DESIGN BASIS REPORT Alumina Unloading and

CONTROL & INSTRUMENTATION Transportation System

DOC. NO. 14L08-000-DBR-I-001

DESIGN BASIS REPORT

FOR

ALUMINA UNLOADING AND TRANSPORTATION SYSTEM

CONTROL & INSTRUMENTATION

NATIONAL ALUMINIUM COMPANY LTD.

(A Govt. of India Enterprise)
Nalco Bhavan, P/1, Nayapalli
Bhubaneswar-751013, Odisha
Phone: 91-674- 2301988 to 2301999
Fax: 91-674-2300550/2300470/2300521/2300640
DOC. NO. 14L08-000-DBR-I-001

JULY 2015

DEVELOPMENT CONSULTANTS PRIVATE LIMITED

CONSULTING ENGINEERS
DEVELOPMENT CONSULTANTS HOUSE, BLOCK DG-4, SECTOR II, SALT LAKE
CITY, KOL - 700091, INDIA
 DESIGN BASIS REPORT Alumina Unloading and
CONTROL & INSTRUMENTATION Transportation System
DOC. NO. 14L08-000-DBR-I-001
 DESIGN BASIS REPORT Alumina Unloading and
CONTROL & INSTRUMENTATION Transportation System
DOC. NO. 14L08-000-DBR-I-001

CONTENTS

CL. NO DESCRIPTION PAGE NO

1.0 GENERAL……………………………………………………….. 1

2.0 FIELD INSTRUMENTATION………………………………….. 1

3.0 CABLE………………………………………………………….. 2

4.0 CONTROL & AUTOMATION……………………………….... 2

5.0 DRIVE CONTROL PHILOSOPHY…………………………..... 6

3
6.0 UPS……………………………………………………………….. 7

7.0 CCTV…………………………………………………………….. 7

8.0 DRAWINGS & DOCUMENTS……………………………….. 7

9.0 SPECIAL TOOLS & TACKLES……………………………….. 8

 DESIGN BASIS REPORT Alumina Unloading and
CONTROL & INSTRUMENTATION Transportation System
DOC. NO. 14L08-000-DBR-I-001

1.0 GENERAL:

National Aluminium Company Limited (NALCO) intends to set up additional alumina handling &
transportation system for existing smelter plant. The purpose of this project is to parallel system of
Alumina unloading & Transportation system (capacity 900000 Ton per year) by introducing a new
wagon unloading system along with transportation system to existing Silo.

2.0 FIELD INSTRUMENTATION:

Instrumentation sensing, transmission, measuring & computing systems will be electronic and final
control elements such as control valves etc shall be pneumatic in general.
Signal transmission from field to control room and vice-versa will be in the current mode i.e. 4-20 mA
DC through signal isolator having gain adjustment feature.
All field Instruments are envisaged to be Smart type giving output with superimposed digital signal
conforming to HART protocol.
All safety switches of the conveyor belt shall have individual local indication as well as remote
indication.
All temperature elements RTD/Thermocouple will be duplex type. Temperature transmitters will be used
for all temperature elements to generate 4-20 mA signals. Up to 2000C RTD shall be used, more than
that Thermocouple may be used.
All site pressure transmitters shall have provision of local indication as well as signal to the control room
for indication. However, all transmitters shall have in built local indication and communicate through
HART Protocol.
Suitable Level measurements / Sensors shall be provided. All level transmitters shall have display unit at
1 meter above grade level. For open environment the enclosure housing the controller shall be of IP 67
protection.
Pull chord switch shall be intelligent type.
All field instrument installation shall have suitable approach for maintenance.
Canopy shall be provided for all open environment installation.
All field instrument enclosure shall have IP 67 protection for open environment installation. Others may
have IP 65 protection.
All Solenoid Valve for pulsing/purging of the bag filter system shall be actuated by centralized PLC (not
a local PLC) directly through interposing relay or contactor. Terminal block shall have Fuse TB along
with Fuse blown indicator.
The dedusting system shall be provided with differential pressure transmitter having local indication as
well as in the PLC.
Separate earth pit shall be provided at new control room for instrumentation like VIZ, PLC etc.

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DOC. NO. 14L08-000-DBR-I-001

3.0 CABLE:

All field instruments will be terminated in the local junction box. Individual & overall shielded, twisted
pair (1.0 sq. mm) cables shall be used for analog signals. Over all shielded (1.5 sq mm) core cable shall
be used for Digital signals. Multicore or Multipair cables will be used from local junction box to the
marshalling cabinets or Input/output terminal blocks of PLC system. All cable shall be ATC Cu cable.
Cabling shall be done in such a way to considering transportation facility of the plant.
4.0 CONTROL & AUTOMATION:

In order to have better supervision, operation and control of the Alumina unloading & Transportation
plant, microprocessor based redundant Programmable Logic Controller (PLC) suitable for industrial
control system has been envisaged. The control system shall have the facilities for remote monitoring
and sequential control, including local operation of individual equipment, audio and visual fault
annunciation, normal status display, signaling, data & alarm logging, report generation, data storage for
historical analysis, data display and printing etc. The PLC will be situated in the New Control Room.

Hot Redundant PLC System (i.e. Redundant CPU, Communication Processor, Power supply of each
rack) has been envisaged in New Control Room (Near Unloading Area). I/O card will be non-redundant.
Make sure all information will be available in the PLC System.

Besides the above new PLC, additional I/O of the following area shall be accommodated in the respective
area existing PLC:
 Control Room - 2 PLC
 GTC - 8 Control Room PLC

Control Room -2 PLC:

Existing Control Room -2 have non redundant Siemens S-7 300 PLC. Additional I/O of the silo 1 & 2
area shall be accommodated in existing Control Room – 2 PLC. There is free space in the existing I/O
panel to accommodate the additional I/O card. Vendor has to supply additional I/O card along with all
accessories like back plane PCB, Terminal Block, interposing relay, Cable, Power supply module etc. to
accommodate additional I/O. Vendor to ensure that all I/O cards & accessories shall be from same make,
family of hardware as that of existing one. Graphics up gradation of existