the sample table do not impose any excessive stress on the tubing. Special tools shall be used for all bending and forming operations. Bends in tubing shall be based on the requirements of the Code for Pressure Piping (ANSI B 31.1), concerning tube thinning at the bends. Tubing shall be carefully handled to avoid flat spots, kinks and short bends. Any tubing so damaged shall not be used in this sample table. All piping and tubing shall be blown with oil free compressed air after installation and before attachment to equipment at either end. All piping and tubing terminal connections shall be suitably capped after completion of installation and tests to prevent entry of foreign materials during transit, storage etc. All piping and tubing shall be installed so as to ensure easy accessibility for any maintenance or repair that may be required. High density tubing runs shall not interfere with accessibility to any system component and shall not impair system function. All sample piping shall be three fourth inch NB seamless type of material ASTM A213 TP316H, conforming to ANSI 36.19. All fitting shall be socket welding type and of material ASTMA 182 F316H conforming to ANSI B16.11. All process connection, piping, valves etc. of SWAS analysers shall be conform to ANSI/ISA SP 77.70 1994 (R 2005) Fossil Fuel Power Plant Instrument piping Installation, ANSI B 31.1 Power Piping, PTC 19.11.1997 & IBR.

f)

g)

h)

i)

j)

k)

l)

5.05.00

Material Specifications for Pipe Lines The piping to be furnished and installed for water and steam analysis system shall be as indicated below:Piping System a) Piping from the sample inlet bulk-head fittings the shut-off valve for low pressure samples Piping from the sample inlet bulk-head fittings to the pressure reducing valves for high pressure samples and sample blowdown piping Material Stainless Steel, ASTM A-213 Type 316, 16 BWG tubing

b)

Stainless Steel, ASTM A-213 Type 316H, 14 BWG tubing

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DESEIN Piping System c) d) e) Blowdown header Miscellaneous drains receiver header Piping from the shut-off valves for low pressure samples and from the pressure reducing valves for high pressure samples to the terminal points including branch piping and the closed cooling water grab sample piping Closed cooling water piping except grab sample Sample through drain piping and waste header piping

Vol-V : Instrumentation & Control Works

Material Stainless Steel, ASTM A-312 Type 316, Sch. 160 Stainless Steel, ASTM A-312 Type 316, 16 BWG tubing Stainless Steel, ASTM A-312 Type 316, 16 BWG tubing

f) g) 5.06.00

Stainless Steel, ASTM A-312 Type 316, Sch. 40 Carbon Steel, ASTM A-53 Gr. A, Sch. 40

Valves and Fittings All valves & fittings shall be furnished as required. All other valves and fittings required for making the system complete as per the intent of this specification shall also be furnished by the Bidder. The make, model and technical features of all valves furnished by the Bidder shall be subject to Owner's approval. All fitting shall be socket welding type and of material ASTMA 182 F316H conforming to ANSI B16.11.

5.07.00

Wiring All control and instrumentation wiring used within the SWAS panel sections shall conform to NEC and NEMA standards. All measurement and control circuits shall be factory wired and tested by energizing at operating voltage. All electric connections shall be made between devices within the SWAS panel sections and shall be made to suitable terminal blocks, if devices are to be connected to equipment outside the SWAS panel. All electrical connections shall enter and leave through the top or bottom of the panels as indicated during detailed engineering. High impedance circuits shall be connected using shielded or co-axial wire suitable for the service. Terminals shall be furnished for termination of shield. Wiring in the sampling section shall be routed in covered metallic trays located as distant as is practicable from sampling lines and drains with due care taken to isolate electric wiring, termination etc. from liquid areas.

5.08.00

POWER SUPPLY

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DESEIN

Vol-V : Instrumentation & Control Works

Power supply to all instruments and control systems shall be separately fused with MCB and it should be possible to disconnect any instrument without interrupting power supply to any other equipment/device. UPS shall provide power supply to the complete SWAS system. 5.09.00 LIGHTING AND RECEPTACLES Sample table and analyzer section shall be provided with rapid start, low noise, fluorescent strip fixtures installed in a continuous row along the top of each section. The panel shall have a ceiling mounted LED lamps for illumination. Light switches shall be provided within the panel sections at suitable locations. Universal type Three receptacles shall be provided on the front of the sample table below the work surface. These will be equally spaced. Two more receptacles shall be provided inside the sample table and one receptacle shall be installed inside the panel. Wiring for lighting and receptacles shall be run in flexible metallic conduits. 5.10.00 GROUNDING One earthing terminal with accessories shall be provided at each end of strip for connecting G.I. earthing strip of 50 x 6 mm size. 5.11.00 Technical Specifications of Conductivity Analyser a) b) Applicable standard Type: i) Cell ii) Monitors ASME PTC 19.11-1970 except as modified in this specification. Flow through type/ removable type (withdraw able with sealing valve) Electronic (Microprocessor based) indicating type with multi range facility

c)

Material : i) Cell ii) Electrode iii) Monitors body Monitor output

Epoxy resin/SS316 Platinised/SS316 Carbon steel/Aluminum/Polycarbonate i) ii) 4-20 mA D.C. with HART protocol spare out put 4-20mA DC with HART protocol for DDCMIS Output load : 500

d)

e) f) g) h)

Power supply Accuracy Stability Repeatability

240V, AC, 50 Hz from UPS + 1% of full scale span + 1% of full scale per month non-cumulative + 0.3% of span

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DESEIN i) Annunciation contacts from monitors i) Number ii) Type iii) Rating Connection: i) Cell

Vol-V : Instrumentation & Control Works

2SPDT Snap action micro switch 5 amp, 240 V, 0.2 Amp, 220V DC

j)

ii) k) l)

Monitors

On line/pipe mounted (ON LINE in sample table) 1/4 (Quarter) inch NPT (F) SCRD for on-line type and Three quarter (3/4) inch NPT (M) SCRD for pipe mounted. flush panel mounting Half (1/2) inch NPT (F) SCRD i) Automatic temperature compensation in the range 0-100C ii)Ammonia (NH3) removal equipment. iii) Sample coolers iv) Flow and pressure regulators v) SS316 impulse tubing and fittings vi) Isolation & drain valves as required vii)Other accessories as required viii)Adequate length of cables for connecting coils to monitors ix) Sample rate set valves x) Alarm settings and Alarm indications on monitor. Cell shall be suitable for maximum pressure of 7 kg/cm2 and maximum temp. of 100C < 3 seconds

Electrical Accessories

m) n) 5.11.01

Other particulars Response time

CONDUCTIVITY COMPARATOR Applicable Standard Type of cells : : ASME PTC 19-11-1970 except as modified this specification Flow through type / removable type with draw able with sealing valve) Electronic (Micro processor based) indicating type with multi range facility pipe mounted. SS316 Platinised/SS316 4 to 20mA DC isolated with HART output

Transmitter

Material of Cell body Material of cell Electrode Output

: : :

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DESEIN Power Supply Accuracy Stability Repeatability Protection class Process connection : : : : : :

Vol-V : Instrumentation & Control Works

240V AC, 50 Hz. From UPS +/-1% of full scale span. +1% of full scale per month non-cumulative +/-1% of span IP - 65 inch NPT (F) / SCRD for on line type. inch NPT (M) SCRD for pipe mounted inch NPT (F) SCRD

Electrical connection Accessories 5.12.00 :

Automatic temp. Compensation in the range of 0-100 Deg.C

Technical Specification of pH Cell and Transmitters a) b) Applicable Standard Type: i) Cell Measuring and Reference Electrode Combination with Flow through type (SS316/Polypropylene flow chambers) for power plants steam & water application. Sensor shall not be affected by flow variation. Sensor shall be designed for power plant applications. Electronic (microprocessor based) indicating type with adjustable range facility. pH electrodes shall conform to IS: 6804-1972 except as modified in this specification

ii) c)

Monitors

Material: i) ii) iii) Measuring & reference Electrode Monitor body i) ii) Toughened sensitive pH glass Carbon steel/Aluminum/Polycarbonate 4-20 mAmp D.C. with HART protocol spare out put 4-20mA DC with HART protocol for DDCMIS Output load : 500

d)

Monitor output

e) f) g) h) i)

Power supply Accuracy/repeatability Resolution Stability

240V AC, 50 Hz from UPS + 0.03 pH/+0.02PH + 0.01 pH or 1 mV. 1C 0.02 pH per week

Annunciation contacts from monitors:

2 x 660 MW ENNORE SEZ Supercritical Thermal Power Project at Ash Dyke of NCTPS Spec. No. CE/C/P&E/EE/E/OT.No.03/2013-14 Vol. V /Sheet - 238

DESEIN i) Number ii) Type iii) Rating Connection: i) ii) k) Process Electrical

Vol-V : Instrumentation & Control Works

2 SPDT 'Hi' and 'Lo' Snap action micro switch 5 amp, 240V AC, 0.2 Amp, 220V DC

j)

One-quarter (1/4)inch NPT(F) SCRD ON-LINE Half (1/2) inch NPT(F) SCRD

Mounting: i) ii) Cell Monitors Pipe Mounted Flush panel mounting i) Automatic temperature compensation with fast response integral temperature sensors in the range 0-100C Co-axial cable as required Sample coolers low and pressure regulators Standard pH solutions SS316 impulse tubing and fittings Isolation & drain valves as required Electrode holders Other accessories as required Sample rate set valves Alarm settings and indications on monitor. RFI/EMI shielded, weather and corrosion proof casing

l)

Accessories

ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) 5.13.00

Technical Specification of Dissolved Oxygen Analyser a) Applicable Standards ASTM PTC 19.11-1970 except as modified in this specification Microprocessor based Electro-chemical Die-cast aluminum/SS/Polycarbonate i) ii) 4-20 mAmp DC spare output 4-20 m Amp, DC Isolated output DCS.

b) c) d)

Type Material Output

for

e) f) g)

Supply Accuracy Response: i) Sensitivity ii) Time (sensor) Connection:

240V AC, 50 Hz from UPS + 5 % of reading

+ Two (2) per cent overall Less than 30 seconds for 90% step change.

h)

2 x 660 MW ENNORE SEZ Supercritical Thermal Power Project at Ash Dyke of NCTPS Spec. No. CE/C/P&E/EE/E/OT.No.03/2013-14 Vol. V /Sheet - 239

DESEIN i) ii) i) Process Electrical

Vol-V : Instrumentation & Control Works

One quarter (1/4) inch NPT(F) SCRD Half (1/2) inch NPT (F) SCRD i) Sample cooler assembly with shut off valve at cooling water inlet, with thermometer and reducing valve at sample outlet. Flow stabilizer Automatic temperature compensation Other accessories as required Calibration device.

Accessories

ii) iii) iv) v) j) k) l) Ranges Mounting Annunciation contacts: i) Number ii) Type iii) Rating

As per sample stream detail table Flush 2 SPDT Snap action microswitch 5 Amp 240V AC, 0.2 amp 220V DC

5.14.00

Technical Specification of Silica Analyzer (SI OX) a) Applicable standard ASME PTC 19.11-197 except as modified in this specification Multi Channel ( max of each Three channel) Colorimetric Analyzer (with auto reagent shut off feature in case of sample loss or power loss) built in phosphate inhibition feature. Micro processor based.

b)

Type

c)

Material: i) Case Cycle/Response Time Analyser output Die cast aluminum Twelve (12) minutes Maximum i) ii) 4 to 20 m Amp DC for spare output 4 to 20 m Amp DC Isolated output for DCS/PLC

d) e)

f) g) h) i) j)

Power supply Accuracy Repeatability Sensitivity Connection: i) ii) Process Electrical

240V AC, 50 Hz from UPS + 1% of span + 2% of full scale 0.2 micrograms/liter

Quarter (1/4) inch NPT(F) SCRD Half (1/2) inch NPT (F) SCRD As per sample stream detail table

k)

Ranges

2 x 660 MW ENNORE SEZ Supercritical Thermal Power Project at Ash Dyke of NCTPS Spec. No. CE/C/P&E/EE/E/OT.No.03/2013-14 Vol. V /Sheet - 240

DESEIN l) m) Mounting Annunciation contacts: i) ii) iii) n) Number Type Rating Flush

Vol-V : Instrumentation & Control Works

2 SPDT Snap action micro switch 5 amp 240V AC 0.2 Amp 220V DC i) ii) iii) iv) v) vi) vii) Automatic temperature compensation between 5 to 50 deg C Automatic zeroing provision SS316 tubing & vessels All chemical reagents for 12 months operation of the analyzer Sample rate set values Comprehensive diagnostic and alarm features. Auto sampling facility with necessary valves & solenoids in the sample lines shall be provided.

Accessories

5.15.00

Technical Specification of Hydrazine Analyzer i) ii) iii) Type Case material Analyzer output Microprocessor based Electrochemical Die-cast aluminum/SS/Polycarbonate i) ii) 4-20 mA DC for spare output 4-20 mA DC isolated output for DDCMIS

iv) v) vi) vii) viii)

Power supply Accuracy Response Time Sensitivity Annunciation contacts: Number Type Rating Mounting

240V AC, 50 Hz from UPS +2% of full scale <4 minutes. 1.0 microgram/liter

2 SPDT Snap action micro switch 5A 240V AC, 0.2 A, 220V DC Flush mounting i) ii) iii) iv) v) Flow regulator Flow gauges Other accessories as required Sample rate set valves Chemical reagents as applicable for 12 months consumption

ix)

Accessories

5.16.00

Technical Specification of Sodium Ion Analyzer i) Type Microprocessor based Continuous flow through sample type with sodium responsive

2 x 660 MW ENNORE SEZ Supercritical Thermal Power Project at Ash Dyke of NCTPS Spec. No. CE/C/P&E/EE/E/OT.No.03/2013-14 Vol. V /Sheet - 241

DESEIN

Vol-V : Instrumentation & Control Works

electrode and reference electrode having pH adjustment facility (Max 3 streams) ii) iii) iv) v) vi) vii) viii) Case material Analyzer power supply Analyzer output Accuracy Response Time Sensitivity Annunciation contacts: ix) Number Type Rating Mounting Die-cast aluminum/SS/Polycarbonate 240V AC, 50 Hz from UPS i) 4-20 mA DC for spare output ii) 4-20 mA DC isolated output for DDCMIS Better than + 5% of full scale 6 minutes. max 0.1 ppb

2 SPDT Snap action microswitch 5A 240V AC, 0.2A, 220V DC Flush All components piped & wired to terminal points i) ii) iii) iv) v) Flow regulator Flow gauges Sample rate set valves Other accessories as required to make the system complete Chemical reagents as applicable for 12 months consumption

Terminal points

x)

Accessories

5.17.00

Technical Specification of Phosphate Analyzer i) Type Microprocessor based Continuous flow through sample type with colorimetric detection system (Max 3 streams) Die-cast aluminum/SS/Polycarbonate 240V AC, 50 Hz from UPS i) 4-20 mA DC for spare output ii) 4-20 mA DC isolated output for DDCMIS Better than +4% of full scale Better than 1 ppm

ii) iii) iv)

Case material Analyzer power supply Analyzer output

v) vi) vii)

Accuracy Sensitivity Annunciation contacts: Number Type Rating Mounting

2 SPDT Snap action micro switch 5A 240V AC, 0.2A, 220V DC Flush All components piped & wired to terminal points i) Flow regulator

viii) ix)

Terminal points Accessories

2 x 660 MW ENNORE SEZ Supercritical Thermal Power Project at Ash Dyke of NCTPS Spec. No. CE/C/P&E/EE/E/OT.No.03/2013-14 Vol. V /Sheet - 242

DESEIN ii) iii) iv) v) 5.18.00

Vol-V : Instrumentation & Control Works

Flow gauges Sample rate set valves Other accessories as required to make the system complete Chemical reagents as applicable for 12 months consumption

Technical Specification of Chloride Analyzer i) Type Microprocessor based Continuous flow through sample type. 240V AC, 50 Hz, Single Phase from UPS i) ii) 4-20 mA, DC spare output 4-20 mA, DC isolated output for DDCMIS

ii) iii)

Analyzer power supply Analyzer output

iv) v) vi) vii)

Accuracy Sensitivity Range Annunciation contacts: Number Type Rating Mounting Terminal points Accessories

Better than +10 % of full scale Better than 1 ppm As per Requirements.

viii) ix)

As per schedule, 2 SPDT Snap action micro switch 5A, 240V AC, 0.2A, 220V DC Flush All components piped & wired to terminal points i) ii) iii) iv) Flow regulator Flow gauges Sample rate set valves Other accessories as required to make the system complete

5.19.00

Technical Specification of Chlorine Analyzer i) Type Microprocessor based Continuous flow through sample type with automatic temperature compensation. 240V AC, 50 Hz, Single Phase from UPS i) 4-20 mA, DC spare output ii) 4-20 mA, DC isolated output for DDCMIS 0.005 mg/ltr. or 1% of range. 0.001 mg/ltr. (1 ppb) As per schedule.

ii) iii)

Analyzer power supply Analyzer output

iv) v) vi) vii)

Accuracy Sensitivity Range Annunciation contacts: Number

As per schedule, 2 SPDT

2 x 660 MW ENNORE SEZ Supercritical Thermal Power Project at Ash Dyke of NCTPS Spec. No. CE/C/P&E/EE/E/OT.No.03/2013-14 Vol. V /Sheet - 243

DESEIN viii) ix) Type Rating Mounting

Vol-V : Instrumentation & Control Works

Snap action micro switch 5A, 240V AC, 0.2A, 220V DC Flush All components piped & wired to terminal points i) ii) iii) iv) Flow regulator Flow gauges Sample rate set valves Other accessories as required to make the system complete

Terminal points Accessories

5.20.00

Technical Specification of Residual Chlorine Analyser SENSOR Method Electrodes Cell Material Electrolyte TRANSMITTER Type Transmitter Output Enclosure Protection Enclosure Material Electrical Connection Mounting Display Type Display Details Diagnostics Meter Range Resolution Area Classification Electromagnetic Compatibility Temp. Compensator Temp. Compensating element : : : : : : : : : : : : : : : Microprocessor Based with self diagnostic features 4 20 mA IP65 Polyester coated Al. NPT (F) FIELD LCD 4 digit backlit LCD matrix Required 0-1 mg/l 0.01 ppm SAFE BUILT IN AUTO BUILT IN PT100 : : : : Amperometric Gold Cathode/Silver Anode PVC Potassium Bromide

5.21.00

Technical Specification of Turbidity Analyser SENSOR Reference type Operating principle Cleaning Electrode holder type Body Material Process Connection : : : : : : On Line Alternating Light Source Self Cleaning Flow Through CPVC NPT (F)

2 x 660 MW ENNORE SEZ Supercritical Thermal Power Project at Ash Dyke of NCTPS Spec. No. CE/C/P&E/EE/E/OT.No.03/2013-14 Vol. V /Sheet - 244

DESEIN Pre Amplifier TRANSMITTER Type Transmitter Output Enclosure Protection Enclosure material Electrical connection Local Indicator Accuracy Repeatability Temp. compensator Cable between transmitter & sensor 5.22.00 : : : : : : : : : : :

Vol-V : Instrumentation & Control Works

Built-In

Microprocessor Based 4-20 mA DC IP65 polycarbonate NPT (F) Provided (LCD Display) 0.2 NTU or 2% of reading 0.1% of span built-in To be provided

All analysers shall be supplied with chemicals/regents required for 12 months operation. Bidder shall also provide start up kits, buffer solution for pH and conductivity analyzer. The analyser supplier shall submit the preparation procedure / formula of the reagent to be used in analyser solution.

5.23.00

Technical Specification of Flue Gas Analyzers The following analyzers are envisaged:i) i) iii) Flue Gas Oxygen & CO analyzer for control and monitoring. Opacity analyzer for ESP (At each Path).refer the clause 16.1.3 for technical Specification. Each analyser shall be independent and shall not share power supply modules, processor etc. with other analyser.

5.24.00

General Specification of Flue Gas Oxygen Analyser a) Type Direct mounted Zirconia probe (In situ) Zirconia probe analyzer should have facility of "in situ" calibration as well as easy replacement of Zirconia cell. Zirconia cell protection shall be by providing ceramic filer at the end of probe. 316SS (1800 mm long) i) 4-20 mA DC HART for spare output ii) 4-20 m Amp, DC HART, Separate outputs for DDCMIS. 240V AC, 50 Hz from Plant UPS + 1 per cent of span (or) better inclusive of linearity, repeatability. + 0.5% of full scale As per Cl. No. 5.27.00. 90% of full scale Less than 3 seconds with test gases, with actual process 20 seconds.

b) c)

Probe Output

d) e) f) g) h) i)

Supply Accuracy Repeatability Ranges System response Connection:

2 x 660 MW ENNORE SEZ Supercritical Thermal Power Project at Ash Dyke of NCTPS Spec. No. CE/C/P&E/EE/E/OT.No.03/2013-14 Vol. V /Sheet - 245

DESEIN Probe Calibration

Vol-V : Instrumentation & Control Works

j)

k)

Diagnostic

l) m)

Drift Operating temperature range Process upto 800Deg.C Transmitter 50 Deg.C max. Prope 70 Deg.C Accessories i)

ANSI flanged Analyser shall be calibrated using standard test gases whilst the probe is installed in the flue gas. Analyser shall have built in auto calibration facility and comprehensive alarm facility. Diagnosis facility shall be available and Alarm for failure of heater, sensor voltage, failure of sensor, failure of thermo couple etc., to be initiated and given with necessary alarm contacts. + 2% full scale per month

n)

ii) iii)

iv)

v)

vi) vii)

viii)

ix) 5.25.00

Electronic unit housed in a rugged sheet steel enclosure (IP54) houses transmitting system, probe heater control circuit etc. Electronic unit shall be separate from the probe and not be head mounted. Calibration gas cylinder & accessories, reference air set, rotameters Shield (316 SS), special cables, electronic control panel and Provision of SS 316 stainless steel diffuser assembly of required thickness for the protection of Zirconia cell. Ownership certificate, pressure test certificate, explosion proof certificate for standard gas cylinders shall be given and these will be used for next filling up of standard gases. To validate the measurement, for mid range value i.e. 6% of O 2 with 94% N 2 , standard gas cylinder to be supplied for each analyzer.( % O 2 shall be decided depending on the supplier & method of calibration during detailed engineering. Moisture separator unit for reference air shall be installed for long life of Zirconia cell. Auto calibration system with necessary solenoid valves, SS316 tubing, connector, zero & span gas, air purge lines etc. Independent air lines with Isolation valves for left side & right side shall be drawn from main air header available in the Boiler area. Any other accessories as required.

Technical Specification of Flue Gas Carbon Monoxide The proposed CO Analyzer should be on-line type, non-sampling device and it displays the combustion condition instantaneously. The on-line type CO monitor shall be provided

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DESEIN

Vol-V : Instrumentation & Control Works

for both indication as well as control of combustion in a boiler to increase the combustion efficiency and optimization. The instruments shall be designed to measure carbonmonoxide concentration in flue gas of boiler burning coal with varying degree of excess air. i. On-line and automatic normalization shall be through inbuilt measurement of CO2, H2O, Pressure and Temp. All these measurements shall be done on line in the analyzer. Calibration and zero adjustment shall be online and automatic. Span verification shall be online and automatic. For Validation: 2 nos. of standard check cell with different ppms are to be supplied for each analyzer.

ii. iii. iv.

General Specification of CO Monitor: a) b) c) Type Principle Output Direct mounted on-line non-sampling device Infra-red absorption i) 4-20 mA, DC spare output ii) 4-20 mA, DC Isolated, separate outputs for DDCMIS 240 V AC, 50 Hz from Plant UPS +3% of Reading/+2% of reading Less than 5 sec. up to 90% of full scale As per sample stream table . Built in automatic calibrating mechanism zero and span check facility. i) Infra-red source ii) Receiver unit complete with electronic unit iii) Any other accessories as required Dual redundant instrument air lines of 1/ 2 " size with sufficient isolation valves & drains shall be laid by bidder nearer to these instruments located in chimney so as to avail the purge air facility. IP 66 + 2% per month

d) e) f) g) h) i)

Supply Accuracy/Repeatability Response time Range Calibration Accessories

j)

Air Purge System

k) l)

Protection Drift

2 x 660 MW ENNORE SEZ Supercritical Thermal Power Project at Ash Dyke of NCTPS Spec. No. CE/C/P&E/EE/E/OT.No.03/2013-14 Vol. V /Sheet - 247

DESEIN 5.26.00 SWAS Sample Stream Details Table


Sample No. Sample Stream Type of Measure ment Range of Monitor/ Indicator

Vol-V : Instrumentation & Control Works

Alarm

1)

Make-up DM Water a) GRAB b) Conductivity 0-10 Micro (Specific & Cat ion) (Mho/cm) c) pH d) Silica Hot well both side a) Conductivity condensate (Insertion Type) Condensate Pump discharge a) GRAB b) pH c) Dissolved oxygen 6-14 pH 0-0.1 ppm 0-10 Micro mhos/cm 6-14 pH 0-20 ppb 0-200 ppb 0-1000 ppb

Yes

Output to SWAS OS Yes

O/P to Distributed Control System Yes

Yes Yes Yes

Yes Yes Yes

Yes Yes Yes

2)

3)

Yes Yes

Yes Yes

Yes Yes

d) Conductivity

0-10 Micro Yes mhos/cm 0-10 Micro mhos/cm 0-100 ppb 0 to 1000 ppb 0-10 ppb Yes Yes

Yes

Yes

e) Cation cond.

Yes

f)

Silica

Yes Yes

Yes Yes

g) Sodium ion

h) Chloride 4) Deaerator I/L a) GRAB

Yes -

Yes -

Yes -

5)

Common discharge Header Deaerator

b) Dissolved oxygen c) Silica d) pH a) GRAB

0-20 ppb 0-100 ppb

Yes Yes Yes -

Yes Yes Yes -

Yes Yes Yes -

0-100 ppb
0- 14 pH -

6)

Feedwater Economiser Inlet

b) Dissolved oxygen c) Sp. Conductivity d) pH a) GRAB b) pH

0-20 ppb 0-100 ppb 0- 14 pH 6-14 pH

Yes

Yes Yes Yes Yes

Yes Yes Yes Yes

0-1/ 10 S/cm Yes


Yes Yes

2 x 660 MW ENNORE SEZ Supercritical Thermal Power Project at Ash Dyke of NCTPS Spec. No. CE/C/P&E/EE/E/OT.No.03/2013-14 Vol. V /Sheet - 248

DESEIN
Sample No. Sample Stream Type of Measure ment Range of Monitor/ Indicator

Vol-V : Instrumentation & Control Works

Alarm

c) Conductivity 0-10 Micro Yes (Specific & Cat ion) mhos/cm d) Hydrazine 0-50 ppb 0-100 ppb 0-20ppb 0-50, 100 ppb Yes

Output to SWAS OS Yes

O/P to Distributed Control System Yes

Yes

Yes

7)

e) DO2 f) Turbidity g) Silica h) Ammonia Boiler Separator a) GRAB outlet steam at LTSH inlet

Yes Yes Yes Yes -

Yes Yes Yes Yes -

Yes Yes Yes Yes -

b) Conductivity 0-100 Micro Yes (Specific & mhos/cm Cation) c) Hydrazine 0-50 ppb Yes 0-100 ppb d) Silica Boiler saturated a) GRAB steam b) Conductivity (Specific & Cation) c) pH a) GRAB b) Conductivity 0-50, 100 ppb Yes -

Yes

Yes

Yes

Yes

8)

Yes Yes

Yes Yes

0-100 Micro Yes mhos/cm 6-14 pH Yes -

9)

Main steam

Yes Yes

Yes Yes

0-10/0-1 Micro Yes mhos/cm 0-1/0-2 Micro Yes mhos/cm 0 to 100 ppb 6-14 pH 0 to 1000 ppb 6-14 pH Yes Yes

c) After cation

Yes

Yes

d) Silica e) pH f) Sodium ion

Yes Yes

Yes Yes Yes

10)

HRH Steam

a) GRAB b) pH c) Sp. Conductivity

Yes

Yes Yes

Yes Yes

0-10 Micro Yes mhos/cm -

11)

Out let Condenser

of a) GRAB

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DESEIN
Sample No. Sample Stream Type of Measure ment Range of Monitor/ Indicator

Vol-V : Instrumentation & Control Works

Alarm

Output to SWAS OS Yes Yes Yes Yes

O/P to Distributed Control System Yes Yes Yes Yes

Polishing unit At O/L Header At O/L Header At O/L header At O/L header

b) pH c) Sp. Conductivity d) Silica e) Sodium ion

6-14 pH

Yes

0-10 Micro Yes mhos/cm 0-100 ppb Yes 0 to 10 ppb Yes

At O/L Header

12)

f)Cation conductivity At O/L Header g) Dissolved oxygen I/L & O/L of each h)Cation stream conductivity Condenser Cooling a) GRAB Water discharge b) Conductivity

0-1/10 Micro Yes mhos/cm 0-20 ppb Yes 0-100 ppb 0-1/10 Micro Yes mhos/cm 0-10 Micro (Mho/cm) 6-14 pH Bidder Specify 0-10 Micro (Mho/cm) 6-14 pH Yes

Yes Yes Yes Yes

Yes Yes Yes Yes

c) pH d) Chlorine 13) DMCW (SG & TG)a) GRAB Water b) Conductivity

Yes to Yes Yes

Yes Yes Yes

Yes Yes Yes

c) pH 14) Boiler blow down a) GRAB to condenser Drain to condenser from Boiler condensate pumps b) Conductivity Condenser Tube Leak detection at each inlet & outlet CW line.

Yes -

Yes -

Yes -

Yes Yes

Yes Yes

Yes Yes

15)

a) Cation 0-1/10 Micro Conductivity mhos/cm (Insertion /Retractable Type)

Note : 1)

The above indicated quantity are minimum and if the process requirement calls for any other services for measurement and performance of the plant the same shall be included in addition to the above services. The system shall be designed to provide 20% more than the maximum sample flow requirement.

2)

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DESEIN
Sample No. Sample Stream Type of Measure ment Range of Monitor/ Indicator

Vol-V : Instrumentation & Control Works

Alarm

Output to SWAS OS

O/P to Distributed Control System

5.27.00 FLUE GAS ANALYSER SYSTEM


Sample No. Analysis Points Type of Measu rement Flue gas after air Oxygen % heater (1 nos for each air heater, total 2 nos) Flue gas at eco. Oxygen % Outlet before air heater (2 nos L & 2 No R) Total 4 nos. Flue gas at eco. Outlet 1Left & 1 Right (2nos) CO Flue Gas at each Opacity ESP outlet path Flue gas at suction Oxygen % side of each ID fan or ESP outlet (2 nos.) O2 Analysers At High temperature Oxygen % locations, 3 nos. of Heater-less O2 probes are to be supplied after Platen SH (L & R) (Exact Locations shall be finalized during detailed Engineering). Range of Monitor/ Indicator Alarm Analog Output O/P to Distributed Control System Yes

01)

0-10 % Volume Yes O2

Yes

02)

0 10%

Yes

Yes

Yes

03)

0-500 PPM rerangeable

Yes

Yes

04) 05)

Yes 0 10% Yes

Yes Yes

Yes Yes

06)

0 10%

Yes

Yes

Yes

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Vol-V : Instrumentation & Control Works

5.28.00
TYPE

LIST OF OTHER WATER ANALYSERS

LOCATION

RANGE

UNIT
Bidder to Specify Bidder to Specify

ACW WATER PUMP DISCHARGE HEADER


Specific Conductivity CatIon Conductivity pH Chloride ACW pump discharge Header ACW pump discharge Header Bidder to Specify Bidder to Specify

COOLING TOWER BLOW DOWN TO SEA Bidder to Specify CT Continuous Blow Down CT Continuous Blow Down Bidder to Specify

Bidder to Specify Bidder to Specify

Note - Quantities & Type of Analysers for BOP/Offsite packages shall be as specified elsewhere in the specification.

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CHAPTER-6 SUPERVISORY CONTROL PANELS, SUPERVISORY CONTROL DESKS, EQUIPMENT PANELS 6.00.00 6.01.00 PANEL AND DESKS GENERAL REQUIREMENTS All DDCMIS/PLC/any other control systems electronic modules, power supply components, other control devices (except field mounted sensors/transmitters) and required for completeness of the system shall be housed in cabinets furnished by the Bidder. All equipment and dedicated cabinets required for termination, marshalling and proper interface within Bidders system and also with other systems shall also be provided by the Bidder. The cabinet mounted equipments shall be fully assembled, installed in mounting racks, wired and fully tested as per specification requirements and Owner approved drawings in the manufacturing works of a qualified manufacturer prior to shipment to the project site. The Bidder shall ensure that the cabinets are complete and ready for installation before dispatch from manufacturing works. The installation work at project site for these cabinets should only involve connections through multi pair cables from marshalling cabinets (wherever provided) to system cabinets and inter-cabinet/cabinet to UCD/UCP/BUP. The Control cabinets shall house all types of modules / hardware to achieve all functions of Control System including signal conditioning modules, controller modules, I/O modules, communication controller modules, and all other requisite hardware for a complete system. 6.02.00 6.02.01 SUPERVISORY CONTROL PANELS AND DESKS Control Desks & Other Furnitures Supervisory control desks for DDCMIS and other systems shall be supplied for mounting the required operating station as specified else where in the specification. Also control desk will be provided for balance work stations located in computer room, supervisor room etc. All furniture including chairs and tables for printers etc. shall also be provided by the bidder. Also control desk & complete furniture will be provided for work stations & printers located in respective control room for BOP packages. Industry standard Cushioned revolving, wheel, independently, adjustable seat and back chairs with provision for adjustment of height shall be provided for the operator & unit in charge & other personnel in central control room area & BOPs control rooms, simulator rooms, Conference room, meeting room, documentation room, staff room, CAAQMS shelters, CAAQMS room etc. These shall be designed for sitting for long duration such that these are comfortable for the back. The exact details shall be finalised & approved by Owner during detailed engg. The actual nos., placement and profile of the main plant control room desk shall be decided during the detailed Engineering.

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The tentative layout of central control desk, LVS & consoles are shown in the Drg. No. 114-05-0108, 0105 & 0111. Control Desk for programmers, Maintenance Engineers, EWS, Serves, PC & diagnostic OWSs: Required numbers of control desks for accommodating programmers/main-tenance engineers/diagnostic etc shall be supplied. These shall preferably have the same dimension as that of supervisory control desks. Also required nos. of control desk will be provided for work stations & printers located in respective control room for BOP packages. Desks for accommodating printer: Adequate number of table/desks/stands for accommodating printers in bidders scope shall be supplied. Each printer shall be on a separate table / stand. Care shall be taken to ensure ergonomically aspects so as to create ergonomically ideal work place considering physical aspects such as an average Indian persons size and reach, physiological aspects such as line of sight and field of vision and cognitive factors such as concentration and perceptivity. Extreme care shall be taken to design the desks with correct angles and dimensions. Glass top teak wood offie table with lockable drawers shall be provided for Chief Enginner room and all other executive rooms. 6.02.02 Supervisory Panel Unit Control Panel In addition to the LVS and OWS, a limited operation from backup unit control panel is envisaged for emergency operation and to provide safe shut down of plant. The Unit control panel shall housed Conventional Push-button (ILPB) stations, Console inserts (for SG, TG & Generator like FSSS, HPBP, SADC, APRDS, ATRS, ATT, DEHC, LPBP etc), Trip Push Buttons, EWLI, Ammeters, chartless recorders, & min. 15 nos. programmable digital display units for Boiler, Turbine & Generators parameters. The mosaic grid shall be heat resistant, flame retardant, self extinguishing, and shrinkage free, non reflecting type. Finish of mosaic grid shall be mat type with out flaring. Hard wired emergency trip pushbuttons shall be arranged on operator station desk & in parallel on UCP. Unit control Panel (UCP), shall be located suitably in the CCR. In addition to above, 21 nos. Programmable digital display units common for both units showing total MW shall be provided by bidder at different locations of plant. The data to this DDU will be fed from DDCMIS through MOD BUS/PROFI BUS /RS 485 protocol and not hard wired. The digit size of the display unit will be 300 mm for 6 Nos. and 200 mm for 15 Nos. The placements/locations shall be decided during detailed Engineering. Control panel cum desk with HW annunciation windows, ILPBs, Ammeters, Annunciation & desk PBs, mimic, lamps, Indicators, recorders, etc. shall be provided as per Annexure A Control System Philosophy for BOP packages.

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(Exact service & quantities will be worked out & approved during detailed engineering by owner). 6.02.03 Two (2) nos. vertical Steel Almirahs shall be provided for keeping documents in each BOP packages control room. Glass doors for each rack shall be provided such that the documents are visible from outside. Size of the rack shall be sufficient to easily fit technical manuals. The exact details shall be approved by Owner during detailed engg. Suitable lockers (min. 24 nos. per unit) shall be provided in the room adjacent to the each central unit control room for storing of personal articles of control room personnel. Similarly suitable lockers (min. 8 nos in each control room) shall be provided in BOP package control rooms for storing of personal articles of control room personnel. Also, vertical steel almirahs (min. 4 nos. per unit) shall be provided in Documentation Room for storing of documents. Vertical Steel Almirahs shall also be provided for the following rooms, wherein final quantity may be decided by owner during detailed engineering a. b. c. d. e. Maintenance room 6 nos. min. (per Unit) ERP room 2 nos. min (Common for both unit). PADO Room One (1) no. min.(per unit) Station In charge room One (1) no. min (common for both unit). Simulator room 4 nos. min. (per Unit)

Thickness of steel almirah sheet shall be 18 gauges. In addition to above, All industry grade furniture including chairs, control tables, tables for printers etc. & Almirahs for storage of consumables/catalogues/manuals shall also be provided by the bidder as on required basis and finalized by owner any where in power plant. Details shall be finalised and approved by Owner during detailed engineering. 6.02.04 Control panels for service system like C.W. Pumps etc. will be located in the respective control room. In addition ,some local panels will be provided near respective system/equipment such as Boiler Feed Pump, Hydrogen seal oil system, Electrostatic precipitator etc. TERMINATION/Marshalling CABINETS & Interposing Relay Panel Marshalling/Termination cabinets for the control system shall be supplied for terminating all cables originating from the field, MCC/SWGR or any other source of signal and for distributing the signals to different functional panels, MCC/SWGR and control cubicles. Incoming cables from the field, MCC/SWGR or any other source of signal shall be terminated in suitable terminal blocks in logical sequence. Prefabricated cables with plug in connectors at both ends shall be used for extending the signals to the functional panels. Matching plug sockets shall be provided in the termination cabinets for terminating the plugs.

6.03.00

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DESEIN

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Interposing relay panels for the system shall be supplied for mounting interposing relays & terminating all cables originating from the DO cards in case of solenoid valves, and other required services etc. IPR panels shall be placed in CER and LCR. Interposing relay shall be mounted in respective SWGR/MCC/integral starter required for commands signals of HT/LT unidirectional drives and bidirectional drives, breakers, isolators & bus couplers etc from DDCMIS/DCS/PLC or any control system. Terminal blocks shall be located inside the cabinets on support wings fabricated of metal plates. The plug socket shall be mounted on hinged plates to provide an access to the rear pins of the plugs. General features of termination cabinets and accessories shall conform to the general design and construction specification of panels. Terminal blocks shall be Rail mounted Terminal blocks (Screw less cage clamp type) with markers. 6.04.00 CONSTRUCTIONAL FEATURES OF PANELS, CONSOLES, CONTROL DESK, CUBICLES & ENCLOSURES All panels, cubicles, consoles, SOV panels and enclosures furnished as per this specification shall be of free standing type and shall be constructed of specified gauge of steel plates. The panel sheet thickness shall be not less than 2 mm unless otherwise specified herein. The panels, consoles/desks shall be reinforced as required to ensure true surfaces and adequate support for instruments mounted thereon. All instrument cutouts, mounting studs, and support brackets shall be accurately located. All welds on the exposed panel surfaces shall be ground smooth. Finished panel surfaces shall be free from waves, bellies, or other imperfections. Unless specified, otherwise, panel doors shall be 4 points hinged and shall have turned back edges and additional bracing where required to ensure rigidity. Door hinges shall be of the concealed type. Door latches shall be of the three-point type to ensure tight closing. Door locks shall be furnished which will allow actuation of all locks by a single master key. All panels shall have removable lifting eyebolts for safe lifting from top during storage and installation handling. Cabinet doors shall be hinged and shall have turned back edges and additional braking where required ensuring rigidity. Hinges shall be of concealed type. Door latches shall be of three/four-point type to assure tight closing. Detachable lifting eyes or angles shall be furnished at the top of each separately shipped section and all necessary provisions shall be made to facilitate handling without damage. Front and rear doors shall be provided with locking arrangements with a master key for all cabinets. If width of a cabinet is equal or more than 800 mm, double doors shall be provided. All panels shall be mounted on vibration dampers, which are secured to channels mounted on the floor. The channels shall be field welded to steel plates set into the concrete flooring. The steel plates shall be located such as to approximate the outline of panel bases. The exact mounting details shall be as approved by the owner during detailed engineering stage. All panels shall be provided with adequate ventilation and packaging density of components shall be restricted so as to limit the temperature rise

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DESEIN

Vol-V : Instrumentation & Control Works

above ambient to 10C under the worst conditions. All panels shall have auto on/off switch for internal lighting. All the power supply circuit for control panels shall be provided with auto changeover circuitry. In each panel /cabinet, a 24 VDC Voltmeter digital type shall be provided to check the Field Interrogation voltage. Exhaust Fans with louvers & filters shall be provided on doors (front & Rear) upper side to remove hot air in all consoles, control desk and panels. Fire/Smoke detectors shall be provided inside the Control room mounted system/control cabinets. UPS, 24 V DC & non UPSs Feeder failure/ healthy indication shall be provided in each cabinet & remote indication shall be hooked up to DDCMIS/ PLC/annunciation & suitably grouped. All the panels shall be equipped with Anti vibration pad of min. 15 mm size. Cable gland plate thickness shall be 3 mm. Doors shall be provided with neoprene/polyurethene gasket only. All the cable entries shall be at the bottom of electronic cubicles/control panels. Protection class of panels shall be as specified at Vol. V, chapter 2. 6.04.01 6.04.01.1 Operator Control Desk In CCR, Operator work station consoles/desk shall be of granite top of curved nature with powder coated frame. OWS consoles shall be provided with the facility for locating the CPU, document etc with all required utilities. Unit In charge desk/consoles shall be of granite top of curved nature with powder coated frame. OWS consoles shall be provided with the facility for locating the CPU, document etc with all required utilities. Station In charge desk/consoles shall be of granite top of curved nature with powder coated frame. OWS consoles shall be provided with the facility for locating the CPU, document etc with all required utilities. 6.04.01.2 Engineer work station and all other consoles/desk shall be ergonomically designed industrial grade type with swivel chairs for use at the various Programming stations and all other plant locations. All the equipment like Programmers stations, PC's, various peripherals & similar devices shall be complete with desks and they shall be of industrial grade stands and other mounting accessories and the same shall be completely erected & commissioned by the bidder. Details for other operating and enginering stations shall be as below: i. Operator Control desk shall be free standing table top type with doors at the back and shall be constructed of 3 mm thick CRCA steel plates. It shall have concealed cable & wire way management system. The top surface of control

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DESEIN

Vol-V : Instrumentation & Control Works

desk shall be 30mm thick with the top 12mm of acrylic solid surface and the remaining 18mm of laminated medium density fibre board. Control desk shall consist of vertical, horizontal and base supports with their coverings for work surface, keyboard trays, Mouse pads, Monitor shelf and concealed cable and wire way management, perforated trays with covers in both horizontal & vertical directions. ii. To achieve durable & water resistant finish, a sheet of plastic PVC membrane" on the surface of control desks shall be provided. Final paint finish with proper smoothening is to be ensured. Final finish of CD should be in line with relevant International standards. For more durability, the membrane sheet of the Control desk should extend 200 mm more into the underside of the desk. The cabling / wiring between OWS & CPUs, power supply cables etc. shall be aesthetically routed and concealed from view. All the control desk shall be equipped with Anti vibration pad of min. 15 mm size. Cable gland plate thickness shall be 3 mm. Doors shall be provided with neoprene/polyurethene gasket only.

iii.

iv. 6.05.00

SURFACE PREPARATION AND PAINTING All panel exterior steel surfaces shall be ground smooth, and painted as specified below: Suitable filler shall be applied to all pits, blemishes and voids in the surfaces. The filler shall be sand blasted so that surfaces are level and flat, corners are smooth and even. Exposed raw metal edges shall be ground burr free. The entire panel surface shall be sand blasted to remove rust and scale and all other residue due to the fabrication operation. Oil grease and salts etc. shall be removed from the panels by one or more solvent cleaning methods. Alternatively 7 tank process shall be followed. Two spray coats of inhibitive epoxy primer surface 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 colour (Catalysed epoxy finish) shall be applied to all surfaces of dry film thickness 2.0 mil. The finish colours for exterior and interior surfaces shall conform to the following shades: a) Exterior b) Interior RAL 7032/RAL 7035. Glossy white two coats/RAL 7035 with fire resistant paint

One uniform colour shade as finalized shall be applicable for complete plant. Paint films, which show sags, checks, blisters teardrops, fat edges or other painting imperfections, shall not be acceptable and if any such defects appear, they shall be repaired by and at the expenses of the Bidder. 6.06.00 PANEL WIRING Interconnecting wiring shall be provided between all electrical devices mounted in the panels, and between the devices and terminal blocks if the devices are to be connected

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DESEIN

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to equipment outside the panels by cabling and through pre-fabricated plug in cables. All alarm contacts located within a panel shall be wired to terminal blocks. Thermocouple and other special circuits shall be field wires direct to instrument terminal blocks without the use of panel wiring. All control and instrument wiring used within the panels shall confirm to NEC and NEMA standards and shall be factory installed and tested at the works of a qualified manufacturer. All interior wiring shall be installed neatly and carefully, and shall be terminated at suitable terminal blocks. Sufficient clearance shall be provided for all control and instrumentation leads, and all incoming and outgoing leads shall be connected to terminal blocks suitably located for connecting external circuits. All panel wiring shall have appropriate ferruling for clear identification. Interior wiring shall be so arranged that the external connections can be made with only one wire per terminal point. Any common connections shall be made internal side of the terminal blocks. Common connections shall be limited to two wires per terminal. Instrumentation cable shield wires shall be connected to separate terminal at the terminal block. Signal circuit shields shall be grounded separately. All internal wiring (except low level instrument wiring) shall be National Electric Code Type SIS, Polymetric/Elastomeric insulated, tinned copper stranded conductor, switchboard wire, or owner approved equal. Panel wiring shall have a flame resistant insulation with adequately sized 650/1100 V grade tinned copper stranded conductor based on current carrying capacities as etc forth by the National Electric Code. Wire sizes shall be as specified herein and suitable for intended applications. Wiring to door mounted devices shall be provided with (49 strand minimum) adequate loop lengths of hinge wire so that multiple door openings will not cause fatigue braking of the conductor. Wiring shall be arranged to enable instruments or devices to be removed and/or serviced without unduly disturbing the wiring. No wire shall be routed cross 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. Panel wires shall be identified with wire number and each termination by means of Action craft products split sleeve or Borden Chemical Co. indelible tubing markers or owner approved equal. Corrections and modifications of all panel wiring shall be Bidders sole responsibility. Any corrections/modifications required at site for successful commissioning shall be done by the Bidder without any additional costs. Terminal lugs furnished must be of the compression, insulated sleeve, half ring tongue type. Open-ended terminal lugs will not be accepted. Wires shall not be looped around the terminal screws or studs. Wires shall not be tapped or spliced between terminal points. Panels, cabinets, consoles/desks will be provided with removable, gasketed cable gland plates and cable glands, for all floor slots used for cable entrance. Split type grommets shall be used for prefab cables.

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DESEIN

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Internal wiring in factory prewired electronic systems cabinets may be installed according to the Bidders standard as to wire size, insulation, and method of termination on internal equipment except that insulation for all wiring power supply wiring, and interconnecting cables between devices shall pass the following tests. a) b) c) d) Flammability test IEEE 383/1974 When tested under UITPP test method or ASTM 2893/77 light transmittance of 80% When tested under IEC 754-1 maximum acid gas generation shall be 2% by weight Oxygen index not less than 30 as per ASTM D 2863.

All terminations for intra panel wiring inter panel cabling and connecting the Bidders panels, PB stations, control stations etc. shall be with cage clamp Screwed less connections. Soldered connections are not acceptable. All field side or external input connections shall also preferably of Cage clamp/Spring Clamp/ Screwed less connection. Conductor Clamping shall also confirm to Standard IEC 60947-1 & IEC-60947-7-1. Identification of conductors may be done by insulation colour coding identified on drawings or by printed wiring lists. Terminal blocks for connection of external circuits in to factory prewired electronic system cabinets shall meet all the requirements as described elsewhere in the specification. For all multicore cables, the outer sheath shall satisfy the properties identified above. However, for panel wiring, the wiring insulation shall also satisfy the properties identified above. The internal wiring shall be done in coloured wiring. 6.06.01 Following Wire size shall be utilized for internal wiring: a. Current (4-20 mA) Low voltage signals (AI/AO & DI signals) : : 0.75 sq.mm

b.

DO signals, Ammeter/ : voltmeter circuit,control switches, indicator,recorder Internal Illumination :

1.5 sq.mm

c. d.

2.5 sq.mm

Size of Power supply cables shall be as below:i. ii. iii. iv. v. vi. 1 to 16 Amp. - 2.5 sq. mm 17 to 20 Amp. 4 sq. mm 21 to 32 Amp. - 6 sq. mm 33 to 40 Amp. - 10 sq. mm. 41 to 60 Amp. - 16 sq. mm Power earth - 4 sq. mm

6.07.00

INSTRUMENTS MOUNTING

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DESEIN 6.07.01

Vol-V : Instrumentation & Control Works

Instruments and relays mounted on the panels shall be easily accessible for repair and replacement without disturbing other equipment their connected wiring. No special tools shall be needed for the purpose. PANEL ILLUMINATION Panels shall be provided with LED based illuminating lamps with door switch and six (6) point 6/16A, 240V AC universal type power sockets with switch for maintenance purposes. These switches shall be with quick make and break mechanism. 100 % spare LED lamps shall be provided with each panel, these are in additional to mandatory spares.

6.08.00

6.09.00

FUSE BLOCKS Where fuse blocks rated 30 amp. 250 Volts are required by the specifications or the manufacturers design, they shall be modular type with bakelite frame and reinforced retaining clips. Blocks shall be class H.2 pole, screw terminal fuse blocks. Blocks for other current and voltage ratings shall be similar in construction.

6.10.00

FUSES & MCB All fuses shall be fast acting semiconductor types for AC supply and compatible to the UPS fuses. For all DC Powered devices, similarly the fuses shall be fast acting compatible to DCDB fuse provisions. All the AC power supplies shall be provided with the protection of Fast acting semi conductor fuses & 2 P thermomegnetic type MCB. Make of Fuses shall be GE or Siemens. For all the DC power supply circuits, electronic type DC MCB shall be used only. Make of DC MCB shall be Siemens, Phoenix contacts, Murr, Weidmuller, or Lutze. 50 % spare fuses shall be provided with each panel, these are in additional to mandatory spares.

6.11.00

MOULDED CASE CIRCUIT BREAKERS Moulded case circuit breakers used in equipment covered under these specifications shall have not less than 5000 amp. Interrupting capacity at 220 Volts DC 10,000 Amp. Symmetrical interrupting capacity at 240 Volts AC. MCCB shall be provided at each main feeder line like ACDB & DCDB main feeders, PLC main feeder, control panels, UPS circuits etc.

6.12.00

GROUNDING All panels and cabinets shall be provided with a continuous bare copper ground bus of minimum 6 mm x 25/50 mm cross section. The ground bus shall be bolted to the panel structure and effectively ground the entire structure. Each Ground bus shall have provision at each end for connection of ground leaks (6 mm x 50 mm GI Flats) by suitable bolting. All system cabinets shall be brought to a common system ground by the bidder. Electronic earthing resistance shall be < 0.5 ohms. Each circuit requiring grounding shall be individually and directly connected to the panel ground bus by ring tongue type compression lugs. For electronic system cabinets the system ground bus shall be insulated from the cabinet enclosure and shall be separately

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connected to the system ground. All system cabinets shall be brought to a common system ground by the bidder. The Bidder shall furnish his recommendations regarding grounding requirements for all equipment/systems and shall specifically indicate the deviations if any from the above requirements as a part of his proposal. 6.13.00 TERMINAL BLOCKS For all inputs to the system emanating from the field or other systems, the bidder shall furnish terminals suitable for correct size of field cables. 6.13.01 All outputs going to MCC/SWGR terminal blocks, shall be rated 600 volts minimum and shall have strap screw less terminals suitable for connection of wires with ring tongue type lugs. Standard terminal blocks shall be screw less cage clamps type. Terminal blocks shall be approximately sized for larger wire size of higher voltage insulated incoming conductors as necessary. All the TBs used shall be 6.6 polymide to withstand corrosion and the metallic portion shall be coated against rust /corrosion. All metal parts should be non ferrous in nature. Terminal blocks shall be provided with white marking strips and re permitted by the safety codes and standards shall be without covers. Fuses shall not be mounted on terminal blocks. Neither step type terminal blocks nor angle mounting of terminal blocks will be acceptable. At least 20 per cent spare unused fully wired terminals shall be provided on each terminal block for circuit modifications and for termination of all conductors in a multi-conductor control cable with each panel, enclosure, cubicle, SOV Boxes etc. NAME PLATES AND LABELS Name plates of adequate size shall be provided for each panel on front and rear of the panel. Instruments/other accessories mounted inside the panels shall have identification marking clearly visible from inside. Devices to be mounted on the panels shall also be labeled on the panels shall also be labeled on the outside of the panel. Name plates shall be of polyamide sheets with black letters on white background. Name plates shall be attached to the boards by means of stainless steel panhead screws. Fuses provided for protection of various boxes shall be accessible for replacement. Fuse boxes shall be provided with circuit label and fuse rated current and voltage. Markings/Labels All markers/labels shall be made of halogen & silicon free polyamide material with inflammability class V2 as per UL 94, ensuring scratch proof printing with the use of environment friendly solvent free ink & latest BLUEMARK UV technology so as to comply the WIPE RESISITANCE according to DIN EN 61010-1/VDE 0411-1.

6.13.02

6.13.03

6.13.04

6.14.00

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DESEIN 6.15.00 Local Instrument Racks & Enclosure

Vol-V : Instrumentation & Control Works

Transmitters and switches located in the field shall be grouped together and shall be installed in the enclosure (closed transmitter racks) in case of outdoor area such as Boiler area etc. And in open type Rack in case of covered area. Racks shall be factory prefabricated & painted and complete with internal tubing, manifold valve, isolation valves, integral junction boxes with outside access door, illumination etc. Racks used for furnace, flue gas and air application shall be provided with intermittent & continuous air purging. 6.15.01 Closed Type Instruments/Transmitter Racks (a) Required number of Instruments/transmitter racks shall be furnished to house transmitters, switches and converters by grouping them suitably, area- wise / function-wise. The Transmitter enclosure shall be constructed of 3 mm thick steel plate. The enclosures shall preferably be of modular construction and with two end plate assembly bolted to the frame. The enclosure shall approximately be 1200 milimeters wide, 1000 milimeters deep and 2200 milimeters high to allow easy access to the internals. Racks shall be reinforced as required to ensure true surfaces and to provide adequate support for instruments and equipment mounted therein. Double interlocking doors with three point locking arrangement shall be provided and shall be arranged for maximum possible access to the interior. Center posts or any member which would reduce access shall not be provided. Doors shall have concealed quick removal type pinned hinges and locking handles. Doors locks shall accept the same key all over the plant. Neoprene material Gaskets shall be used between all mating sections to achieve dust proof enclosure rating for the modules and a IP-65 waterproof and dust tight rating on the terminal boxes. All Enclosures shall have access doors on front side. Bulkheads, especially designed to provide isolation from process line vibration shall be installed on modular bulk head plates of the transmitter enclosures to meet the process sensing line connection requirements. Removable top and bottom plates shall be furnished. All internal wirings and/or data bus connections, if any, between the transmitters and terminal junction box shall run through flexible dust tight conduits connected to the terminal box hub. No exposed wirings within transmitter racks, both open and closed type, is admissible. All racks shall have a common closed drain trough to connect transmitter drain points to a common header aftersuitable pressure breaking. Covered funels shall be used for saturated liquid and steam service, where as, open funnels may be used for cold liquid services. The trough shall be suitably sloped and shall have one end flanged and extending beyond the rack for connection to plant drain header. Vibration dampeners shall be installed for supporting each enclosure. The loading at each corner of the enclosure shall be determined by actual test weighting when construction is complete to determine the correct length of each dampener for proper loading of the dampener in accordance with owner's recommendations. Service Power and Lighting

(b)

(c)

(d)

(e)

(f)

(g)

(h)

(i)

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DESEIN

Vol-V : Instrumentation & Control Works

(i)

(ii)

Each enclosure shall be provided with universal type power receptacle, light fixture & LED lamps with wire guard and lighting switch etc. Lighting switches shall be door actuated & mounted inside the panel. Outlet box, switch box and device covers shall be of galvanized stamped steel. Light switches and power receptacles shall be installed inside the enclosure on the wall near the latch side of the enclosure door. Light fixtures shall be installed on the ceilings of the enclosures. Power Supplies for miscellaneous devices shall be provided with 2P MCB located within the enclosures. MCB shall be mounted in Fuse blocks. Nameplates shall be furnished above the MCB blocks, identifying the devices being served.

(j)

Control Air (i) A control air supply header shall be furnished in each enclosure having pneumatic devices. The header shall be 25 MM NB brass header stock drilled and tapped for 8 millimeter valves. A valve with double compression end fittings shall be installed in each tap. Not less than three spare connections shall be furnished in each enclosure. The air header shall originate at a bulkhead penetration or fittinglocated in one of the bulkhead plates. Each pneumatic instrument shall have individual air shut-off valve. Pressure reduction shall be achieved by air filter regulator sets. One filter regulator shall be furnished for each group of components making a system.

(ii)

(iii)

(k)

Service Air A 15 mm NB service air header shall be furnished in each enclosure housing draft and coal mill instruments. The header shall be furnished complete with a pressure regulating valve, pressure gauge and valve quick disconnect connections. A hose for connecting each header to the draft instrument line four way valve shall be furnished. The hose shall be self-storing nylon tubing having a burst pressure 15 Kg/Sq. cm. The service air header shall originate at a bulkhead penetration or fitting located on one of the bulkhead plates.

(l)

Power supplies Bidder shall supply all required transformers, regulators and other power supply equipment to adapt sources of power to the requirements of the enclosure mounted equipment. This shall include but not be limited tointernal instrument illumination transformers. The circuits shall be separately isolated with MCBs. Equipment Installation Special attention shall be given in the piping layout to avoid air traps in liquid filled piping, or water pockets in piping.

(m)

(n)

Impulse piping/tubing

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DESEIN (i)

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(ii)

(iii)

(iv) (v) (vi)

(vii)

(viii) (ix)

Transmitter enclosures shall be complete with impulse piping & tubing, valves from enclosure bulkhead connection to all instruments and necessary drain / blow down connections. The type ,size, material and pressure class of pipes/ tubes, fittings, valves etc. Shall be suitable for the intended applications. Blow down piping / tubing may be shared, but individual instrument piping/ tubing and valves shall be furnished. Piping/ Tubing material within enclosures shall conform to the aplication requirements. The final flexible connection to each instrument shall be fabricated with a double offset so that it may readily be disconnected to permit "in situ" calibration of the instrument. Bulkhead connection shall be used when instrument piping/tubing enters the enclosure. For instruments lines which enter through the bottom of the enclosure, the primary process line from the instrument valve shall be neatly installed, anchored and terminated at approximately 150 millimeters above the floor of the enclosure. The enclosure shall have a removable, gasketted floor plate to provide an effective seal around the incoming field primary process line. An angle shall be installed 600 millimeters above the floor, running the length of the enclosure for anchoring of incoming field process lines. Pulsation dampeners shall be furnished whereever required. Drain pots shall be furnished for instruments measuring flue gas parameters and vacuum. All liquid filled blow down lines, except those measuring vacuum shall be connected to a header extended through one end of the enclosure and turned downward for directing the blow down into drain. Gas filled lines and lines equipped with drain pots shall not be connected to the blowdown header. The connection between the blowdown valve and blow down header shall be constructed so that it can be removed to permit the connection of test instruments to the blow down valves. The draft instrument line four-way valves shall be installed so that the quick disconnect fitting is readily accessible for connection with the service air hose. Pipe and stainless steel tube welding shall comply with the provisions of the latest applicable ANSI code for Pressure piping. Instrument piping and tubing shall be hydrostatically tested at one and one-half times the maximum system pressure for that instrument except for low pressure and vacuum measurement the test pressure will be as per piping standard.

(o)

Instrument tubing (i) Pneumatic tubing shall be installed in a neat workmanlike. It shall be supported frequently enough that it does not shake when subjected to vibration. All tubes which enter or leave the enclosure shall be terminated on bulkhead fittings in the bulkhead plate. Pneumatic tubing material shall be 6mm OD brass/ 316 stainless steel tubing, unless otherwise specified.Flareless tubing fittings shall be used for tubing connections smaller than one inch. Tubing shall be stretched before installation to assure straightness. Special tolls shall be used for all

(ii)

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bending and forming operations. Tubing shall be carefully handled to avoid flat spots, kinks, and short bends. All piping and tubing shall be air blown after erection and before attachment to equipment at either end. 6.15.02 Open Type Transmitter Racks (a) Open type transmitter racks may be provided for mounting Transmitters, switches, gauges, converters and other accessories in rooms, buildings and closed areas like the power house building. The open type racks may be shop or site fabricated. Transmitters, switches, converters and transducers of enclosure class IP-65 or better can be directly mounted on open racks. However, enclosures not conforming to the above protection standard shall have to housed in enclosures conforming to the above protection standard shall have to be housedin enclosures conforming to IP-65 class prior to mounting them on open structures. Racks shall be constructed on structural members of adequate strength and rigidity to ensure proper support to the mountedinstruments and equipment. Racks shall be of welded construction throughout. Major load-bearing posts shall be suitably supported by gusset plates or moment members. Suitable fenders grill shall be welded to the end-posts of the rack to outline a boundary beyond which no mounted equipment shall project to protect instrument from accidental contact during personnel movement. Each rack shall be provided with a canopy (sheet thickness of 3 mm) to protect the instrument fromdripping water or falling objects. For Operational convenience, the open type racks shall be used for mounting pressure and temperature gauges and switches and the local operating stations for electrical drives in the vicinity. Gauges mounted in racks shall be bottom connected and secured by double lock nuts. All gauges shall be located within 1500 mm from the floor for easy readability. The structural design shall be such that no item shall interfere with maintenance and removal of instrument, equipment and their accessories. Service Power and lighting (i) Each rack shall be provided with Universal type power receptacle, LED lamp light fixture with wire guard and lighting switch etc. Outlet box, switch box and device covers shall be galvanized stamped steel. Light fixtures shall be installed on the canopy of the rack. Power supply for respectacles and lighting shall be arranged. Power supplies for miscellaneous devices shall be provided with 2P MCB located within the rack JB. MCBs shall be mounted in blocks. MCB ratings will given on electrical schemetic diagrams. Nameplates shall be furnished above the MCB blocks, identifying the devices being served.

(b)

(c)

(d)

(e)

(f)

(ii)

(g)

Control Air Same as for closed type transmitter rack. Refer 6.15.01 (j) above

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DESEIN (h)

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Service Air Same as for closed type transmitter rack. Refer 6.15.01 (k) above Power Supplies Same as for closed type transmitter rack.Refer 6.15.01 (l) above Equipment installation Contractor shall prepare rack fabrication and piping drawings indicating the layout of each instrument. The drawings shall clearly indicate contractor's piping arrangement for sharing of process connections between two or more instruments. Special attention shall be given in the piping layout to avoid air traps in liquid filled piping or water pockets in piping intended to be dry.

(i)

(j)

(k)

Impulse Piping/Tubing Same as for closed type transmitter rack.Refer 6.15.01 (n) above Instrument Tubing Same as for closed type transmitter rack.Refer 6.15.01 (o) above

(l) 6.15.03

Wiring of the Racks (a) A fully enclosed IP 65 type junction box shall be provided in each rack for housing the terminal blocks connectors, power supply fuses and other electrical accessories, as required. Junction boxes for modular enclosures shall be fabricated externally on one end of each enclosure assembly to accept field wiring/cabling through the top or bottom of the junction box. A hinged door shall give access to the interior of the junction box. All electrical connections between instrumentsand the junction box terminal blocks shall be made. In addition all utility wiring for lighting and service power shall be installed. All wiring used within the enclosures shall conform to NEC/ IEC standards. All wiring shall run through flexible or rigid conduits and shall be terminated at suitable terminal blocks. Sufficient clearance shall be provided for all controland instrument leads and all incoming and outgoingleads shall be connected to termial blocks suitably located for connecting external circuits. High impedance circuits shall be connected using shielded or coaxial wire suitable for the service. Conduits shall be supported properly at regularintervals with suitable conduit clamps. Wire shall be neatly arranged and routed/laid in PVC trough/tray.

(b)

(c)

(d)

(e)

(f)

(g) 6.15.04

In general, local Instrument enclosures & racks shall be designed considering above cl no. 6.04.00 to 6.14.00 and chapter 9, Vol. V.

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6.16.00

Control Room Layout The TG building operating floor area and other elevations shall be partitioned to different rooms suitably by bidder with approval from owner to house the following equipments/panels/cabinets: (a) Unit Control Desk (UCD), Printers, Backup unit control panel, Electrical Control Panel (ECP), LVS, Fire Alarm Panel, LED TV, BTG CCTV & plant CCTV monitor in the main central control room. The system cabinets, marshalling cabinets and electrical auxiliary cabinets, Electrical panels, DAVR panels, Generator control panels, DDCMIS/DCS Network panels & SEE panels etc in the electronic cubicle room. Maintenance Engineer & Shift Incharges Engineering/OPERATING STATIONs with keyboards, printers and other peripherals in Maintenance Engineer room (Computer Room) and CCR/Shift Incharges Room respectively. Similarly OPC servers, OCAMMMS server, BTLD server, MIS server, station LAN Network panel & PADO server shall be located in separate server room. A separate room shall also be provided for PADO. Uninterrupted Power Supply (i.e., inverters and distribution boards) (UPS) in UPS room and 24 V DC charger with DCDB in 24 V DC charger room.

(b)

(c)

(d)

(e)

6.16.01

Every control room layout shall be designed in line with guidelines given below. (a) Lighting shall be designed for maximum comfort and minimisation of OPERATING STATION/LVS glare and shall be adjustable. Co-ordinated colours and material for floors, walls and ceiling shall be provided. Room designs shall absorb noise in the control room and engineers/shift supervisor room. Positively pressurized and filtered air conditioning shall be provided for all control rooms. Designs and material will be in accordance with NFPA Fire protection for Power/Electric Generating plant. All control Rooms shall be designed to minimise dust ingress. Air locks shall be provided. Double Doors and the corridors shall be of sufficient size and layout to allow access of 2750 mm height for equipments. Fire and Smoke detection equipment shall be located in all ceilings. Temp. & humidity monitoring system in each control room.

(b) (c)

(d)

(e)

(f)

(g)

(h) (i)

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(j)

Air Curtains at each entrance to Main Control room & BOP control room. The main door entry shall be mirror image type only.

6.16.02

Item 6.16.00 (a) to (d) referred above shall be mounted in an air-conditioned control room having false roof and false flooring. The control room will be partitioned with aluminium framed glass panels between the following rooms : (a) (b) (c) (d) (e) (d) Main Control Room and Maintenance Engineers Room/computers room. Maintenance Engineers/Computers Room and Electronic Cubicle Room Electronic Cubicle Room and UPS/24 V DC Room. Main control room and Electronic cubicle room. ERP, PADO & MIS server room and all other rooms. Main control room and Operating Floor.

In additions to above following rooms shall be provided at operating floor1) 2) 3) Conference air-conditioned Room. Station Incharge air-conditioned room. Documentation air-conditioned Centre for storage for all Plant O & M manuals, control system software backup, & all others operating / maintenance files, logs, records etc. Toilets/refreshing room. C&I staff air-conditioned room Pantry Room FSSS/BMS air-conditioned Room EDMS air-conditioned Room

4) 5) 6) 7) 8) 6.16.03

Following C&I rooms shall be provided in service building 1) 2) 3) 4) 5) 6) 7) 8) 9) Training air-conditioned Room. Equipment Storage air-conditioned Room. C & I Maintenance/laboratory air-conditioned Room. DDCMIS/DCS Simulator air-conditioned room. Meeting & Discussion Room 2 Nos. Conference air-conditioned Room. CAAQMS Room WAN server & network panel room Officers/Executive Rooms

6.16.04

Following rooms shall be provided at Local control room building for respective BOP/offsite packages1) 2) 3) Control room and Electronic cubicle room (air-conditioned). UPS room (air-conditioned). UPS Battery room.

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DESEIN 4) 5) 6) 6.16.05 6.17.00 Toilets/refreshing room. Locker & staff air-conditioned room Pantry Room

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Quantiteis of above mentioned rooms are minimum to be met by bidder, however actual quantities & size of rooms shall be finalised by owner during detailed engineering. ASSEMBLY AND INSPECTION As soon as the panels fabrication is over, Owner shall inspect the panels and further work on the panels, namely assembly, wiring and assembly of components shall be carried out only after the inspection.

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DESEIN CHAPTER-7

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UNINTERRUPTIBLE POWER SUPPLY SYSTEM & 24 V DC SYSTEMS 7.01.00 7.01.01 GENERAL REQUIREMENTS This subsection covers design, construction and performance requirements of parallel redundant industrial grade Uninterruptible Power Supply (UPS) System & parallel redundant 24 V DC System to be furnished by the Bidder for BTG, Station C & I Package & BOP/offsite packages & any other control system/sub system specified elsewhere in the specification. The Bidder shall furnish separate parallel redundant industrial grade UPS System for each unit DDCMIS/DCS Package and separate parallel redundant industrial grade UPS System for each BOP package including static inverters, static switches, manual bypass switch, chargers, A.C. Power distribution panels and Batteries with all required isolating and protecting devices and all other equipment and accessories required for completeness of this system. Bidder to note that there will be no common component like in phase transformer (IPT), common power supply to any redundant component and common point of failure in the UPS & 24 V DC system. The requirements of UPS system & 24 V DC system are specified herein on system basis. The Bidder shall be responsible for engineering and furnishing a complete and operational system fully meeting the intent and requirements of this specification and Owner approved drawings. The equipment furnished under this subsection shall meet the requirements of all applicable codes and standards including ANSI, NEMA, TEEE, NEC and IS. The UPS System & 24 V DC system hardware shall be from the latest established product range of a qualified manufacturer. The Bidder shall furnish documents to satisfy the owner that the design, performance and high availability of the proposed UPS System, 24 V DC system and all system components have been established by a considerable record of successful operation in utility power station for similar application. All UPS system & 24 V DC system cabinets, enclosures and distribution boards shall be manufactured, assembled, wired and fully tested as a complete assembly as per the requirements of this specification in the manufacturing works of a qualified manufacturer prior to shipment to the project site. Class of insulation of wound components (All transformers, chokes/inductances etc.) shall be class H with temp rating up to class B. The UPS, 24 V DC system equipment and the complete system shall have surge withstanding capability (SWC) to meet the requirements of ANSI C 37.90a IEEE Standard 472 1974. UPS & 24 V DC charger system should be provided with Class C type surge protection device. The Class C type surge arrester should be single MOV type , pluggable, should have fault indication and should be tested as per IEC 61643-1 to withstand 40KA 8/20 s pulse. The arresters should have potential free contact to ensure maintainability. All non-interrupting components of UPS system & 24 V DC systems shall be capable of withstanding all available short circuit current without damage. Additionally, all circuit interrupting components shall be capable of withstanding and interrupting all encountered short circuit currents without damage.

7.01.02

7.01.03

7.01.04

7.01.05

7.01.06

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DESEIN 7.01.07

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All control and instrument circuits shall be fused. Fuses shall be mounted inside the enclosures and shall have easy accessibility. Fuses shall be Buss man low-peak type or Owner approved equivalent. All load fuses shall be to Owners approval equal. The Bidder shall co-ordinate all load and line fuses applications to ensure that load fuses operate properly. The bidder shall be responsible for ensuring that UPS System, 24 V DC system and the downstream power distribution system for equipment to be serviced by are coordinated such that UPS loads continue to operate without interruption and in accordance with the power supply tolerance requirements (both voltage and frequency) for these UPS loads as long as at least one source is within the limits of voltage and frequency as specified herein. The Bidder shall furnish single line diagrams with his proposal to demonstrate how this requirement is met for all equipment and system covered under Bidders scope. The UPS system & 24 V DC System shall be installed in AC room. Acoustic noise at rated linear load shall be < 75 dBA at 1 meter distance from UPS as per ISO 3746. FUNCTIONAL REQUIREMENTS OF UPS CAPACITY OF UPS SYSTEM FOR main plant PACKAGE, remote I/O panels and BOP/OFF-SITE PACKAGES Parallel redundant UPS shall be sized by the bidder to cater to power for the bidder furnished loads such as plant control, monitoring system. Min. capacity shall be considered as 150 KVA (or as per system requirement in case capacity is higher than 150 KVA) at 50 deg. C ambient. All microprocessor based system, I/o cards, digital equipments, operating stations, printers, peripherals, receiver instruments, SWAS, CEMS, LVS, HMS, TSI, VMS, PADO, C&I Lab, Operator training Simulator system and other devices mounted in supervisory control desk, control panels and other microprocessor based system for BTG shall be operated on UPS power. Each Individual parallel redundant UPS shall be designed considering 20% design margin over and above any capacity mentioned in specification; UPS sizing calculation shall be submitted for approval. While computing the base capacity of the UPS, inrush requirements of connected loads shall be duly considered. The inrush shall be taken as 300% of steady state load lasting for 100 milli seconds. The base capacity shall be computed by bidder on above basis and to provide for at least 10% variation to cater to changed load requirements during detailed engineering stage. Bidder shall detail in the technical bid, the steady state as well as inrush requirements of each of the loads furnished by him and justify the selection of UPS capacity duly satisfying the requirement of 20% design margin. This base capacity shall be guaranteed at 240 V AC, 50 Hz single phase output at 50 deg. C & 95 % RH non condensing at ambient conditions. Ratings other than standard ratings of the manufacture shall not be acceptable. Number of distribution feeders in completely redundant configuration shall be offered to suit the load distribution as decided during engineering. Spare feeders of at least 20% of the total number of feeders with 2 nos. minimum spare feeder of each rating shall be built in.

7.01.08

7.01.09 7.01.10

7.02.00 7.02.01

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Separate industrial grade parallel redudnat UPS system for each set of Remote I/Os cum processor panel of DDCMIS and each BOP/Offsite package & any other control system/sub system specified elsewhere in the specification, shall be provided of suitable capacity with similar features as of main plant UPS by the bidder. UPS system for remote I/Os panels and BOP/Offsite package & any other control system/sub system specified elsewhere in the specification shall be kept in the respective package UPS rooms. UPS sizing calculation shall also be submitted for approval for each system/package. Diversity factor shall be considered as 1 for calculating the UPS capacity. 7.02.02 The parallel redundant Uninterruptible Power Supply (UPS) system of continuous duty shall supply, regulated, filtered and uninterrupted 240 V, 50 Hz, single phase power, within specified tolerances, to system AC loads, UCB mounted monitoring system, and other critical loads. Each of these critical loads shall receive one feeder from the AC Distribution Board of Inverter-A and another feeder from the AC Distribution Board of Inverter-B. However, each inverter shall supply only 50% loads under normal conditions as indicated below. SLD of UPS as per NIT drawing # 114-17-0100 shall also be referred by bidder. All necessary equipment required for protecting UPS equipment and connected inputs and outputs shall be furnished by the Bidder as an integral part of this system. Complete UPS system shall be automatic without any manual interference at any time of operation. True, 100% parallel redundant configuration also means availability of Criss-Cross Redundancy. Hence The UPS system design shall ensure that in case of one of the charger failure, the other healthy charger, shall feed to one of or both the invertors as the case may be and continue to charge the common/individual DC battery banks at all load conditions. UPS system shall work in Criss-Cross Redundancy configuration to safeguard the battery bank from unnecessary drainage. The bidder should note that this situation should not in any way lead to the discharge of the DC battery and maintain the UPS power supply to all loads. The industrial grade UPS system for BTG & for each individual BOP package shall include the following equipment: Sr. No. 1. Quantities for UPS of Quantities for UPS for main plant Package each remote I/O panel & BOP package 100% capacity of IGBT 2 nos. 2 nos. based PWM Inverter with output Voltage, current, frequency, KVA & KW digital display/meter. 100% capacity static (As required) 2 no. ( (As required) 2 no.( switches with input Min) Min) Voltage, current, frequency digital display/meter at bypass line. Manual by-pass switch 1 no. 1no. 100% capacity of 12 2 nos. Descriptions

7.02.03

7.02.04

7.02.05

2.

3. 4.

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5.

6.

7.

8.

9.

10.

11.

pulse controlled floatscum-boast Chargers 100% capacity of 6 pulse 2 nos. controlled floats-cumboast Chargers 100% Battery Set each 2 set (each For 2 hour 1 set (For 1 hour backback-up) up) in case of UPS rating less than 15 KVA. 2 sets (For 1 hour backup) in case of UPS rating more than 15 KVA. Step-down transformer 1 no. 1 no. (415 V, three phase , to 240V, single phase) of required capacity) Static Votage Stabilizer 1 set 1set with input & output ON Red indication and input & output Voltage, current, frequency digital display/meter. Input isolation 1 no. each 1 no. each transformer with input & output ON red indication and input Voltage, current, frequency digital display/meter. Out put isolation transformer A.C. Power Distribution 2 sets (Quantities of 2 sets (Quantities of Panels (including 20 % feeders shall be as on feeders shall be as on spare feeders on each required basis). required basis). panel with 2 nos. minimum spare feeder of each rating) and digital type Ammeter, Voltmeter, Frequency meter, PF meter, Watt meter & VA meter Interconnecting Armored As required As required FRLS ST2 (inner & outer sheath), PVC type C insulated stranded Copper conductor power Cable between UPS equipment & battery, UPS & ACDB, ACDB & loads. For emergency trip push

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buttons, Fire alarm system, safety critical circuit, trip protection circuit and for other services specified elsewhere in the specification shall be fire survival power cable conforming to IEC 60331, BS6387 (CWZ), BS6207 standard and this specification. 12. MCCB (At input, output, 1 no. each 1 no. each battery side, Bypass side, ACDB side etc) and tie breaker with ON, OFF & Trip indication. 13. Online Battery Health 1 set 1 set Monitoring System 14. Battery Junction Boxes 1 set each 1 set each with MCCB, Voltmeter & Current meter. Any other equipment necessary for completion of the system shall be provided by bidder. All equipment, enclosures and accessories for UPS system shall be designed, arranged assembled and connected in accordance with the requirements of this specification. 7.02.06 NORMAL OPERATION Two inverters each of 100% capacity, two battery packs of 100% capacity and two 100% battery chargers are used for main plant UPS. Two inverters each of 100% capacity, one battery packs of 100% capacity and two 100% battery chargers are used for BOP packages UPS. 1. During normal operation, UPS loads shall be supplied by both 100% capacity inverters each working at 50% load. The inverters shall receive power from DC source (Charger / Battery), their static switches shall be in the respective Inverter position and the manual by-pass switch shall be in Position-2. In this mode the two inverters shall act as standby for each other. Necessary paralleling networks shall be included to ensure equal load sharing by both inverters. Load sharing network details shall be detailed to establish all functionalities including fuse clearance. Capabilities of the UPS System as well as each 100% rated inverters are fully satisfied. In addition to UPS output paralleling, Rectifier DC outputs shall also be properly paralleled. 2. One inverter will act as Master, working on its internal oscillator and the other inverter will follow by using the synchronizing signal from master inverter for automatic control of its output frequency.

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DESEIN

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7.02.07

EMERGENCY OPERATION The static transfer switches and the manual by-pass switch shall provide switching means during emergency operation as follows: 1. In case of failure of any inverter the static switch shall automatically transfer the UPS Loads of faulty inverter (say Inverter A) to the healthy Inverter-B which will start working at 100% capacity. Thus the feeding of UPS power is continued automatically to all load connected to both inverters despite power supply to all UPS loads connected to both inverters shall be maintained without interruption. Isolation of faulty inverter shall be automatic and achieved in less than 4 milli seconds. Based on inverter failure alarm, the operator will transfer manual by-pass switch to Position-1 bringing in the plant AC source as the standby source to healthy Inverter B now working at 100% capacity. In this mode the healthy InverterB shall get the synchronizing signal from the stand by-AC source and automatic synchronization, operation on internal oscillator and transfer / retransfer to standby source shall be as follows: i) The output frequency of the concerned inverter shall be automatically synchronized with the plant stand-by source by using synchronizing signal from the standby source. The frequency limits for this synchronism are specified in clause 7.03.05. If the frequency of the standby source is beyond these limits, the Inverter frequency control shall be automatically disconnected from stand-by synchronizing signal and the inverter shall maintain the output frequency at 50 Hz within + 0.1 percent under all conditions of load and input voltage by working on their own internal oscillators. During operation on its own internal oscillator, the inverters shall continuously monitor the frequency of standby source. Upon restoration of proper frequency conditions of stand-by source, the inverter shall automatically start using stand-by source frequency as the synchronizing signal for inverter output frequency control. During the operation of any inverter on its internal oscillator due to synchronising frequency being beyond the specified limits, the transfer of static switch from Inverter to Standby shall be inhibited.

2.

ii)

iii)

3.

During any fault in the branch circuit feeders or inverter output bus, the inverter shall be capable of clearing a fast acting fuse of largest rating in 4 milliseconds and simultaneously provide UPS power to all connected loads (i.e. 50% capacity). In view of the above fault clearing capability of each inverter and due to availability of plant AC source as standby source for inverters the static switches shall not transfer the loads to the other inverter for fault clearing purposes. Retransfer of static switch shall be manual in all cases and shall be accomplished only after synchronism of the inverter output with the stand-by source has been automatically accomplished.

4.

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5.

The manual bypass switch shall have the provision (position 4) for fully bypassing the UPS system and connecting all UPS loads to the standby AC source. This provision may be used during start up to limit the inrush current and at other occasions at the option of the operator.

7.03.00 7.03.01

STATIC INVERTERS AND AUXILIARY EQUIPMENT The static inverters shall be solid state type using proven IGBT based pulse width modulation (PWM) to convert direct current power to essentially sinusoidal alternating current power as per this specification. The inverter equipment shall include all necessary circuitry and devices to conform to requirements like voltage regulation, current limiting, wave shaping, transient recovery, surge suppression network, automatic synchronization etc. as specified herein. INVERTER CAPACITY Each static inverter shall have the following minimum capabilities without causing any damage to the components and with current limit not operation :1) 2) Continuous full load rating Over load capacity: 125% of full load rating as above for 10 minutes, 150% for 1 minute, 200% for 10 seconds minimum & 300% for 4 msec for all specified input voltages. Fuse clearing capacity : Upon a fault in any branch circuit lateral feeder, the inverter shall have the capacity to carry a load equal to one half of its full load rating plus it shall clear the largest rated fast acting fuse in 4 milliseconds or less. All fuses used in inverter power and control circuit shall be fast acting type operating in less than 5 millisecond and each of these fuses shall be provided with kick fuse and alarm contact. Indication and alarm shall be provided to enable fault location. Step load pick up: Upon transfer of full load, the inverter output voltage shall not drop below 85% of nominal voltage during the first half cycle after transfer and 90% of nominal voltage in the next half cycle. The recovery to within + 1% of voltage shall be in less than 50 milliseconds. The inverter shall have sufficient I2t capacity to clear a slow acting HRC fuse having a continuous current rating equal to at lease 20% of the continuous full load current rating of the inveter, while feeding 100% rated loads of the inverter.

7.03.02

3)

4)

5)

7.03.03

INPUT VOLTAGE The inverters shall be fed from a DC Battery and chargers which do not feed any other loads. Input voltage shall be nominal DC output voltage of battery and charger of range from final voltage after discharge of battery to maximum DC bus voltage during equalize charging of battery. The inverter shall also be capable of working satisfactorily meeting the specification requirements with only the chargers connected to its input without battery in circuit. DC input window of each inverter shall be either 315-434 or 320-450 V

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DESEIN

Vol-V : Instrumentation & Control Works

DC. Filtering on the input of the inverters shall be furnished is required to operate within the output ripple of the chargers furnished by the Bidder. Each inverter shall include equipment necessary to protect itself from damage resulting from excursios, loss, or restoration of DC input voltage and synchrnising voltage. The inverter output voltage shall be 230 V AC , 50 Hz, Single phase. 7.03.04 OVER LOADS, SHORT CIRCUITS AND LOAD LOSS PROECTION 1. The inverters shall be provided with suitable fuses at the input and output which will permit proper co-ordination with other protective devices and at the same time protect the inverter against damage due to internal faults. All necessary equipment shall be provided to protect the inverters against over loads, short circuits and 100% loss of load. The inverter shall be self protecting against damage if energized with full load connected. The inverter shall be provided with current limiting circuitry which will limit the output current to a value which will not damage the inverter or blow its fuses. The inverter shall have sufficient I2 t capability to prevent damage to itself until short circuit conditions on the output are cleared. Each inverter shall be capable of operation with nonlinear loads. For bidders loads bidder shall detail the nature of non linearity. For loads provided by owner, bidder may assure a non linear wave form with a current crest factor of 3.0 occuring coincident with voltage peak. With nonlinearity consisting of third, fifth and seventh order harmonics. Output waveform of the inverter(s) shall remain within specified limits when operating with nonlinear loads at 100 percent rated load. The inverters shall be self protecting against all AC and DC transients, voltage surges and steady state abnormal voltages and current likely to be encountered in utility power station.

2.

3.

4.

5.

7.03.05

Automatic Synchronisation Inverter equipment shall include stable solid state oscillator devices designed to automatically maintain the inverter output in phase and in synchronization with the standby AC source. The frequency regulation shall be automatic within + 0.1 Hz of all conditions of inputs, loads and temperature occurring simultaneously or in any combination. Facility shall be provided for automatic transfer to internal oscillator operation when the standby source frequency is not within the synchronization limits. Provision shall be made for step less adjustment of synch disconnect frequency range from 50 Hz +/- 0.5 Hz to 50 Hz +/- 2 Hz. Automatic adjustment of phase relationship between inverter output and standby AC source shall be gradual, at a controlled slew rate, which shall not exceed 0.1 Hz per second.

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DESEIN

Vol-V : Instrumentation & Control Works

The inverter shall normally work on the internal oscillator with either of the two inverters as master synchronizer and the other following it. Suitable selector facility shall be provided to select the master. When any one inverter fails the healthy inverter gets the synchronizing signal from the standby AC source. The DC inputcurrent shall never exceed the full load current except for a short circuit within the inverter. The limitation applies to transient as well as steady state currents and includes in rush currents upto initial energisation of the UPS, load energisation, short circuits external to the inverter etc. For any value of the load and load power factor drawn by the equipment served, the inverter shall not impose on DC source any voltage oscillations in excess of 5 volts (RMS total, all frequencies) or any current oscillations in excess of 3 %(RMS total, all frequencies ) of the DC current at full load. 7.03.06 The inverter shall meet the following specifications in addition to other requirements stated herein :1. 2. 3. 4. Voltage input (Battery output ) Nominal voltage output: Inverter capacity (output KVA) Voltage regulation : As per system requirement 240V, 50Hz, single phase As per clause 7.03.02

: :

a) Steady state : (0-100% load at all input voltages & all power factors) b) Transient voltage regulation (on application or removal of 100% load) :

+1%

+ 5%

c) Time to recover : from transient to normal voltage with + 1% of steady state ( on application or removal of 100% load) 5. Wave Form a) Nominal : Frequency b) Frequency regulation : for all conditions of input supplies, loads and temperature occurring simultaneously or in any combination (automatically controlled)

<50 milli second

50 Hz + 0.1Hz

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DESEIN c) Synchronization : limits ( for maintenance & synchronism between the inverter and standby AC source). d) Field adjustment : range for (c ) above e) Total harmonic : content f) Harmonic content : max.for any single harmonic 6.

Vol-V : Instrumentation & Control Works

48 Hz to 52 Hz ( factory test) 50 + 0.5 Hz to 50 + 2 Hz <4% max. <2.5%

Rated output current at rated output voltage with current limit not operating : a) b) Current Duration : : 200% 10 seconds

7.

Overload capacity at 100% voltage : a) b) c) d) For 4 ms (fuse clearing): For 10 seconds For 10 minutes The proposed inverter has the capacity to clear largest acting fuse in 5 milli second & without entering into current limiting mode App. 300% 200% : 125% ---

: :

8.

Efficiency (watt output/watt input ) a) b) c) at 100% load 1.0 P.F. / 0.8 P.F: at 75% load 1.0. P.F. / 0.8 P.F. : at 50% load 1.0 P.F. / 0.8 P.F. : : : >91%/ 91% >90% / 90% >89% /89 %

9. 10.

Duty Cooling

Continuous Natural convection or forced cooling using redundant fans. Equipment to be designed for operation with full load even without cooling availability.

11. 12.

Ambient temperature SCR derating from

: :

50 deg C, maximum 50%

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DESEIN peak voltage and peak ratings. 7.03.06 STATIC INVERTER AUXILIARY EQUIPMENT

Vol-V : Instrumentation & Control Works

In addition to the inverter equipment specified above, auxiliary equipment shall be furnished with each static inverter as follows: 1) Equipment and material furnished, mounted and wired on the front panel of the inverter enclosures : ITEM Output ammeter, AC, indicating, Scale-0 to 150 percent of rated continuous full load inverter output current, 1 percent accuracy. Output voltmeter, AC, indicating 0-300 volt scale, 1 percent accuracy. Output KVA, AC indicating scale 0-150 percent of Rated capacity, 1 percent accuracy. Input voltmeter DC, indicating 0-300 volts scale, 1 percent accuracy. Frequency meter, 45-55 hertz, 1 percent accuracy. Power factor meter, (0-1. 0-0), 1 percent accuracy Inverter ON-OFF switch Alarm Reset Push Button 2) QUANTITY 1

1 1 1 1 1 1

Indicating lights listed below with proper actuating devices, circuitry and legend shall be furnished on front of the Ups panels. For these abnormal conditions which could be of a momentary nature, the indicating lights shall remain energized and the contract remain closed until cleared by a reset push button furnished on the panel. The indicating lights shall be of make subject to Owners approval. The following indications shall be provided as a minimum : a) b) c) d) e) f) g) h) i) j) k) l) DC voltage to the Inverter Low DC voltage to the Inverter High Loss of DC input to the inverter Inverter output voltage High Inverter output voltage Low (after a time delay to avoid unnecessary alarm due to low voltage on load in rush etc.) Inverter A failure / Inverter B failure Standby AC source failure Inverter A / Inverter B not synchronized with AC source Automatic transfer to AC source. Blown Fuse or Tripped Breaker. Inverter A/ Inverter B feeding 100% UPS Load Standby source feeding 100% UPS loads Redundant fan failure and temperature high ( if provided)

7.04.00

STATIC TRANSFER SWITCHES AND AUXILIARY EQUIPMENT

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DESEIN

Vol-V : Instrumentation & Control Works

7.04.01

The static transfer switches shall be provided to perform the following functions 1) To transfer the load automatically without any break between the inverter to the standby inverter as required to maintain the continuity of power supply to UPS connection loads. The load shall be automatically transferred from Inverter to the inverter source upon any malfunction of one inverter. To transfer UPS load under manual control from standby AC source to inverter when placing the UPS System in service and from inverter to standby AC source when taking the UPS out of service.

2)

7.04.02

The static transfer switches shall have two modes of operation namely automatic and manual. The static transfer switches shall use silicon controlled rectifiers and other static devices required for automatic transfer of load from Inverter to Standby source and vice versa. The static switches shall conform to the requirements specified herein including the following: 1. 2. Capacity (continuous) : Equal to the continuous full load capacity of the inverter. Capacity (overload) : 200% for 10 seconds, 150% of continuous for 60 seconds and 125% of continuous rating for 10 minutes and 300% of continuous rating for 4 msec. Capacity (Peak) : 1000 % of continuous rating for 5 cycles. Transfer Time : < 4 msec. The transition shall be make before break, voltage failure shall be sensed at the output of the static switch. Voltage Rating ( Nominal) : 240 Volts, 50 Hz. Single phase. Transient Voltage Tolerance : 340 Volts peak above the normal line voltage. Ambient temperature : 50 deg C max. Cooling : Natural or forced circulation , using redundant fans. Duty : Continuous

7.04.03

3. 4. 5. 6. 7. 8. 9. 7.04.05

TRANSFER INITIATION 1) The transfer of static switch from normal Inverter position to Stand-by position shall be initiated by one of the following causes : a) b) c) d) e) 2) Inverter failure and UPS System trouble Inverter output voltage failure Over current Manual push button operation Static Output voltage failure.

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 static transfer switch.

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DESEIN 3)

Vol-V : Instrumentation & Control Works

The static switch shall automatically transfer the load from inverter to stand-by AC source when the maximum I2t capability of the inverter is reached when the inverter output voltage drops below 90%. UPS bus current shall be continuously monitored by a current monitoring detector. This detector shall operate the static transfer switch when the load current exceeds the overload rating of any inverter. The detector shall rest when the load current falls below the rated current of the inverter resulting in retransfer of static switch with inverter position. Over current transfer limit shall be continuously adjustable from inverter continuous rating to inverter current limit rating.

4)

5)

7.04.06

TRANSFER INHIBIT The transfer of static switch shall be inhibited under the following conditions: 1) Automatic or manual transfer of load from inverter to stand-by AC source or vice versa, shall be inhibited when the inverter frequency is not synchronized to the alternative source. Transfer resulting from overload shall be inhibited when the standby AC source is not available. In this case the load fed by the inverter shall be automatically disconnected

2)

7.04.07

RETRANSFER TO NORMAL 1) 2) The retransfer to normal shall be manual in all cases. Manual transfers shall be initiated by push button actuation.

7.04.08

Static transfer switches shall be provided with necessary protective devices (circuit breakers / current limiting fuses) both in Normal as well as Stand-by position. The static transfer switches shall be provided duly mounted and wired in enclosures furnished by the bidder. The static switches shall be furnished with contacts to alarm failure of the alternate source or opening of any fuse protecting the static switches. MANUAL BY-PASS SWITCH The manual by-pass switch will be used to isolate any static switch from its load and stand-by power supply and to take the static switch out of service without power interruption to the load. In doing so the manual by-pass switch shall connect both load buses to a single inverter. The manual by-pass switch shall also provide the facility for by- passing the entire UPS system during start up at the option of the operator. The manual bypass switch shall have make before break contacts to ensure continuous supply to UPS loads during the operation of this by-pass switch.

7.04.09

7.04.10

7.05.00 7.05.01

7.05.02

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DESEIN 7.05.03

Vol-V : Instrumentation & Control Works

The manual by-pass switch shall be rated for 600 Volts, 50 Hz, single phase operation. It shall have continuous load carrying capacity equal to full load inverter current and necessary short term load carrying and interrupting capacity to meet the requirements of the UPS system. All other by-pass and disconnect devices shall be provided by the Bidder as required for orderly start up and shut down and maintenance of UPS system and system components. The Bidder shall provide potential free contacts, one closed in each position, for use in DDCMIS & PLC system. The manual by-pass switch and required disconnect devices shall be furnished duly mounted and wired in enclosure, furnished by the Bidder. FLOAT-CUM-BOOST CHARGERS AND AUXILIARY EQUIPMENT Two no. 100% capacity SCR based fully controlled 12 pulse float cum boost chargers shall be furnished for main BTG UPS system and Two no. 100% capacity SCR based fully controlled 6 pulse float cum boost chargers shall be furnished for BOP packages UPS system. Each charger shall confirm to the following requirements.

7.05.04

7.05.05

7.05.06

7.06.00

7.06.01

CHARGER CAPACITY Each charger furnished for UPS system shall be adequately rated to ensure that any one shall meet full DC load of UP system operating at 100% rating plus recharge the fully discharged UPS battery within 8 hours. The Bidder shall furnish the charger rating calculations to the Owner to satisfy that this requirement is met. The charger shall be furnished as per rating approved by the Owner during engineering stage.

7.06.02

The chargers shall be supplied from a 415 volt, 50 Hz. 3 phase system. The chargers shall maintain the output voltage within plus and minus 0.5 percent from no load to full load with an input power supply deviation in voltage level of plus or minus 10 percent and input power supply deviation in frequency of plus or minus 5 percent and with both deviations present in any combination. In addition to supplying DC power for inverters, the chargers shall be designed to charge a fully discharged battery without over loading or causing over voltage or without causing interrupting operation of AC or DC circuit breakers for the entire range of intended operating regimes. Suitable solid state electronic circuits shall be provided to ensure that the charging current is voltage regulated and current limited. After the battery is recharged the charger shall maintain the battery at full charge until the next emergency operation when the UPS battery is again required to provide DC power. Float and equalizing controls shall have an adjustment range of + 5% (without steps). continuous

7.06.03

7.06.04

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DESEIN 7.06.05

Vol-V : Instrumentation & Control Works

The chargers shall be self-regulating, solid state, silicon controlled, full-wave rectifier type designed for single and parallel operation with the battery specified under clause 7.07.00. The chargers shall be designed for automatic load sharing during parallel operation. The charger shall be current limited at 125% of full load to reduce output voltage for charger circuit protection and for protection of battery from overcharge. The current limit shall be continuously adjustable from 80% to 125%. All necessary equipment and devices shall be provided to protect the charger from short circuits, transient voltage surges, load and supply fluctuation including sudden loss of input or load. The charger shall have a slow walk-in circuit which shall prevent application of full load DC current in less than 10 seconds after AC power is energized. The minimum full load efficiency at nominal input and float output shall be 96 %.The output regulation, ripple content and power factor shall meet the requirements of UPS system as well as the inverters furnished by the Bidder as per clause 7.03.00. Chargers and auxiliary equipment shall be mounted in free standing cabinets furnished by the Bidder. Charger cabinets shall be folded steel construction with top, front, back and sides fabricated from not less than 3 mm thick sheet steel. The cabinet front, back, end sides shall extend to the floor to present a finished appearance. Cabinet door shall be provided to permit easy access to all components for maintenance or replacement. Doors shall have concealed hinges and three-point latches. Louvers shall be provided for ventilation as required for operation at the specified ambient but the cabinet top shall be solid. All louver openings shall be covered with corrosion resistant fine screen coverings. GROUND DETECTOR SYSTEM a) Each charger shall be furnished with a ground detector system consisting of a relay and a center tapped resistor. The resistor shall be connected between the positive bus and the negative bus. The relay coil shall be connected between the centre tap of the resistor and ground. The relay shall be furnished with one normally open and one normally closed contact wired to terminal blocks for connection to external circuits.

7.06.06

7.06.07

7.06.08

7.06.09

7.06.10

7.06.11

7.06.12

UPS Signal interfacing with DDCMIS/DCS & PLC a) The bidder shall provide alarms and status indications, current, voltage ,frequency, PF etc through serial link with MODBUS or another compatible protocol . The Bidder shall furnish 4-20 mA signals to DDCMIS/PLC for the following: i) ii) iii) Inverter A & B output voltages Inverter A & B output currents Inverter A&B output frequency

b)

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DESEIN c)

Vol-V : Instrumentation & Control Works

List of alarms (min.) to DDCMIS through potential free contacts shall be as follows:i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. Rectifier 1 Trip. Inverter 1 Trip. UPS battery low. Rectifier 2 Trip. Inverter 2 Trip. Load on static Bypass. Static Bypass failure ACDB 1 Incomer Tripped. ACDB 2 Incomer Tripped. UPS 1 Fan Tripped. UPS 2 Fan Tripped.

7.07.00

UPS/24 V DC System BATTERY AND ACCESSORIES The UPS/24 V DC system batteries shall be heavy duty Ni-Cd type as specified below: i. ii. iii. iv. v. vi. Expected service life is greater than 20 years when operated on float or trickle charge. Low maintenance minimal topping up frequency and self - discharge. Capable of rapid recharging. Transparent containers for ease of inspection and maintenance. Battery racks provided for battery shall be 2 tier made from heavy teak wood to bear 150% over load, anti acid paint etc. One no. 2 sided Folding Aluminium ladder (height 180 cm) for maintenance & removal of battery cells and mounting bracket for ladder shall be provided by bidder with each battery set.

The batteries shall be heavy duty Nickel-cadmium Fiber plated type and shall be sized for an hour of full load operation during non-availability of AC supply / chargers. The Ni-Cd batteries shall conform to IS:10918. For sizing calculation, design margin of 120%, an aging factor of 0.8 and a temperature correction factor (Based on temperature characteristics curve to be submitted by the Bidder and at a temperature of 4 deg. C). Capacity factor shall be taken into consideration, and ambient temperature shall be considered as the electrolytic temperature. The sizing of the battery shall be as approved by Owner during detailed engineering. However, Bidder shall consider a suitable voltage drop from battery room to UPS and UPS to load, while sizing the battery. The system shall also be suitably designed to overcome any over voltage that may arise during lowload operation of the charger. The bidder shall clearly bring out in his offer how the same is being implemented. The battery size shall be calculated taking UPS/24 V DC system capacities as base load. Bidder shall also consider voltage drop from battery room to UPS/24 V DC systems, while sizing the battery. For Plant UPS & plant 24 V DC system, battery backup time shall be 2 hours and for BOP packages UPS & BOP 24 V DC system, the back up time shall be for 1 hour. For Fire alarm panels, batteries shall be provided with min. 10 hours backup.

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DESEIN 7.07.01

Vol-V : Instrumentation & Control Works

In order to monitor the batteries, online battery health monitoring system shall be employed. It is a battery management system based on monitoring the voltage of individual battery cell, which provide the information/details about battery health status to end user/owner. Complete hardware like detector units, Battery clips, cables, monitor (power control unit) and other accessories etc as required to complete the system shall be provided by bidder. LED indication shall be provided on detector units for power, alarm and RUN indication etc. Data from Online Battery Health Monitoring System shall be communicate/transferred to DDCMIS for Monitoring and analysis using different protocol like RS485 Modbus/OPC etc. One complete set of all accessories and devices required for maintenance and testing of batteries shall be supplied for each set of the batteries of each unit/plant auxiliary system. Each set include at least the following: a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s) Hydrometer Set of hydrometer syringes suitable for the vent holes in different cells Thermometer for measuring electrolyte temperature Specific gravity correction chart Wall mounting type holder made of teak woodfor hydrometer & thermometer cell testing voltmeter(3-0-3 V) Alkali mixing jar Rubber aprons Pair of rubber gloves Set of spanners No smoking notice for each battery room Goggles (industrial) Instruction card Minimum and maximum temperature indicator for battery room Cell lifting facility Vent Caps Terminal Bolts & Washers Plastic Filling Bottles Alkali resistant funnel & Mugs 5 Nos 5 Nos 5 Nos 5 Nos 5 Nos 5 Nos 5 Nos 5 Nos 5 Nos 5 Nos 2 Nos 5 Nos 10 Nos 1 No. 1 Set 2 set 1 Set 10 Nos. 10 Nos.

7.07.02

7.07.03

Cell booster charger shall be provided with main plant UPS & 24 V DC batteries set to charge the new & sick cell for revival of cell. The cell booster shall be built in separate portable panel. Resistive load discharge bank shall also be provided with main plant UPS & 24 V DC batteries set to discharge the batteries in case of over charged batteries. VOLTAGE STATIC STABILISER One 415 Volt, 3 phase to 240 Volt, single phase transformer along with associated static voltage stabilizer shall be furnished with each UPS set. This transformer and stabilizer combination shall convert 415 Volt + 10% plant auxiliary AC supply to 240V + 1% single phase standby AC Power which will serve as UPS system back up supply source.

7.08.00 7.08.01

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DESEIN 7.08.02

Vol-V : Instrumentation & Control Works

The transformer and stabilizer shall be sized for 100 percent UPS load and shall coordinate with the largest branch circuit protection device for feeder short circuit current without sacrificing voltage regulation. The voltage stabilizer shall employ silicon solid state circuitry and shall maintain the specified output voltage for 0-100% load with input voltage variations as indicated above. Class of insulation of wound components like transformers etc shall be class H with temp rating up to class B. The stabilizer shall meet the following characteristics as a minimum - Fast rate of correction - within 5 cycles - Output distortion - less than 5% under worst conditions - Efficiency - better than 95% - Overload Capacity 300% for 200 mSec. The make and rating shall be subjected to Owners approval.

7.08.03

7.09.00 7.09.01

24 V DC CONTROL POWER SUPPLY SYSTEM FOR MAIN PLANT The bidder shall offer a completely separate parallel redundant system with 50 % load sharing on each charger to cater to 24 V DC requirements for control, protection interlock & sequencing systems for BTG (Turbine protection, MFT & solenoid valves etc.). 24V DC system shall consist of 1. 2. 3. 100% capacity 12 Pulse float cum 2 nos. charger in parallel booster charger redundant configuration Battery Bank for 100 % load 2 Bank (100% capacity) each for 120 minutes back up DCDB (including 20 % spare feeders 2 set, (Quantities of feeders on each panel with 2 nos. minimum shall be as on required basis). spare feeder of each rating) Armored FRLS ST2 (inner & outer Complete power cables for 24 sheath), PVC type C insulated V DC system with battery, stranded copper conductor Cables. DCDB and loads. For emergency trip push buttons, Fire alarm system, safety critical circuit, trip protection circuit and for other services specified elsewhere in the specification shall be fire survival power cable conforming to IEC 60331, BS6387 (CWZ), BS6207 standard and this specification. MCCB (At input, output, battery side, 1 no. each & DCDB side etc) with ON, OFF & Trip indication.

4.

5.

Input for 24 V DC systems shall be from 3 phase MCC system. 24VDC power supply to load will be through MCCB, MCB, and redundant feeders DCDB - 1 and DCDB 2. Grounding cubicle for 24 V DC system shall be included in scope of supply. SLD of 24 V DC charger system as per NIT drawing # 114-17-0200 shall also be referred by bidder.

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DESEIN

Vol-V : Instrumentation & Control Works

7.09.02

Other than above mentioned services for main plant packages, Parallel redundant 240 V AC to 24 V DC convertor with 50% sharing & 125 % capacity shall be provided for 24 V DC power supply in each cubicle separately as per requirements for main plant BTG packages control system, and BTGs microprocessor based control system. The UPS power supply shall be extended to Parallel redundant 240 V AC to 24 V DC convertor thru redundant UPS feeders. AC to DC convertor shall be SMPS based and shall have wide range of AC/DC input voltage (85-264 V AC & 90-350 VDC). It shall have the necessary diagnostic functions like indications for DC OK, automatic overload monitoring etc. The MTBF for the power supplies shall not be less than 500,000 hours (in Accordance with (IEC 1709) with operating temp. from 25deg. C to 70 deg. C.

7.09.03 7.09.03.01

Float cum boost chargers: Each of the redundant chargers shall be sized to meet connected load requirements and keep the connected battery full charged (Float mode). In Boost mode, each of the chargers shall be able to re-charge the fully discharged battery within 8 hours. However, each charger shall be able to supply full load current requirements plus the battery charging current in boost mode. Complete operation shall be in auto mode. Operator intervention shall not be required for 24 V DC system operations The chargers shall be self regulating, SCR controller, full wave 12 Pulse type designed for single and parallel operation with battery and shall have automatic voltage regulators for a close voltage stability even when AC supply voltage and DC load fluctuates, effective current limiting features and filters on both input and output to minimize harmonics. The charger output regulation shall be 1% from no load to full load with an input power supply variation of 10% in voltage and 5% in frequency. In addition to indications on charger panel, potential free contacts for alarms like charger O/P voltage high, battery isolated, charger failed etc., shall also be provided and the same shall be further connected to DDCMIS for indication. Further isolated 4-20 mA signals shall be provided for important parameters like charger voltage, etc. Bidder shall provide list of alarm outputs & 4-20 mA signals for owners approval during detailed engineering. A auto/manual selector switch and "FLOAT/BOOST" mode selector switch in case of manual mode selection shall be provided for either trickle charging the battery (while supplying the load) or boost charge the battery (isolated from load) respectively. In boost charging mode, the chargers shall operate in constant current mode building up the voltage across the battery to 1.2 V/ cell. Each of the two 100% capacity chargers shall be adequately rated to ensure that 50% load sharing shall be ensured during normal conditions and in case any one of these chargers fails, the other charger shall work at 100% load. The charger circuitry shall be of fail-safe design and failure of any component should not result in any charger output voltage to increase beyond acceptable limits of the C&I system being fed from it.

7.09.03.02

7.09.03.03

7.09.03.04

7.09.03.05

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DESEIN 7.09.03.06

Vol-V : Instrumentation & Control Works

The charger shall be current limited at 125% of full load to reduce output voltage for charger circuit protection and for protection of battery from overcharge. The current limit shall be continuously adjustable from 80% to 125%. The chargers shall have a slow walk-in circuit which shall prevent application of full load DC current in less than 10 seconds after AC power is energised. The chargers shall be fed from 415V AC, 50 HZ, 3 phase. The Bidder shall provide all required power cables from 415 V AC power supply system to his power supply system. The minimum full load efficiency at nominal input and output shall be 70%. Charger design shall ensure that there is no component failure due to fluctuations of input supply or loss of supply and restoration. This feature shall be demonstrated during factory testing at various loads. Bidder shall furnish the equipment complete in all respects along with charger rating & voltage drop calculations, supporting curves/data etc. 24 V DC Charger sizing calculation shall be submitted for approval) at 50 deg. C ambient. Each Individual parallel redundant 24 V DC charger system shall be designed considering 20% design margin. Batteries And Accessories The 24 V DC system batteries shall be Two (2) set of heavy duty Nickel-cadmium Fiber plated type as specified at clause no. 7.07.00. Battery sizing calculation shall also be submitted for approval as per factors specified at clause no. 7.07.00. All other items shall also be furnished by bidder as specified at clause no. 7.07.01 & 7.07.02, 7.07.03. In order to monitor the batteries, online battery health monitoring system shall be employed.

7.09.03.07

7.09.03.08

7.09.03.09 7.09.03.10

7.09.03.11

7.09.03.12

7.09.04

7.10.00 7.10.01 7.10.02

AC & DC Power supply for BOP packages The UPS system shall be separate for each BoP/offsie package. The UPS shall be designed as specified at clause no. 7.02.00 to 7.08.00. Parallel redundant 240 V AC to 24 V DC convertor with 50% sharing & 125 % capacity shall be provided for 24 V DC power supply in each cubicle separately as per requirements for BOP/Offsite packages PLC control system and microprocessor based control system. The UPS power supply shall be extended to Parallel redundant 240 V AC to 24 V DC convertor thru redundant UPS feeders. AC to DC convertor shall be SMPS based and shall have wide range of AC/DC input voltage (85-264 V AC & 90-350 VDC). It shall have the necessary diagnostic functions like indications for DC OK, automatic overload monitoring etc. The MTBF for the power supplies shall not be less than 500,000 hours (in Accordance with (IEC 1709) with operating temp. from 25deg. C to 70 deg. C.

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DESEIN 7.11.00

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CONSTRUCTIONAL FEATURES FOR CABINETS/ENCLOSURES The Construction details for UPS & 24 V DC charger system cabinets/enclosure shall conform to the requirements indicated in chapter 6.

7.11.01

Grounding Normal, AC power supply will be grounded at the source. For grounding other than this, I/P and O/P isolation transformers shall be furnished with the UPS.

7.11.02 7.12.00 7.12.01

All the transformers used any where in UPS & 24 V DC charger circuitry shall be copper wire winded with class H insulation. DC DISTRIBUTION BOARD PANEL Distribution board shall be furnished with components, devices and materials meeting the requirements specified herein. Each DC distribution board shall be constructed for 2 wire DC distribution .All bus bars shall be of solid copper. Each panel shall have four double pole 800 amps MCCB and properly sized fuses for three incoming feeders (two from chargers and one from battery) and two double pole 800 amps Moulded case circuit breakers with thermal over current relays and electromagnetic over current relays for two out going feeders to inverters. Isolators and circuit breakers shall open and close with snap action. Fuses of appropriate capacity shall be provided for incoming feeder from battery. All switches, fuses, circuit breakers and buses shall be rated for D C system fault level, which shall be indicated by the bidder in his proposal. Circuit identification cards mounted in card holders shall be provided on the hinged panel board front. The number of feeders (WITH 20% spare feeders) and rating of each feeder shall be to suit the individual load keeping in view the fuse clearance capability of UPS system already stipulated and shall be as finalised during engineering. No price implication is admissible for the number ratings of feeders as decided during engineering and owners decision in this shall be final. Each feeder shall have fast acting semi conductor fuse, MCB & LED indication for ON status. AC DISTRIBUTION BOARDS PANEL Panel boards for distribution of continuous AC power to essential loads shall be deadfront type panel boards rated for 600/1100 V, AC service. The hinged panel board front shall cover the fuses and wiring gutter but not the switch handles. The hinged front and switch handles shall be covered by the enclosure door. Each panel board shall be constructed for 2 wire, single- phase distribution with a solid neutral bar. Phase and neutral bars shall be of copper. Rating of the main lugs shall be equal to the rated continuous full load current of each inverter. Each panel board shall have one fused disconnect switch & MCCB of adequate rating for incoming feeder for A C Bus and requisite double pole, suitably rated ampere fused, disconnect switch branch circuit devices (MCB). Fused switches shall be equipped with arc quenchers, visible blades, and quick-make quick-break operating mechanisms. Maximum size fuse which branch circuit fuse holders will accept shall be rated at 60 amperes. As each UPS fed load will be provided with two hot

7.12.02

7.13.00 7.13.01

7.13.02

7.13.03

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redundant 100% rated feeders. Main feeders to ACDB shall be provided with digital type Ammeter, Voltmeter, Frequency meter, PF meter, Watt meter & VA meter. One from ACDB-A and other from ACDB-B, boards with feeders shall be constructed in line. The number of feeders (WITH 20% spare feeders) and rating of each feeder shall be to suit the individual load keeping in view the fuse clearance capability of UPS system already stipulated and shall be as finalised during engineering. No price implication is admissible for the number ratings of feeders as decided during engineering and owners decision in this shall be final. Each feeder shall have fast acting semi conductor fuse, MCB & LED indication for ON status. 7.14.00 7.14.01 FACTORY TESTS The UPS system & 24 V DC system shall be factory tested under various stages of manufacture and upon full completion as per Owner approved quality Assurance plan, the tests shall include, but shall not be limited to the following: Type and Routine Tests Type and routine tests for various components and sub assemblies in accordance with IS and/or NEMA, TEE Test Standards. 7.14.03 Functional Tests 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 inverters for synchronisation with range of adjustments; transfer and retransfer of static switches under influence of under voltage and over current, tests on charges, batteries and other system components to confirm compliance with specification. 7.14.03.1 UPS (Factory Acceptance Test) i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv) xvi) xvii) xviii) Power Efficiency (IEC 146-2, IEC 146) at 100% load, 50% load. Load test (Approved Procedure)- load regulation test Audible noise test (IEC 146-2 ) Fuse clearing capability (Approved Procedure) Relative harmonic content (IEC 146-2) Synchronous transfer & synchronization test (IEC 146-4) Temperature rise test without redundant fans (IEC 146-2) Input voltage variation test (Approved Procedure) Overload test on inverter & charger (Approved Procedure) Insulation test (IEC 146) Restart test (IEC 146-2) Short circuit current capability (IEC 146-2 clause 5.10) Output voltage & frequency tolerance (IEC 146-2) Voltage current division (IEC 146-2) Relative harmonic content (IEC 146-2) Parallel redundancy ( * Simulation of Parallel redundant fault (IEC 146-4 ) Overload test (final acceptance test) Any other required as per national international standard or QAP

7.14.02

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DESEIN 7.14.03.2 Battery Charger for UPS & 24 V DC System i. ii. iii. iv. v. vi. vii. viii. ix. x xi. xii.

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Short circuit current capability (IEC 146-2). Temperature rise test without redundant fans (Approved Procedure) SWC test (Approved Procedure) Efficiency / PF (IEC 146-2, IEC 146) Audible noise test (IEC 146-2 ) Fuse clearing capability (Approved Procedure) Relative harmonic content (Approved Procedure) Temperature rise test without redundant fans (IEC 146-2) Overload test on charger (Approved Procedure) Restart test (IEC 146-2) Output voltage tolerance (Approved Procedure) Output voltage harmonic content (Approved Procedure)

The above test shall be witness by owner/owners representative. 7.14.04 Burn-in Tests and Temperature Rise Tests Each component of UPS & 24 V DC system shall undergo burn-in test for 50 hours continuously. All equipment provided under this specification shall be operated under rated conditions and maximum ambient temperature for not less than 120 hours prior to release for shipment. In addition, static switches shall be subjected to not less than 1000 Transfer/retransfer cycles at full load. During temperature rise test final rise in temperature of semiconductor and devices will be measured at rated conditions and the temperature shall be within stipulated limits for components. After manufacture, the system shall be subjected to routine tests as per standards. The bidder shall indicate all these routine tests in their offer. These shall include insulation resistance test, die-electric with stand test (by applying voltage of 2000 V for one minute) noise test, interference noise test, surge with stand capability. 7.14.05 Type test Bidder shall submit following type test report along with final acceptance report. a) b) Battery as per IS-1652, IS 10918 & IEC 62259 latest version. UPS/Charger/24 V DC Charger i. IP degree ii. Surge withstand capability (SWC) iii. Dry heat test ( IEC-68.2.2) iv. Dump heat test (IEC-68.2.3) v. Vibration test (IEC-68.2.8) vi. EMC test ( IEC-61000.4.2)

The above all type test shall be conducted at National / international laboratories only.

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DESEIN 7.14.06

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Bidder shall submit following documents along with Factory Acceptance Test (FAT) report: 1. 2. Internal test report along with heat run test report. Calibration certificate of measuring instruments

7.14.08

Copies of all test reports shall be submitted to the Owner as per procedure to be finalised during contract award. The owner reserves the right to witness all tests. Testing at site Full load test shall be demonstrated after commissioning of UPS & 24 V DC charger with batteries at site for 72 Hrs.

7.14.09

7.15.00

AVAILABILITY REQUIREMENTS A high degree of reliability & availability is required. Following reliability targets are specified:S.No. 1) 2) 3) Equipment Charger Inverter Static Switch MTBF in years 10 3 15

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DESEIN CHAPTER-8

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MATERIAL SUPPLY, WARE HOUSING, ERECTION, TESTING AND COMMISSIONING 8.00.00 General Requirements: This section covers supplies cum services bidders responsibilities for packing, shipping, ware-housing and the installation and commissioning of all equipment and materials furnished and installed under this specification for complete C & I system. Though specifically the work of dismantling of the existing equipments / instruments is not mentioned here it shall be assumed as an integral part of erection work .The work involved in dismantling is elaborated while defining the scope of work and scope of supply in this specification. The requirements of this section supplement other applicable sections of this volume. All materials fabricated and installed shall conform to the latest edition of applicable codes and standards. Work shall be carried out in accordance with the various International & Indian Standards and any local statutory regulations as applicable, listed below, though not limited to them: i) ii) iii) iv) v) vi) vii) viii) ix) x) ISA Instrument Society of America, Standards and Recommended Practices ANSI American National Standard Institute, B2.1 Pipe Threads B16.5 Steel Pipe Flanges & Flanged Fittings ISI Indian Standards Institute NEC National Electric Code API American Petroleum Institute ASME American Society of Mechanical Engineers IBR Indian Boiler Regulations NFPA National Fire Protection Association BS British Standards IS Indian Standards

The work shall also conform to installation standards, hook-up drawings, and support standards. Layout drawings or any other drawings, documents or schedules submitted by the bidder and approved by the Owner. All site-mounted instruments, junction boxes, air headers, tubing and wiring terminations shall be labeled or tagged in a manner approved by the Owner. Terminals for electrical connections shall be numbered and identified to indicate polarity, ground connections, test connections and any other pertinent information 8.01.00 8.01.01 MATERIAL SUPPLY AND WAREHOUSING Delivery Schedule. The equipments specified herein are required to be delivered at site as per the agreed schedule with owner. The delivery schedule shall be clearly indicated and guaranteed. 8.01.02 Crating

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All equipment and materials shall be suitably coated, wrapped or covered end boxed or crated for moist humid tropical shipment and to prevent damage or deterioration during handling and storage at the site. Equipment shall be packed with suitable desiccants sealed in water-proof, vapour-proof wrapping, and packed in lumber or plywood enclosures, suitably braced tied and skidded. Lumber enclosures shall be solid, not slatted. Desiccants shall be either silica gel or calcium sulphate, sufficiently ground to provide the required surface area and activated prior to placing in the packaging. Calcium sulphate desiccants shall be of a chemical nature to absorb moisture. In any case, the desiccant shall not be of a type that will absorb enough moisture to go into solution. Desiccants shall be packed in porous containers strong enough to withstand handling encountered during normal shipment. Enough desiccant shall be used for the volumes enclosed in the wrapping. Review by the Owner of the Bidders proposed packaging methods shall not relieve the Bidder of responsibility for damage or deterioration to the equipment and materials specified. All accessory items shall be shipped with the equipment. Boxes and crates containing accessory items shall be marked so that they are identified with the main equipment. The contents of each box and crate shall be indicated by marking on the exterior. All boxes, crates, cases, bundles, loose pieces, etc. shall be numbered consecutively Form No.1 upward throughout all shipments from a given port to completion of the order without repeating the same number. All itemized list of contents shall be enclosed inside each case, and one other copy securely fastened to the outside of the case in a tin or light weight sheet metal envelope or pocket. The lists shall be plainly marked and placed in accessible locations to facilitate receipt and inspection. The packing list shall indicate whether shipment is partial or complete and shall incorporate the following information on each container, etc. according to its individual shipping number: a) b) c) d) e) Export case markings. Case number. Gross weight and net weight in Kilograms Dimensions in centimeters. Complete description of material including order number.

Packaging or shipping units shall be designed within the limitations of unloading facilities and the equipment which will be used for transport. It shall be the Bidders responsibility to investigate these limitations and to provide suitable packaging to permit safe handling during transit and at the job site. Electrical equipment controls and instrumentation shall be protected against moisture and water damage. All external gasket surfaces and flange faces, couplings, motor pump shafts, bearings and like items shall be thoroughly cleaned and coated with rust preventive compound as specified above and protected with suitable wood, metal or other substantial type covering to ensure their full protection.

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Coated surfaces shall be protected against impact, abrasion, discoloration and other damage. Surfaces which are damaged shall be repaired. All exposed threaded parts shall be greased and protected with metallic or other substantial type protectors. All female threaded openings shall be closed with forged steel plugs. All piping, tubing and conduit equipment collections shall be sealed with metallic or other rough usage covers and taped to sealed the interior of the equipment piping, tubing or conduit. Provisions shall be made to ensure that water does not enter any equipment during shipment or in storage at the plant site. Returnable containers and special shipping devices shall be returned by the manufacturers field representative at the Bidders expense. 8.01.03 Shipping The Bidder shall be fully responsible for the safe and timely delivery of all equipment and materials furnished under this specification. The Bidder shall discuss with the Owner, the routing of shipments and shall route the same as indicated by the Owner, provided freight rates are no greater than by other routes. Shipment of all equipment and materials across land shall be by truck or rail. The Bidder shall take into consideration the effects of shock and vibration to equipment during transit and shall provide safeguards against same. Transfer of equipment between carrier vehicles shall be held to an absolute minimum. Ships used for the transportation of equipment shall have the capability of on-board lifting and off-loading all shipments of equipment and materials. On deck shipment will not be permitted unless prior approval has been obtained from the Owner. 8.01.04 Factory Assembly: All trend recorders, cathode ray tubes, keyboards and printers shall be individually packed for shipment. Electronic control modules of plug-in type shall be removed from equipment racks after factory check-out and individually packed for shipment. Other equipment shall be fully assembled at the factory, except for necessary shipping splits in cabinets. 8.01.05 Consolidated shipments Except where authorized by the Owner in writing, the Owner will not accept direct shipments of bidder furnished materials and equipment from sub-bidders. The bidder shall assembly-shipping units composed of those items of materials and equipment, which he obtains from sub-bidders. Shipping unit assembly shall be at one of the bidders regular business addresses. Each item shall be tagged with its individual identification used on the drawings for this contract and shipped as part of as shipping unit to the construction site.

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DESEIN 8.01.06 Shipping List:

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The Bidder shall submit to the Owner duplicate copies of shipping notices describing each shipment of material or equipment. The shipping notices shall be mailed to arrive approximately 3 days ahead of the estimated shipment arrival. The addressed for each shipping notice will be determined later. 8.01.07 Materials List: The Bidder shall prepare and submit with the first shipping notice duplicate copies of an itemized materials list covering all material and equipment furnished under these specifications. The materials list shall be in sufficient detail to permit an accurate determination of the completion of shipment. 8.01.08 Inspection at Job Site: The Bidder shall inspect all shipments upon arrival at the job site to determine possible damage or shortages and to record the equipment received in each shipment. The Bidder shall maintain accurate upto-date records of all equipment and materials received. These records shall be itemized for ease of comparison with the materials list specified above. All damages shall be corrected promptly and to the satisfaction of the Owner. The bidder shall submit to the owner copies of all receiving and damage reports for a shipment within two working days immediately following receipt of that shipment. All report forms shall be furnished by the Bidder and shall be acceptable to the Owner. 8.01.09 Receiving and handling The Bidder shall be responsible for the prompt unloading of all equipment and materials furnished by these specifications and shall pay all demurrage incurred. The Bidder shall handle all equipment and materials carefully to prevent damage or loss, shall store them in an orderly manners hall keep adequate and convenient records of their location and shall keep a continuously accurate inventory. The Bidder shall be responsible for the return of his own special containers and shipping devices. 8.01.10 Warehousing: The owner will provide open space for construction of a warehouse of appropriate construction for storage of the bidders equipment and materials. The Bidder shall be responsible for the construction of the warehouse and the interior partitions as required to separate his assigned spare from that of other parties. The bidder shall be responsible for the safety and security of his property while in the warehouse. Space requirements shall be as mutually agreed between the Bidder and the owner. The readiness of the warehouse for C&I part shall be completed by bidder before the arrival of C&I items/panels/electric modules to site. 8.01.11 Storage:

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Stored equipment and materials shall be adequately supported and protected to prevent damage. Equipment shall be moved into the permanent buildings or onto its permanent foundation as soon as construction will permit. Stored materials and equipment shall not be allowed to contact the ground. In warehouses that do not have dry concrete or suspended floors, materials and equipment shall be stored on platforms or shorting. Strip heaters and similar heating devices furnished with electrical equipment shall be electrically connected to provide protection during storage. Heaters shall be energized immediately upon placement of the equipment in storage. Equipment not having integral heating devices shall be heated by alternate methods acceptable to the Owner. Mechanical dehydrators provided in the cubicles shall be maintained in operation from the date of receipt of equipment until directed by the owner. All storage equipment excluding warehousing hall remain the property of the Bidder and shall be removed from the job site following construction. 8.02.00 8.02.01 ERECTION & COMMISSIONING General Requirements i) ii) This section supplements the Clause 1.05.09, Section 1. This section describe the scope of Bidders responsibilities for erection & commissioning of the equipment / system, supplied by the bidder as part of this specification though even not specifically brought out under Clause No. 8.02.02. In general, bidder shall erect and commission all the equipments supplied under his scope. The Bidder shall prepare detailed installation drawings for each equipment furnished under this specification for owner review. Installation of all equipment / system furnished by this specification shall be as per owner approved drawings. In general bidder shall erect and commission all the equipments supplied under his scope. Erection procedures not specified herein shall be in accordance with the recommendations of the equipment manufacturers. These procedures shall be acceptable to the Owner. Instrumentation workshop must be prepared first of all before starting the C&I erection work, in order to ensure proper calibration of various instruments.

iii)

iv)

v) 8.02.02

Work Included The Bidder shall be responsible for furnishing materials and performing field construction as outlined below: a) Furnish all constructional personnel, tools, materials and equipment required to perform the work included under these specifications.

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b)

Furnish, install, terminate all cables including prefabricated cables, instrumentation cable, special cables like coaxial, fibre optic cables (soft link) required for the interconnection of all the bidder furnished components located in control equipment room, main control room, BOPs control room or instruments in the fields. This shall also include termination of all cables at Bidders panel as well as other end panel irrespective of the scope of cable and panels at the other end. Prepare cable ends and train into place all cable ends which terminate in the I/O sub-system cabinets, panels, desks, console and annunciator logic cabinets. Check for continuity and terminate both ends of all cables, which terminate in the I/O sub-system cabinets, panels, and desks, consoles supplied under the specification. Installation of all cables and accessories including cable trays from primary sensor / transmitters to first junction box / marshalling box in field. Furnish and install all cable accessories such as lugs, cable glands for all JBs, enclosures, panels, desks, consoles supplied by Bidder. Scope of supply, laying, installation, termination of cables and loop check outs are included under this specification .Bidder shall include all the cables his scope in this and confirm compliance to scope specifically in his bid. The bidder shall be fully responsible for correct installation of all thermowells (in bidders scope) welding on stubs on process pipe lines, though welding of these thermowells on stubs will be done by the Bidder. Transmitters/instruments shall be installed using fabricated supports which are attached to the vertical members provided for this purpose. Construction shall comply with mounting recommendations of the instrument manufacturers. Brackets, clamps and other employed in the construction of supports. Painting of fabrication shall conform to the requirements for enclosure interiors. For all mosaic panel mounted instruments in bidders scope necessary supports and fixtures shall be provided to maintain the aesthetic look of panel after the removal of mosaic grids for this purpose. All prefab cables and other accessories required for these panels mounted instruments installations are in bidders scope. Nameplates shall be provided for all instruments and devices or instruments are themselves provided with a service engraving. Embossed plastic nameplates of acceptable design shall be provided inside the panel section for all devices located there. Each terminal point shall be clearly identified. Sample terminals shall be identified by name and number. Stamped metal tags attached with stainless steel wire shall be provided at the sample inlet bulk head fittings. Control panels and desks shall be mounted on vibration dampeners which are secured to channels mounted on control room floor. The channel shall be field

c)

d)

e)

f)

g)

h)

i)

j)

k)

l)

m)

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welded to steel plate set into the control room floor concrete. The panels and cabinet in bidders scope shall be appropriately mounted so as to match the cutouts provided for each cabinet and panel. n) Primary impulse piping shall be supported at an interval not exceeding 1.5 meter. The bidder shall provide necessary fixtures either by welding or by bolting on columns and structures to support the pipe. Hangers and other fixtures shall be provided either by welding or by bolting on walls, ceilings and structures to support tube trays. Aluminum tubing supports with all necessary fittings, spacers and clamps etc. shall be provided by bidder. The Bidder shall clearly identify through colour marking or by other means the different type of impulse pipes, isolating valves etc. before these are to be stored at site.

8.02.03

Equipment Installation The Bidder shall furnish all construction materials, tools & equipment and shall perform all work required for complete installation, commissioning of all equipment furnished under this specification. The scope of installation shall include all work up to and including placing the equipment in successful operation. Erection procedures not specified herein shall be in accordance with the recommendations of the equipment manufacturers.

8.02.04

Installation Materials All materials required for complete installation of the equipment shall be furnished except concrete bases with anchor bolts and grouting which will be provided by the owner.

8.02.05

Regulatory Requirements All installation procedures shall conform with accepted good engineering practice and to all applicable governmental laws, regulations and codes.

8.02.06

Equipment Assembly Equipment installed under these specifications shall be assembled if shipped unassembled. The equipment shall also be dismantled and re-assembled as required to perform the installation and commissioning work described in this specification.

8.02.07

Equipment Setting All free standing instrumentation cabinets and panels shall be located within the construction tolerance of plus or minus 3% of the location dimensions.

8.02.08

Free Standing Equipment Free-standing cabinets shall be attached to the floor on concrete equipment bases of supporting steel as indicated on the manufacturers approved drawings and the owners plant arrangement drawings. The cabinets shall be shimmed for proper alignment before bolting them to the floor. Adjacent enclosures shall be shipped to maintain mutually level appearance before they are attached to the floor. Vibration isolating pads of min. 15 mm thickness shall be furnished for all cabinets.

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8.02.09

Defects: All defects in erection shall be corrected to the satisfaction of the Owner and the Engineer. The dismantling and reassembly of bidder furnished equipment to remove defective parts, replace parts or make adjustments shall be included as a part of the work under this specification

8.02.10

Equipment Protection All equipment to be erected under this specification shall be protected from damage of any kind from the time of contract award until handling over of each unit. The equipment shall be protected during storage as described herein. Equipment shall be protected from weld spatter during construction. Equipment having glass components or equipment having other easily broken components, shall be protected during the construction period with plywood enclosures or other suitable means. Broken, stolen or lost components shall be replaced by the bidder.

8.02.11

Repair of Painted Surfaces: After erection, touch-up paint shall be furnished and applied to all abraded or damaged areas on ship painted equipment surfaces. Surfaces shall be properly prepared before application of paint. The touch-up paint shall be of a type equivalent of the shop paint.

8.02.12

Equipment Location guidelines: 1. All individual items of equipment not located in cabinets or on panels and racks are located approximately according to the floor elevation and the nearest burning column. Solenoid valves, electric to pneumatic converters and other control loop accessories not located in enclosures or mounted on valves shall be mounted in easily accessible protected locations near the components with which they are associated. All instruments to be locally mounted (those not in instrument enclosures or on valves) shall be mounted on building walls, columns, or local stands approximately 152 mm above floor level. These local instruments shall be mounted to permit ease of adjustment. Local instruments shall not be located outdoors except when approved by the owner. Air filter regulator sets, valve manifold etc. shall be supplied and installed. No field mounted shall be installed such that it depends for support or rigidity on the Impulse piping or on electrical connection to it.

ii)

iii)

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DESEIN iv)

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All brackets, stands, supports, and other miscellaneous hardware required for mounting devices shall be furnished. Permanent temperature wells on the main steam, hot reheat and cold reheat piping shall not be installed until steam blowing has been completed. Any required adapting hardware such as pipe bushings, nipples, drilled caps and the like shall be provided for complete installation of control devices into process connections Indicating type field mounted instruments shall be installed in such a way that center of indicating dial shall be about 1600-1800 mm from operating floor level. Non-Indicating type field instruments shall be installed such that operating handle of that instrument comes within 1600 mm from operating floor level.

v)

vi)

vii)

8.02.13

Installation of Field Mounted Instruments and Devices The Bidder shall submit installation drawings for all field mounted equipment furnished under this specification for Owners approval. These drawings shall meet the requirements of this specification applicable codes and standards and recommendations of manufacturers of instruments / devices. All installation work under this specification shall be strictly as per installation drawings approved by the owner.

8.02.14

Piping Connections Guidelines: i) All equipment having piping connections shall be leveled, aligned and wedged in place but shall not be grouted or bolted prior to the initial fitting and alignment of connecting piping. All equipment shall, however, be grouted or bolted to its foundation prior to final bolting or welding of the connection piping. All flanged joints shall be checked and retightened after approximately 10 days of operation at normal operating temperature.

ii) 8.02.15

Equipment Check-out: i) All equipment shall be cleaned after installation. Equipment subject to pressure differential shall be checked for leakage. After erection, all equipment having moving parts, having electrical apparatus, or subject to pressure differentials shall be trial operated.

ii)

8.02.16

Conductor Accessories All conductor accessories including terminal materials, lugs, splicing materials, markers, tying materials, support, grips, insulating compounds, tapes.. cable cushioning and glanding materials shall be furnished and installed by the Bidder, if the end wire preparation is necessary to fit cables to individual system elements or components (printed circuit cards).

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DESEIN

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Bidders installation instructions shall be obtained for cable accessories. These instructions shall be in the possession of the craftsmen while installing the accessories and shall be available to the owner for reference. 8.02.17 Splicing Connectors Splices in control or signal conductors shall be made with compression type half ring type terminals lugs. The lugs shall be jointed using bolts, booth lock washers and hex nuts, each being of copper or copper bearing metal. Bolt size shall match the opening in the terminal lug. 8.02.18 Crimping Hand Tools: The crimping hand tools used in securing the conductor in the compression type connectors or terminal lugs shall be those made for that purpose and for the conductor sizes involved. The crimping tools shall be of the ratchet type which prevents the tools from opening until the crimp action is completed. Such tools shall be a product of the connector manufacturer. 8.02.19 Screwless cage clamp type Connections: The connections from control cubicles to termination cabinets and other cubicles shall be screwless cage clamp type. For this proper tools shall be arranged by bidder as on required basis. 8.02.20 Support Grips: Cable support grips shall be either split or closed woven wire type. 8.02.21 Wire and Cable Markers: Markers for wire and cable circuits shall be made of halogen & silicon free polyamide material with inflammability class V2 as per UL 94, ensuring scratch proof printing with the use of environment friendly solvent free ink & latest BLUEMARK UV technology so as to comply the WIPE RESISITANCE according to DIN EN 61010-1/VDE 0411-1. Markers for wire and cable circuits shall be arranged to include a marker board, non releasing holding device, and cable fastening tail. The marker board shall not be less than 1 cm wide, 2 cm long and 0.5 mm thick. One side shall be roughened to hold black nylon marking ink. Identification shall be permanent and water proof. The holding device shall be designed to allow the fastening tail to pass around the cable through the holding device, and prevent the removal of the tail without cutting it loose from the marker. 8.02.22 Lacing Materials: Lacing materials for field installed cable shall be non releasing nylon ties. 8.02.23 Splice Insulation: Splices in control and signal wiring shall be insulated with all weather vinyl plastic electrical tape.

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8.02.24

Installation: Immediately prior to the installation of each cable or cable group, the raceway route to be followed shall be inspected and ascertained to be complete in installation and free of all materials detrimental to the cable or its placement. All cable assigned to a particular duct or conduit shall be grouped and pulled in simultaneously, using cable grips and acceptable lubricants. All cables shall be routed as required by the circuit schedule. If at any time during the progress of the work the Bidder finds raceway which appear inadequate to accommodate the assigned cable, he shall notify the owner at once and shall discontinue any further work on the questionable raceway until advised by the owner as to how he shall proceed. All cables shall be carefully checked both as to size and length before being pulled into conduits or ducts. Cable pulled into the wrong conduit or duct or cut too short to rack, train, and splice as specified herein, shall be removed and replaced by and at the expense of the Bidder. Cable removed from one conduit shall not be installed in another conduit or duct without permission of the owner. Fiber Optical Cables shall be routed through suitable grade permanently lubricated HDPE protection pipe as per IS 4984, IS 12235 & TEC.G/CDS-08/01 of suitable size @53% fill factor.

8.02.25

Termination: The termination of cable shall be in accordance with the following requirements:i) ii) iii) iv) Train cable in place and cut squarely to required length. Avoid sharp bends. Remove necessary amount of cable jacket and insulation without damage to the conductor. Install terminals or connectors as required ensuring a firm metal-to-metal contact. Terminate cable shields on one end only to the grounding bus provided in each I/O sub-system cabinets. Isolate these shields at field terminations and in junction boxes cabinets and panels when shielded cables connect between such equipment and the I/O sub-system cabinets.

Cables: The Bidder shall furnish and pull prefabricated cables required for the interconnection of Bidder furnished components located in the Control Equipment Room and the Main Control Room in accordance with the requirements of this specification. These cables shall meet IEEE 383 flame retardant standards and shall have FRLS properties as furnished under clause 9.06.02. The Bidder shall connect both ends of each prefabricated cable specified to be furnished with the system.

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Additionally, the Bidder shall terminate all cables which terminate in the I/O sub-system cabinets and as per cable interconnection scheme furnished with the specification. The Bidder shall take into consideration that cable end preparation is required for all the I/O termination at his cabinets, panels, desks, consoles for each cable. The bidder shall furnish and install all impulse piping, isolating valves, fittings etc. required for installation of all field mounted instruments. The bidder shall furnish all necessary supports and fixtures and shall erect them correctly for installation of all panel mounted instruments. All insulated conductors furnished and installed by these specifications shall be electrically tested after installation. All circuits shall be tested with circuit complete except for connection to equipment. Any circuit failing to test satisfactorily shall be replaced or repaired and retested as directed by the owner. All equipment and labour required for testing shall be provided by the bidder. 8.02.26 Test after Installation: All prefabricated cables furnished and installed under this specification shall be electrically tested after installation. All cables shall be tested with the circuit complete except for connections to equipment. All circuit failing in test satisfactorily shall be replaced or repaired and retested by the Bidder at his expense, as directed by the owner. Cables which are only terminated by the Bidder shall be checked for continuity as they are terminated. All equipment and labour required for testing shall be provided by the Bidder. Test instruments shall be directly traceable to the National Physical Laboratories as far as calibration is concerned. 8.02.27 Continuity, Identification and Short Circuit Tests: All insulated conductors shall be tested for continuity and checked for 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 circulated to another conductor in that cable. 8.02.28 Insulation Tests: All insulated conductors shall be tested with a 1000 Volt megger or an equivalent testing device. Insulation resistance measurements shall be made between each conductor ground and between each conductor and all other conductor of the same circuit. Minimum acceptable resistance values shall be 500 mega-ohms.

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8.02.29

Additional Tests and Checks: The Bidder shall perform additional tests and construction checks in accordance with the sections of this specification dedicated to shop and site tests.

8.03.00

Bidder must offer general tools & tackles and special calibration instruments required during start-up, trial run, operation and maintenance of the plant. S.No. 1 2 Details Crimp pliers, for ferrules as per DIN 46228 Part 1+4, 0.14 - 10 mm, lateral insertion, square crimp Cable cutter for copper and aluminum conductors Stripping tool, for wires and conductors of 4 - 16 mm, selfadjusting, stripping length up to 18 mm, cutting capacity up to 10 mm stranded /1.5 mm solid Screwdriver, bladed, matches all screw terminal blocks up to 4.0 mm connection cross section, blade: 0.6 x 3.5 mm, without VDE approval Screwdriver, blade: 0.6 x 3.5 x 100 mm, length 180 mm The digital multimeters with volt sensor function as per the internationally applicable standards IEC/EN 61010. The devices can be used in the case of voltages of up to 600 V, category III or 1000 V, category II.

4 5 6

8.04.00

Calibration, Testing and Commissioning: Bidder shall provide all testing facilities for each and every equipment/instrument in his scope as per detailed description provided in this specification. It is Bidders responsibility for correct installations and commissioning of all equipment/ instruments in his scope. Bidder shall provide a group of highly skilled personnel for installation and commissioning of the entire equipments supplied under this scope.

8.04.01

CALIBRATION a) All instruments shall be calibrated strictly as per the manufacturers instructions prior to installation. The scope of calibration includes all field instruments of all types namely electronic, electrical etc. Bidder shall use his own oil free instruments and air compressor for calibration purposes. Conversion from one unit to another for the purposes of calibration is not allowed. Procedures for calibration for different items are as outlined below. However, the detailed procedure shall be submitted to Owner for approval before proceeding with the calibration: All pressure and differential pressure transmitters shall be calibrated to the settings as per instrument data/specification sheet and instruction of Owner. Pressure instruments shall be calibrated by applying pressure to

b)

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the instrument using dead weight tester and manometer (for low pressure). Receiver instrument shall be calibrated and aligned using test hookup as per instruction from the manufacturers/Owner. Pressure transmitters shall be calibrated at 0%, 25%, 50%, 75% and 100% and vice-versa of range using dead weight tester. DP transmitters shall be calibrated at 0%, 25%, 50%, 75% and 100% and vice-versa of range using dead weight tester. Control valves and positioners shall be checked for hysteresis and linearity and calibrated for rated strokes. Prior to calibration, valves shall be cleaned externally. The stem shall then be lubricated, if required and stroked few times to extreme positions of plug to ensure that movement is free from friction. The valve shall then be calibrated for rated stroke and linearity also. Subsequently, the valve shall be checked for hysteresis to the accuracy of 1% FS.

All calibration readings shall be recorded in the prescribed format and submitted to the Owner for approval. Where significant deviations from specifications are obtained, the matter shall be brought to the immediate notice of Owner for corrective actions. The bidder is responsible for calibration of all instruments/ items covered under the scope of works. The test reports shall be submitted to Owner on a daily basis. Calibration test facility shall be located near the work site. 8.04.02 LOOP TEST a) Loop test shall be performed after calibration of all instruments and leak test of signal lines. Loop test is conducted to check the functional performance of all elements comprising the loop thereby ensuring proper connections and operations. Before proceeding for loop test, the calibration results of individual elements shall be recorded on the prescribed Performa and shall get it approved by Owner for correctness of installation, measurement and calibration results. Loop testing for all control loops shall be generally by simulation of process conditions and shall fix points namely 0%, 25%, 50%, 75% and 100% of full scale inputs. Detailed procedure shall be submitted to Owner for approval before proceeding with the loop testing. The field/receiver pressure switches are simulated for abnormality by disconnecting the wires of terminals and function of all associated system are checked. Performance of individual loops may be accepted for an overall accuracy of +0.5%. Where deviations exist, bidder shall recalibrate the instruments, which forms part of the loop checking where required, at no extra cost. After the loop test is complete, the bidder shall connect back any terminations and connection removed for loop check. A loop shall be considered as completed, only after measurements in that particular loop are complete and certified by the Owner, in addition to loop sheets being duly filled in all respects

b)

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and approved by the Owner. Final certified loop sheet shall be submitted in four copies and one transparency. a. Loop checking of following shall be carried out: b. c. d. e. 8.04.03 TESTING a) INSTRUMENT IMPULSE PIPING i) Flushing of impulse piping shall be carried out while the line is pressurized after the isolating valve of the instrument is closed. The connection near the instrument shall be opened so that no dirt enters the instrument. Testing of impulse piping/tubing shall be carried out after the installation of instrument with primary piping/tubing and flushing is complete in all respects and approved by the Owner. Primary piping/tubing shall be tested hydraulically to 1.5 times the maximum operating pressure. After thorough flushing, lines shall be isolated from both instrument and vessel/piping ends. After pressurization, the source shall be cut-off and the pressure shall not drop during 15 minutes testing period. The lines shall be blown with air, after hydraulic test. In case, no isolation valve is provided near the instrument, impulse piping/tubing shall be pressurized along with the instrument to the maximum pressure of the scale in case of pressure instrument and maximum operating pressure in case of differential pressure instruments with equalizing valve open. In special conditions, where hydrotesting is not permissible due to service requirement, the testing shall be carried out by using air/nitrogen as per instructions by the Owner. All local loops All loops upto local (control) panels All loops unto control room All loops to control rooms for DDCMIS/non-DCS/DCS instruments such as gas detectors, fire detectors and other special instruments.

ii)

b)

INSTRUMENT AIR LINES/SIGNAL TUBING i) Flushing of instrument air lines shall be carried out while the line is pressurized to 7 kg/cm2g after disconnecting the copper tube at each air regulator upstream end. The line shall be blown for 15 minutes to remove trace of oil and dirt. The air regulator shall be taken in line, the copper tubing at the instrument end is disconnected and blown for 3 minutes to remove trace of dirt. Testing of instrument airlines shall be carried out with instrument air at 7 kg/cm2g upto the upstream of filter regulators after thorough flushing. All lines shall be checked with soap solution and bubbler unit for possible leak at joints. All the signal tubing shall be tested with 1.5 kg/cm2g air after proper flushing.

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DESEIN ii)

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All air tubing shall be tested and inspected by one of the methods given in ISA RP 7.1 Pneumatic Control Circuit Pressure Test. Clean & oil-free instrument air shall be used for the test instrument air tubing and piping shall not be hydrostatically tested. Instrument air mains shall be isolated from the instrument and pressurized to 7 kg/cm2g. Then they shall be isolated from the pressure source and pressure reading on the gauge shall not fall by more than 1 psi in ten minutes or as per the acceptance of Owner.

c)

All cables (signal, control, T/C extension, special, power supply, etc) shall be laid as per the junction box/cable schedule. Before and after laying, the cables shall be tested for continuity and for the insulation resistance by a certified megger and checked for proper connections and results recorded and approved by the Owner. The testing shall be done after disconnecting the cable at both the ends. Cables shall be identified with aluminium tags at both ends and termination ends by ferrules. Wiring shall be checked to ensure that is correctly connected and properly grounded. Correct connections of all electric switches shall be checked. Alarm operation checks shall be made by the bidder to check functionally all alarms and trip system. Wherever possible, process conditions shall be simulated to check the operation. Faults in wiring or piping shall be corrected in the presence of Owner. Earthing of local panels/cabinets etc shall be done as per the documents and instructions of the Owner. Erection procedure will be further discussed in detail after award of contract and shall be subject to the approval by owner/client.

d)

8.04.04 8.04.04.1

INSTALLATION CABLE INSTALLATION & ROUTING Immediately prior to the installation of each cable or cable group, the raceway route to be followed shall be inspected and ascertained to be complete in installation and free of all materials detrimental to the cable or its placement. All cable assigned to a particular duct or conduit shall be grouped and pulled in simultaneously, using cable grips and acceptable lubricants. All cables shall be routed as required by the circuit schedule. If at any time during the progress of the work the Bidder finds raceways, which appear inadequate to accommodate the assigned cable, he shall notify the owner at once and shall discontinue any further work on the questionable raceway until advised by the owner as to how he shall proceed. All cables shall be carefully checked both as to size and length before being pulled into conduits or ducts. Cable pulled into the wrong or duct or cut too short to rack, train, and splice as specified herein, shall be removed and replaced by and at the expense of the Bidder. Cable removed from one conduit shall not be installed in another conduit or duct without permission of the owner. Cable carrying analog current and mV signal shall be segregated from cables carrying binary signals.

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Thermocouple extension/compensating cables to be laid from instrument location to control room as per required standard. Identification tags shall be provided on either end of individual cores, multicore/pair/triad cables including unused cores as per wiring diagram/cable/junction boxes schedules. Ferrules & Markers shall be used for identification of cores. Aluminium tag plates shall be used for identification of cable/junction boxes. All cables shall be cut, after the exact site measurements are taken between ends and the cable drums shall be so selected before cutting the lengths, as to avoid any wastage. Meggering should be done for each drum and length. While terminating the leads at the field instruments, a 300 mm length loop shall be provided to facilitate easy removal of instruments. In the field, the cables shall be laid in the overhead ducts and trays as per layout drawings. While laying cables in ducts/trenches or burying them, care shall be taken to ensure that two signal cables like alarm, analyzer cables, special cables compensating/Extension cables, etc are separate from other power supply cables. Separation of low signal cables and power supply cables in trays/ducts shall be done as shown in the tray/duct drawing. Jointing of cables are not permitted. At each road crossing and other places where cables enter pipe sleeves, adequate bed of sand shall be given so that the cables do not slack and get damaged by pipe ends after pack filling. After laying all the cables, the cable entry to control room shall be suitably filled and sealed so as to achieve a positive seal against the entry of gas/water etc. All cables shall be laid in accordance with the layout drawings and cable schedule and tubing schedule. Multicore/multipair cables shall be bent in a large radius as per manufacturers standards All cable glands shall be properly sealed with a sealing compound. Wherever cable glands are provided at field devices/instruments/JBs/panels, the same shall be covered along with the cable end by suitably designed flexible PVC sleeves matching dimensions on cables and glands. All cable runs shall be identified by tag nos which shall be provided at both junctions boxes and panel ends and also at the bends and the places where the cables is shifted from one tray to other tray. For screened cables, proper ground connections shall be provided. For DC voltage signal, additional precautions are to be taken which are indicated below: a. Line voltage drop due to high resistance splices, terminal contacts, insulation leakage at terminal block, very long transmission line etc. shall be reduced as far as practicable. Receiving instrument should have an input impedance of around 1000 times the impedance in the rest of the circuit to reduce the loading error.

b. 8.04.04.2

CABLE IN TRAYS All cables shall be carefully laid or pulled in the trays so that neither the cable nor the trays are damaged. Cable may be laid along the side of the tray system during installation provided; it is protected from dirt, water, oil, or other detrimental materials and from mechanical injury. Cable shall be cut sufficiently long to conform to the contour of the trays, with particular attention paid to vertical inside bends. All excessive slack shall be removed from the cable so that it lies parallel to the sides of the trays. The cable shall be tied to the tray with nylon ties at 2-meter intervals to hold it in place.

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The cable routing can be done after consulting site Owner without increasing the cable length, all cable tray shall be suitably supported at an interval of 150mm(max) horizontally & 750mm(max) vertically, all branch routing shall be done with 100mm/50mm perforated trays, cable trays shall be routed below the platforms without affecting the walkways, supports and equipment foundations. Furnish, install, terminate and test all signals cable which interconnect between various equipments supplied by the relevant bidders including marshalling cabinet/termination cabinets/system cabinets TBs, control cabinet relay cabinets, vibration cabinets, various peripherals etc. located in control room, control equipments room, SWAS room, charger and UPS room etc.

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DESEIN CHAPTER-9

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ERECTION HARDWARE 9.00.00 9.00.01 PROCESS CONNECTION AND PIPING General Requirements This section covers the material requirement for instrument connection to process, instrument process, piping, tubing, supports, Instrumentation cables, control cables and power cables for connecting UPS, 24/48 V DC, unregulated power supply for cubicle illumination, compensating cables/Extension cables, transmitter racks and main accessories to be furnished under this specification and the requirements of installation and routing. Impulse lines, fittings and other accessories required for the erection of complete Instrumentation and Control System supplied under various packages of this specification shall be supplied on as required basis. Bidder shall offer all necessary items for this section based on his experience on similar plants, plant layout diagrams, installation drawings and other applicable sections of this specification. Based on the good engineering practices Bidder shall furnish installation drawings during the engineering of the system for Owners review and approval .The installation of the drawings shall be suitable for his installation of his range of instrumentation. The Bidder shall furnish and test all required erection hardware, which is necessary for proper installation and interconnection of the equipment/systems furnished by the Bidder and their integration with main equipment/systems as per the enclosed installation drawings and other applicable clause. The Bidder shall furnish all hardware and accessories to ensure that the equipment/systems furnished form a complete and operational system meeting the intent and requirement of this specification. All materials, furnished shall conform to the latest editions of America National Standard Code for Pressure piping, Power piping, ANSI B311.1, ANSI B16.11, ASME Boiler and Pressure Vessel Codes, IBR and other applicable ASME, ANSI and Indian Standards. Schedule numbers, sizes and dimensions of all carbon steel, stainless steel and alloy seamless steel pipe shall confirm to ANSI B.36.10 and of stainless steel pipe shall confirm to ANSI B 36.19 unless otherwise specified. All materials supplied under this section shall be suitable for intended service; process operating conditions and type of instruments used and shall fully conform to the requirements of this specification. The Bidder is responsible for the performance of the equipment furnished on system basis any shortfall in erection material observed during erection stage shall be compensated by the Bidder at no extra cost. (Installation drawings # 114-04-0000, 0100 to 0113 shall also be referred by bidder). 9.01.00 9.01.01 GUIDLINE FOR INSTALLATION AND ROUTING OF INSTRUMENT PIPING General Requirements The following general erection guidelines have been enumerated here to enable the Bidder to estimate the requirement of instrument piping in plant:-

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i)

All instrument piping shall be in accordance with good engineering practice. It shall be finalized during engineering stage. Instrument piping shall be complete with fittings, valves and other required accessories. Instrument piping shall not be routed:a) b) c) d) Across equipment removal areas Below mono-rails and cranes Above or below removable gratings Above or below cable trays.

ii)

iii)

Primary Impulse Piping System: a) The primary impulse piping system shall include the instrument piping and all required accessories from process tap off point (root valves onwards) up to the respective instruments. From the same source, Tee off for instruments are not allowed. Separate tapping shall be provided for each instrument. The Bidder shall provide the necessary fittings and accessories along with impulse pipes for completeness and arrangements as per the finalized Instrument Installation Diagrams. Special accessories such as reservoirs and other devices shall be installed as required for flow primary element connection as required by the design of instruments, in accordance with the instructions of the instrument manufacturer. The Bidder shall prepare impulse pipe routing drawings. Impulse piping shall include a blow-down line and shut-off valve adequate for the duty requirements and for withstanding continuous design pressure and temperature of process medium. For process pressure above 40 Kg/Cmg, double valves shall be used before connecting to the blow-down header (This arrangement shall be provided for installation for the new transmitter if the existing transmitter has the same arrangement.) To assure a constant static head the connections from low pressure steam and low pressure liquid filled lines should preferably slope downward continuously towards the instrument as the instrument is mounted below the source point. If downward slope is not feasible or the instrument is mounted above the source point, the line should slope upward continuously and a pigtail installed at the instrument to assure a water seal for temperature protection. Upward sloping liquid lines should be used only if the process pressure is sufficient to assure a head of liquid at the instrument. Horizontal runs should have a slope of not less than 40 mm per meter and must be adequately supported to maintain a constant slope. Vacuum connections to the condenser should always slope upward to the instrument. Primary process piping for steam flow, liquid flow and manometric level measurement systems should preferably slope downward from the primary element connections to the instrument. Primary piping for flue gas and air flow measurement systems should preferably slope upward from

b) c)

d)

e)

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the primary element connections to the instrument. If these requirements cannot be met, special venting or drain provisions will be required. Horizontal runs must have a slope of not less than 40 millimeters per meter and must be adequately supported to maintain a constant slope. f) Primary process piping from the field which enters the instrument enclosure from the bottom shall extend into the enclosure approximately 150 millimeters and be equipped with a socket weld to flare less tubing coupling of stainless steel. This coupling shall be used to connect the field primary process line to the enclosure process line. The field primary process line shall be anchored to the enclosure angle with U-bolts. Holes for supporting U-bolts shall be field or drilled. All impulse piping shall be supported rigidly at an interval not exceeding 1.5 meters so as to prevent excessive sag in piping. Process piping shall not be used for supporting impulse piping. Impulse lines subject to severe sonic pulsations such as boiler feed pump discharge, shall be of sufficient length and of suitable configuration to scatter harmful sonic wave energy before it reaches the instrument. Impulse piping shall be installed to permit thermal expansion without placing excessive stress on the piping and without affecting the gradient of slope. Long continuous straight runs of piping shall always be avoided. If required, expansion loops shall be provided at least every 2.5 meters to break the continuity. All welded and screwed fittings shall conform to ANSI B16.11. Threads of piping components shall be taper pipe thread in accordance with ANSI B2.1. All threads shall be clean machine cut with all burrs and chips removed. Lubricants shall be of dry filc type. Any one of the following compounds may be used as a pipe thread sealer. Bidder shall supply adequate amount of his preferred sealer for erection purpose. a) Permatex b) Molycote c) Neolube (Teflon tape shall not be used as a pipe thread sealer). 9.01.02 Impulse Piping System Impulse piping system consists of primary impulse pipes/tubes, valves, fittings, valve manifolds and other accessories between the source connection point (source shut-off valve onwards) and all instruments/devices. Impulse pipe span for supporting clamp shall be 1.5 mtr. This will also include all piping and valves etc. required for instrument drain and vent connections. The Bidder shall furnish and test all items required for completeness of this specification. 9.01.03 AIR SUPPLY PIPING

g)

h)

i)

j)

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The piping for air supply shall be as specified below (However the Bidder shall supply the materials as required basis to complete the system in all respect) i) Individual Supply Lines and Control Signal Lines:Air lines shall be inch size, connected by brass/SS316 flare less tubing fittings. Copper/SS316 tubing shall be light drawn tampered tubing conforming to ATM B75 except copper tubing in tubing cables shall be annealed soft temper tubing conforming to ASTM B68 or B75. Fittings on the branch line to facilitate connections to the individual supply line shall be cast brass screwed type. ii) Flexible Hoses:Flexible hoses shall be inch SS flexible hose pipe and with Buna-N liner steel wire braid reinforcement complete with inch brass/SS316 fittings and shall have swivel male pipe threads. Each hose shall be done meter in length. iii) Pipe Material Specification:The piping material shall be carbon steel hot-dipped galvanized inside and outside as per IS-1239 or the equivalent of these standard heavy quality with screwed ends. The piping threads shall be as per ASA B.2.1. iv) Isolating Valves:Gate valves as per ASTM B62 inside screw rising stem screwed female ends as per ASA B.2.1 valve bonnet shall be union type and trim shall be stainless steel body rating 150 pounds ASA. Valves sizes shall be inch to 2 inch. v) Fittings:Forged cast steel A234 Gr. WPM galvanized inside and outside; screwed as per ASA B2.1 dimensions as per ASA B16.11, rating 2000 pounds, elbows and soft seats. The size of the fittings shall be inch through 2 inch. vi) Air Filter Regulator Set:An instrument Air Filter Regulator Set with mounting assembles shall be provided for each pneumatic device requiring air supply. vii) Instrument Air Piping System:a) Instrument Air shall be made available by the bidder at 3.5 to 7.0 Kg/cm pressure. The instrument air may be arranged as under:11. For the control valves and power cylinders in owners scope but controlled by bidders control system, the instrument air requirement for E/P converter shall be tapped from the nearby instrument air header laid by bidder / already laid existing piping with accessories available near the control valves or damper.

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Complete hardware required for interfacing with Owner system shall be in bidder scope. b) Air supply piping shall be installed at site always with a slope of over 1/100 to prevent accumulation of condensed water within the pipe. All joints in the instrument air sub-header shall be of screwed type. Instrument air line shall be separate for each individual instrument, equipment & drive with own isolation valve and other required hardware. Tee off of instrument line for two or more same/similar services instrument, equipment & drive are not acceptable. Instrument air flushing/purging lines shall be provided for Bowl Mill DP, secondary air flow measurement instrument and other all flue gas services instruments etc.

c) d)

e)

viii)

Signal / Control Air Tubing System:Necessary tubes with fittings and accessories for output signal from pneumatic instruments mounted in the field and control signals to final control elements shall be covered under this tubing system.

9.02.00

SPECIFICATION FOR ERECTION HARDWARE The erection hardware shall meet the following specifications:Item Specification

9.02.01

Impulse Piping i) High pressure and high temperature services (Medium: Steam & Water and furnace region) Seamless Alloy Steel piping to ASTM A335 GR.P91/22 (schedule XXS/160 for high pressure & high temperature) Seamless carbon steel piping to STM A106, Gr.C

ii)

Low pressure and low temperature services (Medium: Steam & Water) Low pressure and low temperature services (Air, Flue gas) Steam and water analysis system

iii)

ERW carbon steel piping to IS 1239:1973 Heavy class System) Seamless stainless steel piping to ASTM A312 GR. TP-321 ASTM B-75

iv)

v)

Seamless copper tubing

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DESEIN 9.02.02 Fittings Double compression type i) Material for socket weld fittings

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ASTM A105 ASTM A182, Gr. F22 6000/3000 lbs ANSI B16.11 Gr. F-321

ii) iii)

Dimensions of fittings Fittings for steam and water analysis.

9.02.03

Valves i) 3 way valves SS body/forged CS body stellited internals and SW ends as per requirement for 2500 lb/800 lb ASA ratings. FAS body/FCS body 316SS stellited internals with NPT(F) SCRD ends for 3000/2500 lb/1500 lb/800 lb ASA ratings. Construction Single block (Bar stock) FAS body/FCS body 316SS stellited internals with NPT(F) SCRD ends for 3000/2500 lb/1500 lb/800 lb ASA ratings. Construction Single block (Bar stock) FCS body, 316SS stellited internals, NPT(F) SCRD ends. Construction Single block (Bar stock) Globe valves with FAS body/FCS body, 316SS stellited internals SW ends for 3000/2500 lb/1500 lb/800 ASA ratings. FAS/FCS body with NPT (F) SCRD connection and vent plugs for 3000/2500/1500/800 lb ASA ratings. ANSI C83.9-1972

ii)

5- valve manifolds

iii)

3-valve manifolds

iv)

2-valve manifolds

v)

Isolation and drain valves

9.02.04

Condensation vessels

9.02.05

Racks and Associated Equipment Code for pressure piping, welding and Hydrostatic testing

9.02.06

ANSI B-31.1

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9.02.07

Flexible conduits with fittings

Lead coated, paper insulated, heat resistant flexible metallic conduits with necessary fittings.

9.02.08

3 Valve manifold shall be used, wherever Diff Pressure transmitter/switch have been used for pressure measurement. 5 Valve manifold shall Transmitters/Switches. be used for Diff. Pressure & Flow measurement

9.02.09

9.02.10

In addition to above, table # 9.1 shall also be followed for selection of specific erection hard ware as per process requirements. TRANSMITTER & SWITCHES ENCLOSURES In general, BTG process transmitters & switches installed at outdoor location and in areas where they are subjected to splashing oil, water, steam etc., shall be mounted in closed type transmitter rack. For other areas (indoor), open type racks may be used for installation of transmitters and process switches. However the actual requirement shall be finalized during detailed Engineering considering following:i) Transmitter/Switches enclosures shall be free standing, enclosed type offering protection against dust, moisture and vermin. Enclosures shall be suitable for outdoor installations, in thermal power plants. The enclosures shall comprise of Galvanized Sheet mounting plate internally. Also external-mounting brackets in Polyamide or Stainless Steel shall be available. Alternatively transmitter enclosures can be glass Fiber Reinforced Polyester (GRP) compression moulded and shall be weather proof. Instrument piping inside the enclosure shall conform to the specification and in line with typical installation drawings enclosed with the specification. Blow down header shall be provided inside the enclosure as called for. Bulk head connection shall be provided to receive and terminate the impulse pipes from root valves. Instrument tubing, fittings and isolation, drain valves shall be to ANSI code for pressure piping. Piping/tubing shall be subject to hydrostatic tests at 1.5 times maximum system pressure. Support angles shall be provided for valve manifolds, wiring trays etc. Enclosures shall be complete with necessary bulk head fittings, junction boxes, drain header and other accessories as needed on the basis of approved hook up drawings. Sufficient spacing among adjacent transmitters shall be maintained to offer easy accessibility and operational convenience. The enclosure shall be designed with sizes to suit the grouping and to completely include all the hardware for hooking up

9.03.00

ii)

iii)

iv) v)

vi)

vii)

viii)

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the transmitters to the process on the basis of approved installation diagrams. A maximum of five (5) transmitters are envisaged to be grouped in one enclosure. x) A minimum of twenty (20) percent spare terminals shall be provided. Only one wire per terminal shall be used on the outgoing side of these blocks (for cable panel). Any common connections required shall be provided on the panel side of the block. All incoming power terminals are to be clearly identified in a manner distinctly different from all other terminals and grouped in a logical pattern. Chapter no. 6 of this volume shall also be referred for designing of Transmitter/Switches enclosures.

xi) 9.04.00

LOCAL INSTRUMENTS, LOCAL BOARDS AND TAPPING POINTS i) All local gauges as well as sensors, Transmitters and switches any other instruments for parameters like pressure, temperature, level, flow etc for safe and efficient operation of equipment under the scope of specification, shall be provided by bidder as approved by Owner. Such equipment shall be listed by the Bidder detailing the items with the respective functions in service. All field mounted instruments shall be mounted in such a way as not to be affected by vibration & environmental conditions. Racks to mount these instruments shall be furnished by bidder complete with requisite erection hardware, tubings and junction boxes with all terminals of the instruments duly wired complete with cable glands. Groupings of instruments, actual number of racks for instruments and its construction shall be to Owners approval. Transmitters & Switches provided shall be mounted in transmitter/Switches enclosures to owners approval. The junction box for electrical connections shall be outside the transmitter enclosures. All erection hardware required for complete installation/ implementation of entire instrumentation specified is included in bidders scope. Any change in size, type, rating or in quantity deemed necessary during engineering shall be supplied within package price with no additional financial implication to owner. Bidders scope includes providing counter flanges on pipe lines/ vessels to suit owner arranged flanged devices. Counter flanges shall be complete with gaskets, nuts, bolts and other requisite accessories for proper installation. Separate and independent tapping on equipment/associated piping shall be provided to suit the philosophy of redundant primary sensors. Separate sensors for control and monitoring etc are as decided by Owner. This shall include application such as first stage pressure. Wherever the process value being measured needs to be compensated for temp, pressure variations, the tapping points for such compensating elements shall be provided in requisite number along with the tapping for the process value. Whereever transmitters & switches are provided, in addition Local gauges shall also be provided by bidder for local field monitoring.

ii)

iii)

iv)

v)

vi)

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DESEIN vii)

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Local instruments and remote sensors & transmitters to be furnished with the equipment shall generally be as indicated herein and as per redundancy criteria indicated elsewhere but not be limited to the following: -

1. Pressure Measurement i. Pressure Gauge for: a) b) c) d) Shell pressures of all Deaerator, HP and LP heaters and other vessels. Mercury manometers shall be provided during air outlet flows measurement. Bleed steam pressure at extraction point for all turbine extractions and for pressure on drain lines. Pressure gauges at inlets and outlets of condensate extraction pumps, main oil pump, each auxiliary oil pump, AC standby oil pump, DC Emergency oil pump, jacking oil pumps, DM makeup pumps, DMCW pumps, BFP, or any other pumps etc. Pressure Gauge at outlet of each type of Fan. Lube oil pressure before and after oil coolers, HPT & IPT front seal chamber leak off pressure. MS pressure downstream of ESV, after HPT control valves and after HPT first stage, HRH steams pressure after IV, Gland steam header pressure, HPT exhaust etc. Condensate pressure in condensate pump discharge header, and feed water pressure at inlet and outlet of each LP & HP heaters. LP turbine exhaust pressure and condenser pressure Relay/Lube/Control oil pressure, Drain oil lines pressure. Pressure gauges for vacuum pumps and each pump discharge. Pressure gauge at Instrument and service air header in compressor room and in the field at the main location of instrument/service air header, the pressure gauges shall be provided. Pressure gauges at inlet and outlet of each heat exchanger and cooler. Frame mounted Pressure Gauges (FMG) shall be provided for Main steam Pressure, Feed water pressure to economizer, CRH Steam Pressure, HRH Steam Pressure etc. For condensate storage tank the pressure gauge in terms of 0-10000 mm wc or suitable range having dial size of 300 mm or bigger size shall be provided. U tube manometer with Hg filled for direct measurement of condenser vacuum shall be provided in the fixed with isolation valve for local indications. Above are the minimum requirements, actual quantities shall be as decided during detailed engineering by owner. Pressure gauge for all BoP packages as decided during detailed engineering by owner.

e) f)

g) h) i) j) k)

l) m)

n) o)

p) q) ii.

Pressure Switches a) Pressure switches at condensate Extraction Pump Discharge header, Boiler feed pump, seal water line or any other pumps for alarm (high & low) and interlock purpose.

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DESEIN b) c) d) e)

Vol-V : Instrumentation & Control Works

f) g) h) i) j)

k) l) iii.

Pressure switches for steam supply to LP/HP heaters. Pressure switches for initiation of turning gear. Pressure switches for control oil, jacking oil and lube oil pressure for all required alarms and interlocks. Steam pressure downstream of ESV, steam pressure after first stage of HPT, gland steam header pressure and suction line from turbine glands to Gland cooler. Pressure switches for condenser vacuum low, very low alarms & interlocks. Condenser water box pressure for alarm interlocks. Pressure switches (low & high) for individual pumps/blowers suction/discharge and discharge header alarms, interlocks and protection At the main location of instrument air header the pressure low switches shall be provided for alarms in DDCMIS Pressure switches/any other process switch etc. for OLCS / Alarms / Interlocks / Protection. Pressure switches at inlet, outlet of individual pumps and discharge header of pumps for protection and auto start / stop & alarms. Above are the minimum requirements, actual quantities shall be as decided during detailed engineering as per redundancy criteria by owner. Pressure switches for all BoP packages as decided during detailed engineering. by owner.

Differential Pressure Transmitters, Diff Pressure Switches & Diff. Pressure Gauges a) b) c) Pressure across strainers and filters. Diff. Pressure Transmitters/switches/Gauges for all BoP packages as decided during detailed engineering by owner. Diff. Pressure Transmitter across condenser on CW lines, Air pre heaters on air & flue gas lines, on PA lines, CEP suction strainers, Feed control station etc. Above are the minimum requirements, actual quantities shall be as decided during detailed engineering as per redundancy criteria by owner.

d) iv.

Pressure Transmitters a) b) For all services as mentioned for Pressure gauges & Pressure Switches. Pressure Transmitters at condensate Extraction Pump individual Discharge and discharge header, Boiler feed pump individual Discharge and discharge header, seal water line or any other pumps/fans/HT/LT unidirectional drive for alarm (high & low) and interlock purpose. Pressure transmitter for wind box (Left/Right) & pulverizer seal air fans discharge pressure. Pressure Transmitters as on required basis for monitoring, interlocks & controls as per redundancy criteria and approved by owner. Above are the minimum requirements, actual quantities shall be as decided during detailed engineering as per redundancy criteria and approved by owner. Pressure Transmitters for all BoP packages as decided during detailed engineering by owner.

c) d) e)

f)

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2.

Temperature Measurments:The Bidder shall furnish all temperature sensing elements to be installed in their piping. The scope of supply shall include, but not limited to the following: -

i) ii) iii)

iv)

v)

iv) v)

Duplex RTDs for all bearing, drain oil from bearings, LPT exhaust steam, 3 nos of duplex RTDs each on left and right CW outlet of condenser etc. 6 no. duplex or 12 no. simplex Embedded temperature detectors for various motor stator windings and duplex RTDs for Motor/Pump bearing temp. Chromel-alumel surface/other thermocouples for turbine casings, ESV, IV bodies, superheated steam, hot reheat steam piping, steam of first stage HPT, inlet bowl of IPT, steam exhaust of HPT, down stream of ESV and IV, steam in ESVs and IVs, steam admission pipes metal temperatures, HPC, IPC flange metal temperature etc. For all HP heaters remote monitoring with redundant independent sensors of inlet/outlet temperatures of feed water and extraction steam shall be provided in addition to local gauges. For all LP heaters remote monitoring with redundant independent sensors of inlet/outlet temperatures of feed water and extraction steam shall be provided in addition to local gauges. Temperature sensors for HP-LP bypass system for measurement as well as for control. Adequate number of temperature Elements shall be furnished to provide initiating contacts for temperature interlocking and trip circuits. The temperature elements shall be provided, but not limited to the following: Steam temperature of HPT exhaust, steam temperature after ESV (L&R), IV (L&R), LPT exhaust hood steam, drain oil temperature of all journal bearings and thrust bearing & lube oil header temperatures, thrust bearing of each condensate extraction pump and vacuum pump protection, interlocks. Metal Temp measurement and steam temp measurement at each super heater & Reheater location. Temp. Element & Temp gauges at Feed water line to economizer inlet, economizer to steam separator, spray water lines to desuperheaters, Soot blower steam, Soot blower steam drain lines, steam drain lines, Flue gas & air lines etc Temp. Measurements (Local & remote) for all BoP packages as decided during detailed engineering. Thermocouples for Temp. above 200 deg C shall be provided by bidder. For plate heat exchangers, spare thermowell provision shall be made at inlet & outlet of ACW & DMCW lines in addition to local & remote temperature monitoring points. Each ESP Hopper shall be provided with RTDs to control the temperature of ash through Hopper heater. Temperature gauges. a) b) For bearing temperatures AC and DC lube oil pumps, LPT exhaust hood etc. For condensate and feed water at inlet and outlet of HP heaters, Vacuum pumps, LP heaters etc.

vi) vii)

viii) ix) x)

xi) xii)

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DESEIN c)

Vol-V : Instrumentation & Control Works

xiii)

Steam & water inlet/outlet of LP and HP heaters, steam and air mixture inlet to vacuum pumps, and drain lines etc. d) Journal/thrust bearing drain oil, lube oil at inlet/outlet of oil coolers, cooling water at inlet and outlet of oil coolers etc. e) Thrust bearing of each condensate extraction pump. f) Temp. Gauges at inlet and outlet of each heat exchanger and cooler. g) Frame mounted Temperature Gauges (FMG) shall be provided for Main steam Temperature, Feed water Temperature to economizer, CRH Steam Temperature, HRH Steam Temperature etc Above are the min. requirements, actual quantities shall be as decided during detailed engineering by owner.

3. Level Measurement i) Level gauges - level gauges for boiler separator, HP heaters, LP heaters, deaerator, drain cooler, gland steam cooler, vacuum tanks, condenser hot well CBD tank, stator water tank, Stator water expansion tank and other pressure vessels, main oil tank and all oil tanks in BTG & BOP package. The level gauges shall be mica shielded steel armoured transparent glass type. Level gauges for condenser hot well shall be provided on both sides. Level switches for HP/LP heaters, drain cooler, gland steam cooler, condenser hot well, deaerator, main oil tank and other pressure vessels, tanks, sumps etc. The separate switches for high, very high and low levels shall be provided as per interlocks and protection requirements. External cage mounted magnetic level switches/ displacer type shall be employed for low pressure & low temp. services. However conductivity type level switches shall be provided for high pressure & high temp services like HP heaters, CRH/HRH drain Pot, Turbine Drains etc. iii) Level Transmitters (Type as sump/tank/bunker/vessel/heaters. per Owner approval) for open

ii)

iv) v) vi)

Level measurement for all BoP packages as decided during detailed engineering. Level switches for OLCS / Alarms / Interlocks / Protection. Level switches for sump/tank level high/normal/ low/very low interlocks. Each ESP hopper must be provided with 3 nos. level switch (switches 2 nos. for high level and One no. for low level.) Above are the min. requirements, actual quantities shall be as decided during detailed engineering by owner. Flow Measurements:Primary Elements: Flow nozzles shall be used for feed water flow and other critical measurements where weld-in construction is required. Flow nozzles shall be made of stainless steel, with three sets of pressure taps installed in the pipe wall where required. One no. spare set of pressure tap shall also be provided on flow nozzle,

vii) 4. a)

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wherever required. Installation of flow nozzles and pressure taps shall be made in the pipe fabricator's shop and shall be witnessed by a representative from the flow nozzle manufacturer. b) Paddle type orifice plates shall be used for other flow measurements where flanged construction and higher pressure loss are acceptable. Orifice plates shall be made of stainless steel. Orifice flanges shall be of the raised face weld neck type with dual sets of taps. Construction and installation of flow nozzles and orifices shall conform to the requirements of ASME Performance Test Code PTC-19.5, and discharge coefficients shall be predicted in accordance with data published in ASME Research Report on Fluid Meters. Airfoil or venturi flow sections, shall be used for measuring boiler combustion airflow. A special high accuracy flow nozzle pipe shall be provided to determine feed water flow to the economizer. This nozzle shall be hydraulically calibrated and utilized for feed water flow control and for turbine testing as described in ASME PTC 6 (latest revision). Orifice plates shall be supplied with carrier rings as per process requirement. Doppler effect type flow meters shall be used for sludge applications. For Raw water, water treatment plant and effluent treatment plant, ultrasonic type flow meters to be used. Secondary Elements: Secondary elements for differential type flow sensors shall be strain gauge or capacitance type differential pressure transmitters. Square root extraction required for the DP transmitters shall be performed electronically in the transmitter itself. HFO/LDO flow meters shall be based on coriolis mass flow technology. Fuel Oil meters shall be provided for fuel oil unloading system and near boiler after day oil tank (at main supply & return lie). Flow nozzles shall be provided for following services in main plant:i) ii) iii) iv) v) vi) vii) Steam flow measurement for BFP Turbines. Feed water flow measurement Auxiliary steam flow measurements HP bypass flow measurements BFP suction flow. Deaerator water flow measurement HP heaters drain Flow measurements.

c)

d)

e)

f) g) h)

i)

j)

k)

Orifices shall be provided for following services:i) Spray water flow measurement

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DESEIN ii) iii) iv.) v) l) m)

Vol-V : Instrumentation & Control Works

Condensate flow measurements DM/hotwell makeup to condenser. Condensate dump flow to CST Gland Steam Condensate flow measurements flows measurements online

For DM water flow & Ash Slurry electromagnetic flow meter shall be used.

At CW & ACW pump discharge headers flow transmitters shall be provided (Non Contact ultrasonic Type are preferable). In addition flow measurement shall also be provided for CW water used any where except condenser service. Instrument and Service Air - Vortex/Swirl type Flow meter Flow transmitters pressure type for general applications shall be of the differential

n) o) . p) q)

Flow switches for OLCS / Alarms / Interlocks / Protection. Lubricating oil Flow transmitter/meter with switch shall be provided for Bearing systems of APH, FD, PA, etc., Sight glasses flapper indication type shall be provided on lube oil cooling water piping as required to ensure indication of fluid flow. On line Fuel flow & velocity measurement facility in each Pulverized Fuel (PF) pipe for each coal pulveriser shall be provided by bidder for accurate, absolute and simultaneous measurement of coal velocity, coal density, coal mass flow rate and air-to-fuel ratio. The equipments shall compromise of sensors working on micro wave technology. In addition to the conventional triple DP measurement techniques involving venturi/Airfoil for secondary air flow measurement, One number Flow measurement system each on Left side and Right side shall be provided as redundant/checking measurement for secondary air flow which could be used in the optimization package. On line secondary air flow & velocity measurement facility in each on left side & right side shall be provided by bidder for accurate, absolute and simultaneous measurement of air velocity & flow rate. The equipments shall compromise of sensors working on tribo-electric (Correlation technique) technology.

r)

s)

t)

u)

Any other flow element/meter required for system shall be finalised as per system requirement and as per approved drawings/documents by owner.

9.05.00

Process Connections The type of instrument source connection shall depend upon the process parameters and the tapping size. The source connection drawings shall be finalised during the engineering stage.

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Size of tapping point stub, number and size of root valves for different types of measurements are as follows: Sl. Quantity of Size of stub and Service Condition No. root valves root valve Pressure and Differential Pressure Measurement (i) 2 25NB > 40 bar(g) OR 4250C (ii) 1 15NB < 40 bar(g) AND 4250C. Level Measurement (a) Level Gauge & Switch (i) 2 25NB > 40 bar(g) OR 4250C (ii) 1 25NB < 40 bar(g) AND 4250C (b) Level transmitter (displacement type) (i) 2 40NB >40 bar(g) OR 4250C (ii) 1 40NB <40 bar(g) AND 4250C (c) Stand pipe for level measuring instrument (i) 2 80 NB >40 bar(g) OR 4250C (ii) 1 80 NB < 40 bar(g) AND 4250C Flow Measurement (i) 2 25NB > 40bar(g) OR 4250C (ii) 1 25NB < 40 bar(g) AND 4250C Sampling system measurement (Steam and Water Service) (i) 2 25 NB >40 bar(g) OR 4250C (ii) 1 25 NB < 40 bar(g) AND 4250C

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Technical Specifications for C&I Systems-Table-No. 9.1 System/Line Description S.No. 1 Main steam, Up steam & down stream of HP bypass and up stream of auxiliary steam pressure reducing valve. BFP discharge/ superheater attemperator/spray to PRDS Reheater attemperator Piping Class A Impulse Pipe material ASTM-A335 Gr.P91/22 (Note-2) ASTM-A106 Gr. C Schedule (Size) XXS ( Inch) Materials for fitting/ valve body Note-3 Valve steam material Note-3 Rating of Piping Fitting 9000lb Pressure Class of valve 3000 SPL

160 ( Inch) 160 ( Inch) 160 ( Inch)

Note-3

ASTM-A-182 Gr.F6a ASTM-A-182 Gr.F6a Note-3

6000lb

2500 SPL

ASTM-A106 Gr. C

ASTM-A-105

6000lb

1500 SPL

Hot. Reheat/Down stream of Aux.Steam pressure reducing valve upto desuperheater/flash tank drain manifold, HRH upstream & down stream of LP Bypass valve. Cold reheat upto Tee-off for HP bypass. Cold reheat down steam of Tee-off (HP Bypass)

ASTM-A335 Gr.P91/22 (Note-2)

ASTM-A182 Gr.F-22

3000lb

2500 SPL

ASTM-A335 Gr.P22 ASTM-A106 Gr. C

80 ( Inch) 80 ( Inch)

ASTM-A182 Gr.F-22 ASTM-A105

ASTM-A-182 Gr.F6a ASTM-A-182 Gr.F6a

3000lb

800

3000lb

800

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BFP suction/condensate system/Extraction to LPH/HPH and Extractions to BFPT, Desecrator, auxiliary steam. Air/Flue gas outside furnace.

ASTM-A106 Gr. C, ASTM-A335 Gr.P-11/22 ASTM-A106 Gr.B/C ASTM-A335 Gr.P22 ASTM-A106 Gr.C ASTM-A312 TP 316 ASTM-A106 Gr.C

80 ( Inch)

ASTM-A105

ASTM-A-182 Gr.F6a

3000lb

800

80 (3/4 Inch) 80 (3/4 Inch) 80 (3/4 Inch) 80/40 (1/2 Inch) 80 (1/2 Inch)

ASTM-A105

ASTM-A-182 Gr.F6a ASTM-A-182 Gr.F6a SS316 SS316 SS316

3000lb

800

Air flue gas inside furnace

ASTM-A182 Gr.F-22 ASTM-A105 ASTM A 182 F 316 ASTM-A105

3000lb

800

10. 11. 12.

Purge Air DM Cooling water CW & ACW

O P Q

3000lb 3000lb 3000lb

800 800 800

Note:1). 2). 3). 4). Above requirements are minimum to be complied by bidder. Rating of piping / fittings / valves etc. is subjected to be approved by owner as per the final design pressure & temperature finalized during the detailed engineering, as per ANSI B 31.1. In case temperature is more than 540 deg C, the material shall be P-91 only. Material shall be compatible with that of the impulse pipe material and design parameter. For DM Plant or DM water services, complete erection Hardware material shall be SS316 only.

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9.06.00 9.06.01

INSTRUMENTATION AND CONTROL CABLES General Bidders scope of supply, laying, erection & commissioning of instrumentation and control cables shall include the following:a) Bidder shall supply, lay, erect, terminate all type of cables required for power plants i.e. the control, instrumentation, interfacing (coaxial, fibre optic) cables etc. irrespective of other end scope. All interconnecting cables and prefabs between bidders supplied instruments, local JB, local instrument/transmitters, cabinets, panels and termination cabinets and interconnecting cables between Bidders panels to equipment / instruments/ Plant Control Room. All field JBs / all field instruments/MCC/SWGR to DDCMIS/DCS cabinets in CER/ PLC cabinets/Relay cabinets/local control panels/desk etc. All power, Signal & Special cables from Sensor to JB, JB to MCC, JB/Drives to PLC/DDCMIS/DCS, MCC/SWGR to DDCMIS/DCS/PLC cabinets wherever one end or two ends are in EPC bidder's scope. Complete Cables shall be supplied, laid, terminated & commissioned by EPC bidder including preparation of Cable schedule and supply of cable Trays irrespective of other end scope. 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). K Type Thermocouples Extension cables, T Type thermocouple Extension cables and S/R type Thermocouple Compensating cables Interfacing cables (Coaxial, fibre optic etc) between owner supplied PLC/control systems (if any) to DDCMIS. Fire survival cable Preparation of Complete cable schedule, Interconnection diagram & JB schedules shall be in bidder scope. All others cables not included above however required for completeness and operation of plant. The cables shall be provided in non returnable wooden drums. The drum length shall be 1000 m + 5% up to & including 12 pair cables and 500 m + 5 % for above 12 paired cables.

b)

c)

d)

e)

f) g)

h)

i)

The quantity of the above types of cables shall be estimated by the Bidder based on his experience. Any shortfall in cable quantity during actual laying at site shall be compensated by the Bidder at no extra cost to the owner.

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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. 9.06.02 9.06.02.01 SPECIFICATION AND STANDARDS Except where specified otherwise all materials , cables and construction shall conform to the Indian Electricity Act and Rules and the Indian and other international standards with latest revisions and amendments issued up to date. MATERIAL SPECIFICATIONS General All materials shall be new and of tested quality conforming to applicable National and Manufacturer's Standards and Indian Electricity Rules. All materials shall be transportable to and suitable for installation at site with ease and without any damage. It shall give continuous reliable operation over long period under worst specified site conditions. All materials shall be designed to withstand extremes of all magnetic, electrical, mechanical and thermal stresses which may be encountered during normal and abnormal operating conditions. Cables Design Criteria Cables shall be so designed and manufactured that damage does not occur in handling, during transit, storage, installation and operation under any or all the climatic and operating conditions which they may be subjected to. Outer sheath of cables shall have rodent and termite repulsion property. Cables shall be suitable for laying in conduits, ducts, trenches, trays or for direct burial in ground in both and wet locations. 9.06.04.02 Cables shall be capable of operating satisfactorily under the power supply voltage and frequency variations as specified in the specification. Current ratings and ratings factors of cables shall not be worse than the ones specified in IS: 3961. Performance characteristics of cables shall be based on the following conditions of laying: 1. 2. All cables shall be laid in multilayer and touching each other. Cables shall be suitable for laying in duct or burying in ground upto a depth of 1.5 meters with uncontrolled back fill and chances of flooding by water.

9.06.03 9.06.03.01 9.06.03.02

9.06.03.03

9.06.03.04

9.06.04 9.06.04.01

9.06.04.03

9.06.04.04

Fillers in multiple conductor cables shall be flame retardant and moisture resistant.

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9.06.04.05

All cables shall be provided with marking including manufacturers name, insulation material, conductor sizes, no of pairs, voltage ratings, type of cable, etc, progressive markings to read marking of the length of the cable at each meter interval and FRLS. All cables shall be suitable for continuous operation at 85 deg C except for high temperature resistant Teflon insulated cables, which shall be suitable for continuous operation at 205 deg C. All the cables used in the Hot/high temp. Zone (Combustor region), for emergency trip push buttons, Fire alarm system, safety critical circuits, Trip protection circuits and for other services specified elsewhere in the specification shall be fire survival cable conforming to IEC 60331, BS6387 (CWZ), BS6207 standard and this specification. The instrumentation cables in other area shall be FRLS conforming to IEC 60332 standards and this specification. All external field signals for DDCMIS/DCS/PLC shall be terminated in separate marshalling/termination cabinets. Under no circumstances, Field cabling to be directly terminated in DDCMIS/DCS/PLC system cabinets. All cables shall be paired cables. All cables shall be provided with anti termite, Anti Rodent & moisture resistant properties. All spare contacts/terminals on relays, control switches, limit switches or similar devices, process switches, duplex RTDs & Duplex T/Cs shall be wired to accessible terminal blocks/JBs for Owner's future connections. All wiring leaving a junction box or enclosure shall leave from terminal blocks and not from other devices in the enclosure. Two (2) pair (individual & overall shielded) cables shall be provided for terminating the thermocouples, transmitters & switches i.e Analog & Binary signals to local JBs. Similarly four (4) pair (individual & overall shielded) cables shall be provided for terminating the Duplex (3/4 wire) RTD to local JBs. 10% spare pairs or min 1 pair cable (which ever is more) shall be provided with all type of cables.

9.06.04.06

9.06.04.07

9.06.04.08

9.06.04.09 9.06.04.10

9.06.04.11

9.06.03.12

Cable size & type shall be as below for different type of signals and control system. a) Cables for analog signals shall be instrumentation cable of 0.5 sq. mm copper conductor size, with individual pair shielding & over all shielding as per cl. No. 9.06.04.02 mentioned below. Cables for binary signals shall be instrumentation cable of 0.5 sq. mm copper conductor size as per cl. No. 9.06.04.02 mentioned below with exceptance of over all shielding only. Cables for binary signals in relay based system and Fire protection & detection system shall be instrumentation cable of 1.5 Sq.mm conductor size, overall shielded as per cl. No. 9.06.04.01 mentioned below.

b)

c)

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d)

Cable for power supply to each solenoid valves shall be control cable of 3C x 2.5 Sq.mm copper conductor size. Specification shall be as mentioned elsewherein the Electrical part. For cables single length more than 500 meters, the size of conductor shall be 1.5 sq. mm only irrespective of type of signals.

e)

9.06.05 9.06.05.1

Cable Specification The Instrumentation cables shall function without breakdown for surges experienced in the control system. Voltage class and insulation levels shall be compatible with the signals they convey. Cable Specifications Cable shall have the following specification: Sr.No. Description 1. Voltage Grade and Type Cable N 660 V/1100 V grade multipair annealed tinned copper conductor overall shielded armoured instrumentation cable. IS: 1554 (Part-I Generally) Nominal 1.5 Sq. Area concentric lay Annealed tinned high conductivity Stranded 7x0.53 mm dia. Electrolytic Copper conductor. Extruded HR PVC type C to IS:5831 Minimum 0.06mm thick aluminum mylar tape shall be provided on each pair with hundred percent coverage, 25% overlap and tinned copper drain wire of diameter 0.8mm with 7 strands. FRLS HR PVC type ST-2 to IS:5831/VDE 0207. Colour Black. Galvanized steel wire/strip to IS:3975 & IS 1554 Part II FRLS HR PVC type ST-2 to IS:5831/VDE 0207. Colour Blue. Twisted pair with 25 - 40lay/mt 1. Flammability Test The cables shall pass The requirement of IEEE-332 part B fire propogation test in this regard.

9.06.05.2

2. 3.

IS Reference Conductor

4. 5.

Insulation Shield

6. 7. 8. 9. 10.

Inner sheath Armouring Outer sheath Lay Tests for FRLS Properties

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2.

3.

4.

5.

6.

Smoke generation by Sheath under fire When tested as per ASTM-2843, the cable shall meet the requirement (60%) smoke density. Acid gas generation of sheath during fire When tested as per IEC-754-1,the maximum Acid gas should be less Than 20% by weight. Oxygen Index Test The oxygen index when tested under ASTMD 2863 shall be minimum 29. Water immersion test shall be carried out as per VDE 0815 Swedish Chimney Test

Other Tests: 1. Fire resistance test to IS-5831 for 20 minutes. (PVC insulation & sheath of electrical cables) Thermal stability at 200 deg. C to IEC-540 for100mts. Rodent and termite proof. Heat shock test to IEC-502.

2. 3. 4. 11. Conductor and Pair :

The wires of pairs shall be coded by base colours on insulation which are repeated in every unit. Base colours of the pairs in a unit shall be as follows: Pair 1 2 Grey 3 4

a) b)

wire wire

Blue Red

Green White

Yellow Brown Black

The units shall be coded by colours of rings on the insulation cores as tabulated below in order to distinguish between wires of various units in cables : --------------------------------------------Unit: Ring Colour: Ring Group ---------------------------------------------

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1. 2. 3. 4. 5. 6. 7. 8.

PINK PINK PINK PINK PINK ORANGE ORANGE ORANGE

l ll lll llll lllll llllll lllllll llllllll

The vertical lines under column (Ring Group) in the above table indicate number of rings at intervals of approx 60 mm length of the wires of the units. For cables above 4 pair, each 4 pair units shall be open helically lapped with numbered binder taped for the purpose of binding & unit identification. 12. Marking Marking on length of the cable shall be at every meter interval on the outermost PVC sheath of cables.

13. a)

Electrical Properties at 20 Deg.C: Conductor resistance of the loop not greater than 78.4 Ohms/Km for 0.5 sq mm. Conductor size. 24.6 Ohms/Km for 1.5 sq mm. Conductor size.

b)

Insulation resistance not less than

100 Meg Ohms/Km 100 nF/Km 2000 Vrms 370 Ohms for 0.5 sq mm. Conductor size. 230 Ohms for 1.5 sq mm. Conductor size.

c) d) e)

Mutual capacitance at 0.8 KHz not greater than Test Voltage-cond/cond. and cond/shield Characteristic impedance at 0.8 KHz

f) g) h) i) j)

Image attenuation at 0.8 KHz Image attenuation at 10 KHz Cross talk attenuation at 0.8 KHz greater than Coupling capacitance at 0.8 KHz not greater than Min Vol. Resistivity :

0.11 dB/100 m 0.29 dB/100 m 70 dB/Km 200 pF/100 m

3.5 x 1014 at 27 deg C

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3.5 x 1011 at 85 deg C k) High Voltage Test Conductor to Conductor Conductor to Shield 9.06.05.3 Cable Specifications Cables shall have the following specifications:Sr.No. 1. Description Voltage Grade and Type Cable M 660V/1100 V grade multipair annealed tinned copper conductor individual pair and overall shielded armoured instrumentation cable. IS:1554 (Part-I) (Generally) Nominal 0.5 Sq.mm. area concentric lay annealed tinned high conductivity stranded 7 x 0.307 mm dia. Electrolytic Copper conductor Overall dia of each conductor including insulation should be between 1.4 to 1.65 mm. For 0.5 sq mm. size conductor. Extruded HR PVC type-C to IS:5831 Through aluminum mylar tape min 0.06 mm (0.075 mm) with min 25% overlap and 0.8 mm dia tin coated copper drain wire (7 stranded) laid under the contact with aluminum side of the tape. FRLS HR PVC type ST-2 to IS:5831/VDE 0207, Colour Black Galvanised steel wire/strip to IS:3975 FRLS HR PVC type ST-2 to IS:5831/VDE 0207, Colour Black See details as specified in Cable Type N. - do- do: : : Duration 2000 Vrms, 50 Hz for 1 min. 2000 Vrms, 50 Hz for 1 min.

2. 3.

IS Reference Conductor

4.

Conductor size

5. 6.

Insulation Shield

7. 8. 9. 10. 11. 12. 9.06.05.4

Inner sheath Armouring Outer sheath Test for FRLS properties Colour Coding & Marking Electrical Properties

Specification for Co-axial Cables Cable-C Co-axial cables are used for high frequency equipments and systems for transmission and reception purposes and computers. Co-axial cable should have minimum following characteristics:-

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Construction Di-electric Outer conductor

: : :

Outer sheath Diameter over Di-electric Outer diameter Nominal impedance Nominal capacitance Nominal attenuation

: : : : : :

Solid silica coated, annealed tinned copper conductor. Low loss solid polyethylene foam, semi and spaced construction. Braided or longitudinal tube of copper or Aluminum giving 100% coverage with slight overlap. FRLS PVC type ST2 7.24 sq.mm. 10.29 sq.mm. 75 ohms 20.5 pF/ft. 8 dB at 1000 MHz Per 100 ft.

Co-axial cable shall be low smoke (ASTM- E 662), flame retarded (IEEE 383) and halogen free (IEC 754: 1 & 2), MIL C-17 G. 9.06.05.5 Extension & Compensating Cables 1. 2. 3. 4. 5. Applicable Standards Type Conductor Size Conductor Diameter Insulation : : : : : ANSI MC96.1; IS:1554 (Part-I) IS:5831-1984 Single / Multipair twisted and shielded type as per ANSI MC96.1 1.31sqmm, solid alloy (16 AWG) 1.29 mm PVC insulated, heavy duty, Self extinguishing type. Colour coded extruded PVC inner sheathed with overall PVC sheathed Type ST2 FRLS IS: 5831. Insulation of each wire with high grade 0.6 mm 85 deg.C Extruded HR PVC Type C as per IS: 5831, voltage grading shall be 1.1 kV. Twisted pairs within 50 mm max. lay. Single pair cable assembly only. Multiple pair - each pair and cable assembly. Each conductor shall be individually and overall shielded Through aluminum mylar tape min 0.06 mm (0.075 mm) with min 25% overlap & 100% coverage and 7 strand 20 SWG minimum size tin coated copper drain wire. FRLS HR PVC type ST-2 to IS:5831 See "Cable Details" as below Galvanised steel wire/strip to IS:3975 Each pair numbered every 250 mm

6. 7.

Lay Shield

: :

8. 9. 10. 11.

Outer sheath Conductor Identification Armour Multiple pair identification : : :

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12.

Electrical Parameters:

Thermo electric specification, limit of error shall be as per IEC, ANSI Description E.M.F at 100 Deg.C E.M.F at 200 Deg.C Tolerance KX type SX/RX Type TX Type 4.095mV 0.646/0.647 mV 4.279 mV 8.137mV 1.441/1.469 mV 9.228 mV + 2.2 C from 0C to + 1.5 C from 0C to + 1.0 C from 0C to 200C 200C 100C Conductor loop 760 (Typ) 95 (Typ) 390 (Typ) resistance for 1.31 sq. mm (16 AWG) size as per ANSI MC96.1 at 20 Deg.C Ohms/K.Mtr Insulation Resistance ( min) : 100 M ohm x KM Mutual Capacitance at 0.8 resp. 1 KHz (max): - Single pair and pair screened - upto 4 pair overall screened - above 4 pairs overall screened 13. CABLE DETAILS : : : 120nf/KM 96 nf/KM 80 nf/KM

ANSI Type

Conductor Material Positive Negative KX type Extension (NICR/NIAI) (Nichr/NiAl) cable for K type Cromel Alumel Thermocouple SX/RX type Cu Cu Ni (CopperCompensating (Copper) Nickel alloy) cable for type S & R thermocouple TX type Extension Cu Constantan cable for type T (Copper) thermocouple 14. Tests to be conducted:

ANSI Colour Code Positive Negative Yellow Red

Overall Yellow

Black

Red

Green

Blue

Red

Blue

-Thermo-e.m.f characteristics -Continuity test -Measurement on capacitance, inductance and loop resistance. -Insulation resistance -High voltage tests as per IS(latest) -Tensile and elongation tests -Flame retardency as per IEC 332 -Oxygen index test

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9.06.05.6

Fiber Optic Cable A Fiber: The optical fiber core shall be of ultra pure fused silica glass coated with UV-cured acrylate suitable to withdraw temperature of about 80 Deg C (continuous). Fiber Optic cables shall be suitable for installation on cable tray, duct bank, cable trench, direct burial as necessary. Type Multiple single mode & Multi-Mode Fiber to avoid usage of any repeaters. Core Diameter Multimode Fiber Singlemode Fiber cable cable 62.5 2 microns or 9 1 microns 50 2 microns depending upon distance between source & destination. Cladding Diameter 125 2 microns Fiber Proof test As per IEC/EIA & other international standard. Coating Diameter Test As per IEC/EIA & other international standard. Number of Fibers/core Six (Colour Coded) with min. 100% spare core (Fibers) Optical Charactertics Bandwidth, Attenuation & Numerical Aperture Bandwidth @ 850 nm Bandwidth @ 1300 nm Attenuation @ 850 nm Attenuation@ 1300 nm Numerical Aperture Optical Charactertics - Attenuation Attenuation@ 1310 nm Attenuation@ 1550 nm For multimode fiber cable with core diameter 62.5 2 microns: 160 MHz-Km min 500 MHz-Km min 3.0 dB/Km max 0.8 dB/Km max 0.275 + 0.015 for Singlemode fiber cable outside plant: 0.35 dB/Km max 0.2 dB/Km max For multimode fiber cable with core diameter 50 2 microns: 500 MHz-Km min 500 MHz-Km min 3.0 dB/Km max 0.8 dB/Km max 0.200 + 0.015 for Singlemode fiber cable inside plant: 1 dB/Km max 1 dB/Km max

1 2

3 4 5 6

B1

1 2 3 B2 1

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Cable Construction: Fiber Optic cable shall be of loose tube design. Typically, fibres 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 tools & 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. Fillers shall be flame retardant and moisture resistant. The cable shall be of dual jacket & armoured. Optic Fibre cable shall be polymer coated, galvanised corrugated steel taped armoured, fully water blocked with central dielectric material for outdoor/indoor application so as to prevent any physical damage. 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 Termite & rodent protection. A ripcord is also placed underneath the armour for easy outer jacket removal. Outer Colour Orange Outer Jacket Polyethylene minimum 1.5mm thick, Flame retardant & UV resistant. Inner Jacket Core-locked flame retardant polyethylene Filler / Strength member As per Manufacturers standard Central Strength member FiberGlass reinforced plastic (FRP) and Buckle resistant material to provide both tensile and anti bucking strength to the cable. Details marked at every Manufacturers Name, Month and Year of meter on outer sheath. Manufacturer, Coded description of the cable based on telcordias (bellcore) SR2014 suggested optical cable code (SOCC), Sheath identification Number, Sequential Length marking in meter, A telephone Handset symbol to distinguish communication from power cable as per NESC section-35G. Life Expectancy Fiber Optic cable shall provide a long life expectancy of minimum 25 years under continuous operation without degradation to optical or mechanical performance. Stripping Ability All layers easily removed Commercially available tools with

1 2 3 4 5

6.

7.

E 1

Installation: Minimum bending radius

20 X D (D=core Diameter) - During Installation , Short Term , loaded 15 X D (D=core Diameter) Installed, Long

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2 3 4 F G

Maximum Load/Strength Method of laying Pulling

Term , No load Tensile During Installation: 2200 N Installed: 1500N Directly laid in cable trays / duct bank / clamped with available structure Ordinary cable grips - 20 0 C to 60 0 C

Storage Temperature

Operating Temperature & - 20 0 C to 70 0 C & 100% Humidity Data Speed performance 10 Gbps minimum

H I 1 2 3. J

Test Specification (EIA/TIA STD455 or Equivalent): Impact Resistance 2000 Impacts minimum Crush Resistance 4000 N/10cm minimum Compressive Strength 3000 N minimum Moisture/Water Resistance Water blocking layer, 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. Domain a. A recording optical time domain reflecto meter (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. 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

K.

Optical time reflectometer

b. i. ii.

iii. OTDR location with a minimum of 20 characters iv. Far End location with a minimum of 20

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characters. v. c. Test operator initials with a minimum of 3 characters. The printer shall preferable be internal. The printer shall be able to print data traces within 30 seconds or less. The machine setting 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, data and time. 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 must be able to recall historical traces from a discrete 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 the each fiber shall be displayed, and the differences between the two readings clearly shown. 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. Bidder shall provide all mounting accessories, cables and connectors required to establish data communication.

d.

e.

f.

L.

Fiber Optic splicer, terminator and tool kit box

Bidder shall provide new unused tools comprise of splicer and fusion jointer and tool kit comprise of cutter, stripper,

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M.

Standards

polishing tool, handheld microscope, heat shrinkable sleeve, scissor, knife etc as required for maintenance and commission. Optical cable shall be conform to i) IEC 60794/IEC 60793 & EIA/TIA 455. ii) Low smoke(IEC 1034 -light transmittance of 80%). iii) Halogen free(IEC 754: 1&2maximum acid gas generation shall be 2% by weight and PH >4.3). iv) Fire & flame retarded (IEC 331,IEEE 383). v) Rodent resistant. vi) Crush Resistant (EIA -455-41). vii) Impact Resistant (EIA -455-25). Bidder shall submit Type test report for review ,conform to IEC 60794, IEC 60793, IEEE 383, IEC 754: 1 & 2,IEC 331 ,IEEE 1034 and EIA/TIA standard. Colour codes shall be as per EIA/TIA 598-A. Following minimum test as per any approved standard shall be carried out on the cables: a. Attenuation and Dispersion characteristics tests b. Proof Tests c. Macro-Bend resistance Test d. Mechanical Test 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. Colour permanence Test n. Cable Aging test o. Water penetration test p. Lightning Test q. Kink Test r. Crush Test

N.

TESTS

9.06.05.7

Data Cable:

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Data transmission cables are control & signal cables used in electronics of computer system, electronic control equipment etc. in power plant data processing system. The cable has an overall screening which suppresses external electrical influences and ensures precise pulse transmission. The screen braiding of tinned copper wires is wrapped around the core or inner sheath. i) Min. bending radius for flexing ii) Temp. Range iii) Loop resistance iv) Inductance v) Coupling : : : : : 15x cable diameter. (-30 to +80) deg. centigrade Max.78.4 ohm/km. 0.65 mH / Km. 200 pF / Km.

Co axial and fibre optic cables are also used as data cables. 9.06.05.8 NOTE: All cables near high temperature zone shall be high temp cables, which shall be terminated at a junction box in normal temperature zone. Thermocouple extension cables and copper conductor cables for high temperature applications shall be with insulation of individual conductor and outer sheath of extruded FEP (i.e. Teflon) as per VDE 0207 Part 6 and ASTMD 2116. The thickness of insulation shall be 0.5 mm nominal (i.e. 0.4 mm minimum). These cables shall be single / Multipair twisted & shielded. Fire survival instrumentation Cables shall be similar to the Fire survival control cables specified in electrical section (Vol. IV) except that Cables for analog signals shall be annealed tinned copper conductor 0.5 sq. mm sized, with individual pair shielding & over all shielding and Cables for binary signals shall be annealed tinned copper conductor 0.5 sq. mm sized with over all shielding only. In addition the cables shall have high degree of immunity from electromagnetic interference. TYPE AND ACCEPTANCE TESTS FOR INSTRUMENTATION CABLES After completion of manufacture, type and acceptance tests as specified in relevant standards and herein shall be conducted and requisite number of copies of test certificates as per Distribution Schedule shall be furnished. The Owner may, at his discretion, waive type tests provided type tests reports of tests carried out on identical materials(s)manufactured by the Bidder in India in last 5 years are furnished. The Bidder shall furnish copies of such type test reports with the Bid or indicate when they expect to make these available. After completion of manufacture, following minimum type and acceptance tests as specified in relevant standards and herein shall be conducted and requisite number of copies of test certificates shall be furnished. The Owner may, at his discretion, waive type tests provided type tests reports of tests carried out on identical materials(s)manufactured by the Bidder in India are furnished. The Bidder shall furnish copies of such type test reports with the Bid or indicate when they expect to make these available. I. TYPE TESTS:

9.06.05.9

9.06.06 9.06.06.01

9.06.06.02

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The type tests shall be carried out on one drum out of every 10 drums or less for each size of cable in each lot, in presence of Owners representative as per applicable standards in Govt. approved Laboratory if adequate testing facility is not available at works of the supplier. Sr. No. Name of Test Governing standard IS : 8130/84 IS : 10810 IS : 8130/84 IS : 3975 IS: 1554 (I) IS : 1554 (I) Special requirements as per owners specification. As per IS: 8130/84 As per approved G.T.P. As per IS: 8130/84 As per IS:3975 As per G.T.P. As per G.T.P. approved approved

1. 2. 3. 4. 5. 6.

7.

Annealing test (for copper) Conductor resistance test & Diameter test Per sulphate test (for tinned copper wire) Test for armours wires / strips Test for measurement of DC resistance of armour Test for measurement of thickness of insulation & sheath & other dimensions. Measurement of volume resistivity of HRPVC insulation

IS : 5831-1984

i. 3.5 x 1014 Ohm-cm at 270C / room temp.(Min). ii. 3.5x1011Ohm-cm at 850C (Min.)

8.

9.

10. 11. 12. 13. 14. 15. 16.

Tensile strength and elongation test for insulation & sheath. Ageing test for insulation & sheath. Loss of mass test for PVC insulation & sheath. Shrinkage test for PVC insulation & sheath. Shrinkage test for PVC insulation & sheath Hot deformation test for PVC insulation & sheath Cold bend test for PVC insulation. Cold impact test for PVC sheath. Heat shock test for PVC insulation & sheath. Thermal stability test for PVC insulation and sheath.

IS:5831/1984

As per IS:5831/84

IS:5831/1984

As per IS:5831/84

IS:5831/1984 IS:5831/84 IS:5831/1984 IS:5831/1984 IS:5831/1984 IS:5831/1984 IS:5831/1984

As per IS:5831/84 As per IS:5831/84 As per IS:5831/84 As per IS:5831/84 As per IS:5831/84 As per IS:5831/84 As per IS:5831/84

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17.

18. 19. 20.

Test for bleeding and blooming of pigments for PVC insulation of sheath. Colour fastness to water. Colour fastness to day light. High voltage test (water immersion test) Test for rodent & termite repulsion property of sheath. Oxygen index test on inner & outer sheath material. Temp. index test on inner & outer sheath material Acid gas emission test on inner & outer sheath material. Smoke Density test on inner & outer sheath material Flammability test on finished cable samples as per following methods: i. Swedish chimney test ii Vertical tray flame propagation test. iii. Single vertical cable fire resistance test.

IS:5831/1984

As per IS:5831/84

IS:5831/1984 IS:5831/1984 IS:1554(I)

As per IS:5831/84 As per IS:5831/84 IS:1554(I)

21.

Presence of lead shall be detected. Min.29 Min.250oC Acid gas generation shall be less than 20% by weight. Min. 40% light transmission during test.

22. 23 24

ASTM:D-2863/77 ASTM:D-2863/77 IEC-754-1

25.

ASTM-D-2843/77

26.

SS-424-14-75 Cl. F-3 IEEE-383 IEC-332-1

SS-424-14-75 Cl. F-3 IEEE-383 IEC-332-1 As per G.T.P. approved

27.

28.

29.

30.

Tests for all electrical properties at 20oC & maximum operating temp. as per GTP. Oxygen index test & Acid Gas generation test for Fillers Continuity test, Shield thickness, Overlap test of Al Mylar shield Noise interference test, Cross talk test, Mutual capacitance, Drain wire continuity test.

As per GTP

ASTMD 2863, As per approved GTP IEC 60754-1

As per GTP

As per approved GTP

IEEE Transaction, As per approved GTP VDE 0472

ll

Routine Test: Routine test shall be carried in presence of owners representative for all types of cables.

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1. 2.

High voltage test Conductor Resistance Test Acceptance Tests:

IS:1554 (I) IS:8130/84

2 KV (RMS) for one minute As per GTP

lll

Following tests shall be carried out on 1 drum out of every 10 drums or less for each size of cables in each lot, in presence of owners representative. 1. 2. 3. High voltage test Conductor Resistance Test Volume Resistivity IS:1554 (I) IS:8130/84 IS:5831-1984 2 KV (RMS) for one minute As per NIT 3.5x1014-cm at 27 deg C/room temp (Min) (ii) 3.5x1011ohm-cm at 850C Min. 100 NF/Km (max) (i)

4.

Measurement of Mutual capacitance at 0.8 KHZ Calculation & Verification of Characteristic impedance on the basis of value obtain for mutual capacitance at 0.8 KHZ with the help of following formula R = ---------2 fc = = = =

5.

320 Ohms(nominal)

where Z R f c 6.

characteristic impedance in ohm Loop resistance of cable per km in ohms at 20 0C Frequency of test in Hz (800) mutual capacitance per km. IS:1554 (I) As per NIT

7.

8.

*9.

Measurement of thickness of insulation and sheath & other dimensions Tensile strength and elongation at break of insulation & sheath Oxygen index test on inner & outer sheath at room temp. Temp. index test on inner & outer sheath

IS:5831/84

IS:5831/84

ASTM-D-2863 Min.29 Min.2500C

--do--

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*10.

11.

12. 13.

Acid gas emission test on inner sheath & outer sheath. Smoke density test on inner sheath & outer sheath Flammability test Additional Test

TEC-754-1

Max.20% by weight

ASTM-D-2843

Min.40% light transmission during test. SS-424-14-75 SS-424-14-75 Class F-3 Class F-3 IEC 331 for fire survival characteristics

* (If no. of drums selected for acceptance test for a particular cable size are more than one, the tests marked with * i.e. 5 no. 9&10 under acceptance tests shall be carried out on one drum only). 9.07.00 SHOP TESTS FOR ERECTION HARDWARE i) a) b) General Requirements:The equipment as per this section shall be subject to shop tests. The Conductor shall furnish all materials, equipment, tools, instruments, bulkheads, blanking plates and all personnel required for completing these tests. Personnel performing the tests shall be qualified and experienced. Tests shall be performed as many times as necessary to assure Proper quality of materials and workmanship. If any test reveals Unsatisfactory materials or workmanship, such materials shall be Repaired or replaced to the satisfaction of the Owner. Hydrostatic and pneumatic tests shall be performed on all pipes, Tubings and systems supplied by the Bidder and shall conform To ANSI B31.1 Code for Pressure Piping. Hydrostatic Testing All instrument piping, which connects to process piping, shall be Hydrostatically tested.

c)

d)

ii)

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CHAPTER-10 ANNUNCIATION SYSTEM 10.00.00 10.00.01 General Requirements Alarm annunciation system for presenting alarms with BTG package shall be integrated & part of DDCMIS system as mentioned below: a) Conventional hardwired alarm annunciation system has not been envisaged. All alarm will be displayed in DDCMIS/DCS. In addition to the DDCMIS/DCS alarms, LVS based alarm system and LED TV based alarm system shall be provided. Two No 40 full HD LED TV shall be provided for monitoring the annunciation of enlarged version and to view the process mimics in CCR. Each LED TV shall have their own work station controller sitting on DDCMIS data highway. First three (3) rows of LVS will be used for critical alarm display. First row will be kept reserved for fixed alarm and the other two rows will be used for other alarm display for which location of window may vary. b) Quantities of DDCMIS/DCS alarm and LVS/LED TV alarm will be decided during detailed engineering stage.

10.00.02

Whenever control system is PLC based, HW annunciation system shall be driven by PLCs Digital output. For other relay based control systems, stand alone solid-state annunciation system shall be provided. SCOPE & SUPPLY Requirement of annunciation system are specified on a system basis. Bidder shall be fully responsible for engineering and furnishing a fully operational system complete in all respects meeting the intent and requirements of this specification. All equipment and accessories required for completeness of the system shall be furnished by the bidder within the quoted price, whether these are specifically mentioned herein or not. Annunciation system offered shall be from reputed, experienced manufacturer of specified type and range of equipment whose trouble free performance has been proven at least for two years in not less than two pulverized coal fired utility power stations of reheat type. The evidence regarding experience shall be furnished.

10.01.00

10.01.01

Visual display of alarm messages in the VAS for each type of control system i.e PLC & relay based control system shall be through panel mounted annunciation windows. The annunciator components shall be designed for 50 deg.C ambient temperature and 90 percent highest average monthly humidity.

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The windows shall be in multiple groups as required. The arrangement on the panels will be decided and advised when panel layouts are finalised. Each window shall be 50 mm high and 75 mm wide and shall be provided with sixteen high intensity LEDs wired in parallel, and capable of replacement from the front. The life expectancy of these LEDs shall be minimum of 100,000 hours. 10.01.02 Minimum 2 Sets of push buttons, namely, Silence 'Acknowledge', Alarm Ack, Reset, System Test and Lamp Test shall be provided for Annunciation system on back up control panel/control desk/UCP/BUP. Set of Push buttons may also increased depending upon width of back up control panel/control desk/UCP/BUP. In addition, set of Annunciation PBs shall also be provided on Operator control desk in parallel to Annunciation PBs provided on Unit control panel/backup control desk/panel. The system shall be so designed that during the lamp test, the existing fault annunciation is automatically disconnected from the lamp test circuit. Also any additional fault occurring during the lamp test shall automatically be isolated from the lamp test circuit & annunciated in the normal way. In the case of group annunciation windows, the group alarm shall be annunciated every time any of the inputs associated with the group go into alarm status. Facility shall exist in the system to specifically identify the particular input in alarm state within the group. A separate annunciation shall be provided on each panel to failure for which 220V DC feeder shall be provided by bidder. 10.01.03 indicate mains supply

Integral Audio Visual Annunciation System with facia windows (60 nos. (min.) for each package & sub package having high intensity 16 nos. LED shall be provided in backup control desk as per Annexure A (Control system for BOP Packages). In addition, 20% spare windows (fully wired) up to digital output cards shall also be provided by bidder. The system shall be designed for bidding purposes that up to 30% of the windows will be group alarms with each group consisting of about four (4) inputs. Input sizing and provision of group alarm modules with retransmission facility shall be affected in line. ANNUNCIATION SEQUENCE The sequence of annunciation for main control panels shall be as follows:Sl. No. 1 2 3 4 Condition Normal Alarm Silence PB actuated Return to normal Visual OFF Fast Flash Fast Flash Audible OFF ON OFF

10.01.04

10.02.00 10.02.01

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a) before acknowledge

Slow Flash

ON(different tone) ON(different tone)

b) after acknowledge

Slow Flash

Alarm Acknowledge i) before return to normal ii) after return to normal Steady ON Slow Flash Fast Flash OFF Fast Full Operational sequence. ON OFF

6 7 8

Return to abnormal (alarm) Reset System test

ON(different tone) ON OFF

Lamp test

Note : Pitch and volume of the tone generators for the audible alarms shall be adjustable. Three sets of hooters buzzers, beacon lamps etc shall also be provided above control panel sections. Each audible device shall be driven by separate tone generator. Hooters and Buzzers provided on the panel shall be electronic with adjustable volume and pitch control. Operator interface push button stations shall be provided in appropriate sets on panels as per functional groupings desired. Push button stations shall also be provided in Operator interface. Bidder to provide redundant audible devices like Hooters & buzzers. Buzzer for non fist up alarm points 1st Hooter for first up points 2nd Hooter for Main supply failure Annunciation system shall be designed to ensure during LED / System test, existing fault annunciation is automatically excluded from test program with latching of status at card level. Once test command is removed, the system should display once again the faults annunciations. 10.02.02 LED box assemblies: LED boxes shall have removable impact polystyrene windows of snap ON type. Inscriptions shall be black lettering on white background/film inserts with character height of typically 5 mm with 16 characters per line and 4 lines per window. LED illumination shall ensure clear readability. 10.03.00 STAND ALONE ANNUNCIATION SYSTEM

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10.03.01

Stand alone Visual Alarm Annunciation System shall consists of requisite Buffer Terminal Cabinets, Input sharing networks, Remote annunciator logic cabinets with logic cards, power supplies in completely redundant mode, panel mounted lamp box assemblies, set of operator interface devices such as push buttons, audible devices, prefabricated FRLS interconnecting cables with connectors for signal transmission from logic cards to lamp windows as per actual length as required. Panel type logic cabinet/cabinets to be furnished under this specification, shall receive cables from all contacts. Spring loaded type termination shall be provided for each contact input. This cabinet shall also contain the input logic cards and all other logic cards. The necessary contact interrogation and contact bounce filtering to provide a delay of 15 milli seconds shall also be provided. Modular construction shall be employed. All printed circuit boards shall be of epoxy fiber glass construction. All contacts shall be gold plated. Solid state CMOS Logic circuits/microprocessor based system shall be furnished for all windows. The driver circuits for LEDs shall be provided with current limiting features and regulate current to LEDs and shall protect against short circuits in the LED circuit. Spurious alarms shall not be generated when system is switched ON. The logic cards shall be provided with optical isolation feature for all input signals. Solid State Logic circuits shall be capable of meeting surge withstand capability in accordance with ANSI C37.90a or IEEE Standard 472-1974. The logic cabinet shall be constructed of 3 mm MS sheet. Cable entry shall be from the bottom. The logic cabinet shall be provided with anti-vibration mounting. 20% spare completely wired in slots with all internal and external cabling shall be furnished. The system shall require adding of additional logic cards only for these spare capacity to be implemented. To utilise this expansion capacity, prefab cables with requisite connectors to windows shall also be furnished as part of the system. Each window or a group of windows shall be provided with Solid State CMOS Logic Cards, which shall be mounted separately in cabinets. Jumper switch shall be provided on each card so as to make it suitable for contacts that either open or close.

10.03.02

The flash frequencies among annunciation windows distributed in various panel sections shall be highly regulated to offer uniform flashing rate throughout the control room. The flasher module for this function shall also be uniformly distributed within the logic cabinet to approximate the finally decided window distribution in control panel sections. Generally not more than 30 points are expected to be hooked up to one flasher module. The Buffer terminal cabinet with their auctioneering diodes shall receive field inputs on rows of terminals. The diode matrix shall be mounted on plug in type printed circuit boards and shall offer clear isolation of input status signals to annunciation system & other control system. The Diode matrix card shall be designed for a maximum of eight inputs per card.

10.03.03

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Multipin sockets for the prefabricated plug in cables and the terminal block shall be interconnected through Diode matrix by cabinet internal wiring. Prefabricated plug in cables with connectors shall be furnished for interconnection of signals from Buffer cabinets to Visual Annunciation System cabinets, Control system. Signals used for HW Annunciation shall not be multiplied/ diode auctioneered, it shall be thru control systems digital output only. 10.04.00 10.04.01 TERMINALS AND WIRING Separate cage clamp type terminal blocks with twenty (20) percent spare terminals shall be provided for contact input termination and 240V AC supply. Terminals for each point shall be suitable for connecting two (2), size upto 2.5 sq.mm copper, 650 grade PVC insulated, single strand, flexible, single/multicore conductors. Wiring inside panels shall be of copper, 650V grade PVC insulated, flexible conductor. Both ends of wiring shall have numbered ferrules for identification. PREFABRICATED CABLES Prefabricated cables with plug-in connectors for connecting IPR/logic cabinet to annunciator windows (VAS) as well as interconnection among IPR/logic cabinets, shall be supplied and installed by the BIDDER. All the interconnecting cables shall be FRLS type. All terminations on his equipment shall however be executed by the Bidder. Bidder shall clearly specify if any special type of cables (e.g. Screened cables) are required for field connection. Cable Specification 1. Reference 2. Insulation 10.06.00 POWER SUPPLIES The cabinet shall be furnished with a system of duplex universal type receptacles fed from the 240 V AC UPS power supply. The logic and other power supplies requirements shall be derived by the BIDDER internally in the logic cabinets/IPR cabinets. Redundant solid-state power supplies shall be furnished for the logic levels. Contact interrogation, and lamp drives. The outputs of the supplies shall be short circuit proof and diode auctioneered to ensure continuity of power within the system even with one power supply failure. The system shall also be furnished with "Earth fault" detection and monitoring equipment. Bidder shall ensure that the interrogation voltage levels for Visual Annunciation System and DAS portion of the Distributed System are matched. 10.07.00 Factory Tests : IS-1968, part-I : Any polymeric/Elastomeric material conforming to IS-5831/IS-6380

10.04.02

10.05.00

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Annunciation system shall be factory tested under various stages of manufacture and also on full completion with total system with its attendant subsystems fully integrated as per owner approved Quality Assurance Plan. The tests shall include but not limited to the following : 10.07.01 Type tests 1. 2. 3. 4. 10.07.02 Enclosure test as per IS-2147 Surge withstand capability (SWC) test as per ANSI C37.90a IEEE-472 1974. Damp heat cycling tests as per IS-2106 Part-II-1962 or equivalent international standards. Noise immunity test

Routine test (All Tests shall be performed as per applicable IEEE/ANSI & IEC latest standards.) 1. 2. 3. 4. 5. Burn-in power on test Complete operational tests Insulation resistance, high voltage, tests and continuity test of panel and cubicle wiring Short circuit test for current limiting functions. Under voltage/over voltage tests

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CHAPTER-11 CONTROL VALVES WITH ACTUATORS 11.00.00 11.01.00 11.01.01 CONTROL VALVES, ACTUATORS AND ACCESSORIES GENERAL REQUIREMENTS This section covers the design and construction requirements of Control Valves, their Actuators and Accessories. Except as otherwise specified herein, the Control Valves and accessory equipment furnished under this specification shall be designed, constructed and tested in accordance with the latest applicable requirements of code for Pressure Piping ANSI B31.1, the ASME Boiler and pressure vessel code, Indian Boiler Regulation (IBR) and other standards referenced herein as well as in accordance with all applicable requirements of the "Federal Occupational Safety and Health Standards, USA", or acceptable equal standards. The design of Control Valves shall comply with relevant codes and standards, account for relevant design criteria viz. environmental conditions, power and air supply, established reliability (reliability target and life expectancy), design of enclosures as specified in Sections earlier. All Control Valves and accessories furnished under the Section shall be of Owner approved make, fully meeting the qualifying requirements. Each control valve station shall be provided with pneumatic bypass control valve or Inching type motorised bypass valve as per process requirement and subject to owner approval. In addition each control valve shall also have upstream motorised valve. Downstream motorised valve shall also be provided as per process requirement and as finalized during detailed engineering. CONTROL VALVE CONSTRUCTION AND SIZING General 1. Valve Construction shall be in accordance with the requirements specified herein. (Bidder to also refer NIT drawing # 114-18-0100). The design of all valve bodies shall conform to the requirements of ANSI (USA) for dimensions, material thickness and material specification for their respective pressure classes. The valve sizing shall be suitable for obtaining maximum operating conditions with valve opening at approximately 80% of total travel. Valves shall be open not less than 15 % of full opening for minimum flow condition and shall be capable of handling at least 120% of the required maximum flow at full open condition. Actual pressure drop is indicated in the specification sheets. Permissible pressure drop shall be calculated and

11.01.02

11.01.03

11.01.04

11.02.00 11.02.01

2.

3.

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used by the Bidder for sizing calculations. Valve sizing shall be in compliance with the latest edition of ISA Handbook on control valves, ISA standards ANSI/ISA-75.01.01, Flow Equations for Sizing of Control Valves with due consideration for the measures to avoid choked flow. Bidder shall ensure that the valve outlet velocity does not exceed 8 meters/second for liquid services, 150 m/second for steam services and 50% of sonic velocity for flashing services by selecting proper body size for the required Cv. 4. a. The Bidder shall provide valves designed to prevent cavitations, wire drawing, flashing on the downstream side of valve and in downstream piping, when operating through full range under the specified conditions. For cavitating services, valves with anti cavitation trims shall be offered. This shall ensure cavitation prevention by multiple stages of pressure drops. Detailed calculations shall be furnished by bidder to establish cavitations occurrence or otherwise for various process conditions each service wise. For flashing services such as heater drains, control valve design shall be specially effected to ensure suitability for the adverse high pressure drops and minimise its detrimental effects on control valve parts. Bidder shall furnish detailed establish compliance to these valve. No price implications admissible to comply with specification. b. catalogue, calculations, write ups to stipulations with the selection of each during engineering stage would be these stipulations and intents of

The Liquid pressure recovery factor (FL) shall be 0.995 or better for severe flashing/cavitation services. The Liquid pressure recovery factor (FL) shall be 0.985 or better for low flashing/cavitation services.

c.

5.

Each valve shall be designed for tight shut-off against pressure, the valves shall have maximum permissible leakage rate as per ISA RP 39.6 Leakage Class IV (0.01% of rated valve capacity) or specified other wise. Control Valves for Application such as HP/LP heaters emergency level control, SH spray & RH Spray control, Emergency makeup to Hotwell, Deaerator drain to condenser hotwell & heavy oil heating, HFO & LDO and Pressurizing control system, condenser normal make up control valve shall have permissible leakage rate as per leakage class V (ANSI/FCI). All SH/RH block valves, shut off valve of LDO & HFO and BFP recirculation valve shall have leakage class MSS-SP-61.

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6.

The valve design shall take into account noise abatement considerations. The design objective will be to limit the generation of valve induced noise to 85 dBA at 1 Meter from the valve surface under actual operating conditions. The noise abatement shall be obtained by valve body and trim design and piping arrangement and not by the use of silencers. The Bidder shall be responsible for proper sizing of the valve and selection of appropriate model and materials of constructions for meeting the operating requirements specified herein and details subsequently furnished during the detailed engineering stage. The valve travel time shall be less than 10 second for non critical services valves. Rangeability should be 50 to 1 (min.) for non critical services valves. Control Valves Linearity, Hysteresis, Accuracy shall be < +1% and Sensitivity shall be < + 0.5%.

7.

8.

9. 10.

Bidder shall furnish the Control Valve data sheets and sizing calculations with the proposal which will be subjected to owner approval during detailed engineering. The bidder shall furnish all valves as per Owner approved data sheets and drawings. 11.02.02 Valve Construction 1. All valves shall be of globe body design and straightway pattern. Straightway pattern valves shall be either single or double ported as specified. Double ported and single ported valves shall have high lift cage guided plugs, unless otherwise specified. 2. Where specified, valves with cage guided plugs and quick change trim shall be supplied. The quick change trim shall consist of a cage and seat ring clamped in the valve body by the valve bonnet and sealed with a spiral wound stainless steel asbestos gasket. The trim shall be removable through the top after bonnet removal without any cutting or welding of the valve. Where applicable, plugs shall be designed to include pressure balancing for cage guided valves. Direct acting and self-contained pilot type valves may have low lift plugs. Cast iron valves are not acceptable. Bonnet joints for all control valves shall be of the flanged and bolted type or other construction acceptable to the Owner. Bonnet joints shall be designed for easy disassembly and for assurance of correct valve stem alignment. Bonnet joints of the internal threaded or union type will not be acceptable. Plugs shall be of one-piece construction either cast, forged, or machined from solid bar stock. Plugs shall be screwed and pinned to valve stems or shall be integral with the valve stems.

3. 4. 5.

6.

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7.

When Teflon packing is used, the lower valve stem which passes through the stuffing box shall be polished to at least 2x10-4 millimeters r.m.s. Valves gland packing shall normally be Teflon on liquid and gas services up to 100kg/cm2 and 230 Deg.C Teflon impregnated asbestos shall be used above 230 Deg.C and graphite impregnated asbestos with lubrication shall be used for steam services. All valves shall be arranged so that the plugs may be removed from the valve bodies from the bonnet side.

8.

9.

10. Each valve shall have an arrow permanently fixed on the valve body to indicate the correct direction of flow. 11. Each valve shall have a stainless steel name plate permanently fastened to the yoke which shall be visible when the valve is in service. The name plate shall include a. Tag No. and Valve Serial No. b. Body material, size and pressure rating c. Trim material, size characteristics d. Action on air failure e. Spring range f. Stem travel g. Valve action, etc. 11.02.03 Valve Materials 1. Valve material shall be as specified in Suppliers approved Control Valve Specification sheets. The following table defines abbreviations used for valve materials: Abbreviations BR CS Description Bronze ASTM B 61 Carbon Steel Forged - ASTM A 105 Cast - ASTM A 216 Grade WCC 1-1/4 % Chromium Alloy Steel Forged ASTM A 182 Grade F11 Cast ASTM A 217 Grade WC6 2-1/4 % Chromium Alloy Steel Forged ASTM A 182 Grade F22 Cast ASTM A 217 Grade WC9 5% Chromium Alloy Steel Forged ASTM A 182 Grade

S.No. a b

1- CR

2-

CR

5 CR

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f.

SS

F5 Cast ASTM A 217 Grade C5 Stainless Steel AISI Type 316 ASTMA 351 Grade CF8M

2.

Body material shall be selected by the Bidder to be compatible with the nature of the fluid, service conditions, and piping material to which it is welded and shall be subjected to Owner approval. In general, cast or forged carbon steel bodies shall be provided for non-corrosive process applications up to 275 Deg.C. Alloy Steel castings shall be provided when the media is non-corrosive and the temperature exceeds 275 Deg.C and is within 550 Deg.C. Stainless Steel of suitable grade shall be provided when media is corrosive and the temperature is below 300 Deg.C. Service Non Corrosive, Non Flashing, and non cavitations service for process temp. up to 275 deg. C like Aux. steam flow to Deaerator, Cond. Flow to deaerator, Fuel Oil, Atomising steam service etc. Non Corrosive, Non Flashing, and non cavitations service for process temp. above 275 deg. C. and up to 550 deg. C. and for CRH flow to Deaerator. Severe Flashing/ cavitations service like Feed Control Valve, Spray Control valves, LP/HP heater emergency level control valve, HP BP spray control valve, Deaerator Overflow control valve etc. Low Flashing/ cavitations service like LP/HP heater normal level control & Condensate/feed water below 275 deg. C. DM Water Application (Condenser Hotwell normal & Emergency make up etc.) Body Material Cast Carbon Steel ASTM A216 Gr. WCB/WCC Cast Alloy Steel ASTM A217 Gr. WC9 Cast Alloy Steel ASTM A217 Gr. WC9 Cast Alloy Steel ASTM A217 Gr. WC6 Cast type 316 Stainless Steel ASTM A351 Gr. CF8M

Sr. No. 1.

2.

3.

4.

5.

3.

Unless otherwise specified, all control valves shall have stems, guide bushings, plugs, seat rings, stem lock pins, stuffing box parts, and other trim, all made of stainless steel. Valve guide posts and bushings shall be stellite faced for valves where specified. Stellite faced guide posts and bushings shall be differential hardened. For applications involving high pressure drop as also for flashing and cavitation services, trim material shall be properly chosen to ensure required degree of hard facing (such as17-4 PH SS) so as to avoid erosion. Service Trim Material Non Corrosive, Non Flashing, and non cavitations SS316 Stellited service for process temp. up to 275 deg. C. like Aux. steam flow to Deaerator, Cond. Flow to deaerator, Fuel Oil, Atomising steam service etc. Non Corrosive, Non Flashing, and non cavitations SS316 Stellited service for process temp. above 275 deg. C. and up

Sr. No. 1.

2.

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3.

4.

5.

to 550 deg. C. and for CRH flow to Deaerator. Severe Flashing/ cavitations service like Feed 440 SS Control Valve, Spray Control valves, LP/HP heater emergency level control valve, HP BP spray control valve, Deaerator Overflow control valve etc. Low Flashing/ cavitations service like LP/HP heater 17-4 PH SS normal level control & Condensate/feed water below 275 deg. C. DM Water Application (Condenser Hotwell normal & 17-4 PH SS Emergency make up etc.) Where stellite facing is not specified, hardened for all surfaces subject to wear. stainless steel shall be furnished

4.

5.

Manufacturer recommended materials for cage guided valves may be substituted for materials specified provided they satisfy the specified service conditions. Also where substitutions are made, the manufacturer shall guarantee performance of recommended materials to be equal to or better than the specified materials for conditions specified. Bidder may offer valve with body and trim material better than the specified material and in such case, bidder shall furnish the comparisons of properties including cavitations resistance, corrosion resistance, temp. resistance, erosion resistance, hardness etc. of the offered material vis a vis specified material for owner approval.

11.02.04 1. 2.

End Preparation Valve body ends shall be butt-welded type. Flanged ends shall be of a pressure class equal or greater in pressure-temperature rating to the body design pressure and temperature indicated on the control valve. Unless otherwise specified, steel flanges shall be raised face type. Flanged ends for valves shall be in accordance with ANSI B 16.5. Welded end for control valves where specified shall be socket-weld per 16.11 for control valves of sizes 50 mm (2") and below and Butt connections per ANSI B16.25 for control valves 65 mm (2-1/2") and The end preparation for butt welded control valves shall be matched corresponding details for the piping on which the valve is installed. ANSI B welded above. to the

3.

4.

All end preparations shall be as per Owners requirements indicated during Contract stage. Miscellaneous Parts

11.02.05

1. Extension bonnets shall be used on all valves when the maximum temperature of the flowing fluid is greater than 275 deg. C or when specifically required in the control valve. 2. Stem travel indicators shall be provided on all valves.

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11.03.00 11.03.01

VALVE OPERATIONS All control valves shall be furnished with pneumatic spring opposed diaphragm, spring less diaphragm, or piston operators as specified herein. The bidder shall be responsible for proper selection and sizing of valve operators in accordance with the pressure drop and maximum shut-off pressures. Valve operators and stems shall be adequate to handle the unbalanced forces occurring under the specified flow conditions or the maximum differential pressure specified. An adequate allowance of stem force, at least 0.15 kg/sq. cm per linear millimeter of seating surface, shall be provided in the selection of the operator to assure tight seating unless otherwise specified. The operators shall be designed to produce the required stem force with supply air pressure of 3.5 kg/sq. cm maximum unless otherwise specified. Diaphragms shall be moulded synthetic rubber and diaphragm housing shall be of pressed steel construction. Diaphragms shall not be fabricated of natural rubber. Piston operators shall use cast pistons and cylinders with 0-ring seals. Operators shall be supplied with name plates which indicate the diaphragm air pressure at full open and full closed positions. for single seated valves the pressures shall be listed for maximum differential and for zero differential across the valve. Pistons and cylinders shall be cast aluminum. Piston rod and extension shall be chrome plated stainless steel. Cylinder seal bushings shall be brass and seal rings shall be nitrile. Yoke shall be cast iron. Valve operators shall be capable of operating at 60 C continuously. CONTROL VALVE ACCESSORIES & DEVICES The following accessory equipment shall be provided for control valves:

11.03.02

11.03.03

11.03.04

11.03.05

11.03.06

11.03.07 11.04.00

11.04.01

Air Locks: Air locks shall be designed to shut off the diaphragm loading air line if the supply air pressure to the associated pilot or Positioner fails. Air locks shall be of the automatic reset type and shall be furnished with alarms. Hand Wheels: Hand Wheels shall be provided. Hand wheels shall be side mounted unless specified to be top mounted. However the mounting shall be as decided during engineering to offer maximum accessibility. Limit Switches: Each control Valves shall be provided with limit switches for monitoring of end position in DDCMIS/DCS/PLC. Switches shall have not less than two normally open and two normally closed contacts in both open and close directions. Electrical rating of the limit switch contacts shall be 240V AC, 5 amp or 220V DC, 0.5 amp. Limit switches should be National Acme Co., or Honeywell micro switch type or Owner approved equal. The enclosures of the limit switches

11.04.02

11.04.03

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shall be as per NEMA-4 Standard. Limit switches shall be constructed to withstand the temperatures encountered in the actual service. Explosion proof construction shall be furnished where required by applicable code or these specifications. Limit switches shall be factory mounted on the valves with provisions for adjusting the mounting. The Bidder shall stroke the valves to check limit switch operation prior to shipment. Limit/micro switches can be offered as an integral part of Smart valve positioner. 11.04.04 Smart Valve Positioner: Control valve actuators for modulating and throttling services shall be provided with HART protocol based smart electro pneumatic valve Positioner to ensure accuracy & repeatability of response. The valve Positioner shall be designed suitable for vibration and service conditions of a steam electric power station. The Positioner shall have the following features: a) b) Shall provide a pneumatic output signal of range 0.2 to 1.0 kg/cm2or as desired for the actuator. Shall have integral type position transmitter, input & output gauges, local keypad, display, 4-20 mA input and 4-20 mA output for position indication in DDCMIS/CCR/PLC. Shall be suitable for direct mounting on control valve assembly both for rotary & linear valves. Shall be capable of functioning under hot, humid & vibrating conditions. Shall have dust tight, corrosion resistant & weather proof IP 65 metal casing. Shall be operated at signal range of 4-20 mA for full travel of the valve. Split range operation in few case my be required. This facility shall also be available in positioner. Shall have in built mechanical position indicator. Shall have fail safe & fail freeze function as per loop process requirement. Shall have in built auto tune facility.

c) d) e) f)

g) h) i) 11.04.05

Solenoid Valves: Solenoid Valve will be provided for the following i. ii. iii. iv. ON / OFF Duty type Control Valve For over-riding the controller signal with Modulating type Control valves. For control valve stay put position requirement on controller signal failure with Modulating type Control valves. For construction and detailed specification of Solenoid valve, Chapter 3, Vol. V shall be referred by bidder.

11.04.06

Diffusers : Diffusers shall be provided as per service application requirements. The diffuser shall be designed to reduce the pressure drop across the control valve below the critical value and reduce the sound pressure level. Details of the diffusers shall be submitted.

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11.04.07

External Volume Chambers: External volume chambers with adjustable bleed valves shall be provided for Control Valve. Volume chambers shall be furnished, mounted on the control valve yoke assembly. Position Transmitters: Position transmitters shall be provided for control valves as a part of smart positioner. The signal shall be 4-20 mA DC range, 24 V DC. For non smart positioners applications and power cylinders, contact less position transmitter shall be provided by bidder. Tubing and Air Sets: All pneumatic tubing required to interconnect devices assembled together shall be furnished complete with each control valve. The tubing shall be fully annealed soft temper copper tubing conforming to ASTM B68 to B75 (USA). Swage lock flare less tubing fittings shall be used for tubing connections (Swage lock or approved equal). Each device requiring an air supply shall be equipped with a combination filter-regulator. Devices mounted together on a valve yoke may be served by a single regulator, provided the supply pressure is satisfactory and the regulator capacity is not exceeded. Filter-regulators shall be mounted on the device served. Filter- regulators shall be suitable for a 10 kg/sq. cm maximum inlet pressure. Filterregulators shall have built-in housing blow down valves and a 2 inch pressure gauge. The filter shall be of size not more than 5 microns and shall be made of sintered bronze.

11.04.08

11.04.09

11.04.10

Pressure Switch Pressure switch suitable for the above the pneumatic system shall be provided. The contact rating shall be 2 A for 240 AC, .2 A, 220 VDC 2 SPDT Contact. Enclosure IP 65.

11.04.11

I/P Converter For non smart positioners applications and power cylinders i/p converters shall be required and owner approval shall be obtained for the use of i/p converter for such applications. Electro-pneumatic, outdoor type, field mounted Linear. 4-20 MA DC input and 0.2 1.0 kg/Cm2 output. Die cast aluminum casing with IP65 or equivalent enclosure class. Accuracy of + 0.5% of span or better and repeatability of + 0.5% of span or better will be provided. Easily accessible span and zero adjustment will be provided I/P converter shall be provided with all accessories and erection hardware. The I to P converters shall retain the pneumatic signal (last value) even in failure of control signal and shall have self volume boosters.

11.04.12

Separate moisture separator unit for ensuring dryness of air entering I/P as well as the power cylinder is to be supplied with each control valve and control damper. FOR FOLLOWING CRITICAL APPLICATION SPECIAL CONTROL VALVES ARE REQUIRED.:

11.05.00

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1. 2. 3. 4. 5. 6. 11.05.01

HP & LP Bypass Valves and Control System BFP Minimum Re-circulation Valve Feed Water Control Valve SH & RH spray Control Valves APRDS System Soot Blower control valve

General Requirements for Critical Application Control Valves for -. i) The valve accessories shall include hand wheels, limit switches, smart valve positioner (4-20mA DC type), electro pneumatic converter, Air lock relay, Solenoid valve and all other items required for the completeness and the accessories shall be explosion proof type as per hazardous area classification wherever applicable. Control valves shall be furnished with IBR certification wherever required. 1. Noise: The maximum allowable noise level shall be 85 dba or less at 1 m. distance from the downstream bare pipe surface. The specified noise level shall be attained without the use of orifices, mufflers, diffusers. No credit for thermal or acoustical insulations shall be taken. Valve Trim: Valve shall have quick change type trim utilizing top entry. No components shall be screwed or welded into the body. The valve shall have equal pressure distribution around the plug to avoid chattering / vibration. Trim of severe/critical service valve shall be of multi stage & multi path design with sufficient no. of discrete pressure drop stage to eliminate the chance of erosion, cavitations, noise, vibration through out the control range of valve. 3. Leakage Class: The valve shall have minimum class-V leakage for all steam applications including APRDS, HP/LP bypass spray control valves & Low Load feed water control valve. In case of minimum boiler feed pump re-circulation applications, RH/SH spray control valves and HP/LP Bypass control valve application, the leakage class should be MSS-SP 61 (block valve leakage). 4. Actuator: Actuator type should be pneumatic double acting piston/Hydraulic.

ii)

2.

11.06.00 11. 06.01

Specific Requirements / Specifications for Different Valves: Design Criteria for selection of Feed Water Control Valve : The valve trim should be multi stage, multi path, multi disk design having sufficient no.s of discrete pressure reductions (turns / stages) to ensure elimination

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of vibration, cavitations, erosion and noise effects. Pressure reduction / drop achieved by valve designs incorporating single or multistage orificed cage, diffusers are not acceptable. Bidder should work out no. of pressure drop turns in the trim of the valve and should provide calculations of trim exit velocity. Seat ring and trim fitment should not have any part screwed or welded. It should be easily replaceable type. Flow vs. valve opening characteristic: The trim is to be so designed that the min. flow indicated in the bid specifications of the valve is achieved with min. lift of 20mm of valve plug from Close position. Subsequent characteristic should be equal percentage i.e. corresponding to the parabolic characteristics. Characterizing the cam of the positioner to minimise the required flow char is not acceptable. Rangeability should be 50 to 1 (min.). Each pressure - reducing element should have a uniform pressure distribution around the plug to avoid mechanical vibrations (pressure equalizing rings / grooves). To prevent flow induced vibrations and the line trash damage to seat, the flow direction should be over the plug. During throttle opening of the control valve, flow should be diverted away from the body seat. Required leakage should be better than ANSI B - 16 104 Class V with metal to metal seating. Soft seat is not acceptable. Requisite calculations in support of above leakage class to be submitted with the offer. The bidder should indicate how this will be achieved in their valves and actuators. Actuators should be pneumatic double acting piston type. Diaphragm type actuators are not acceptable. The seating force on the valve seats to achieve the required leakage class (better than ANSI B - 16 104 Class V) should be about 180 kg / cm on seat ring. Pl. indicates the closing force on the seat in Kgf / cm of seat circumference applied for actuator. Trim exit velocity should be less than 22.5 M / sec. Calculation sheet should be attached demonstrating satisfactory compliance of this requirement. Noise level at 1 meter distance from the valve should be less than 85 dB without insulation, orifices, silencers, mufflers etc. Calculation sheet to be attached for each valve offered. Critical cavitation index (Kc) for all control valves should be 1 (one). This is specific requirement to avoid even remote possibility of cavitational damage to valve internals. Material of the valve internals should be as under: Guide Plug / Seat ring Stem 11.06.02 11.06.02.01 : : : 400 series SS 400 series SS 17 4 PH

Control Valve Specifications For Turbine By Pass System Turbine Bypass Control System: Standalone turbine bypass control system for each unit shall be provided. The control system shall include operator selectable manual or automatic modes with bump less transfer between modes. The turbine bypass system shall be included in the plant automation sequence for unit start-up and bypass operation.

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Complete operational design for the control system, including logic, modulating controls, schematics and wiring shall be provided. The design shall integrate the operation of both the HP & LP bypass stations into a single coordinated operation. The bypass system shall be operationally tested to assure acceptable functional performance of the bypass control system. Hardware, instrumentation, wiring interconnections and accessory devices necessary to be interfaced and will be implemented in the DDCMIS for control. The turbine bypass system shall be utilized to warm up the boiler and main steam lines after an appropriate vacuum is established. The HP/LP bypass system shall cut in operation automatically in case of (a) generator breaker opening, (b) Turbine trip (i.e.) ESV/CV close, and (c) sudden reduction in load. 11.06.02.02 The bypass system shall comprise of the following: HP BYPASS: Angle body high pressure bypass valve complete with hydraulic actuator spray valve --- 1 No. for each HP bypass valve complete with hydraulic actuator Isolation valve --- a common isolation valve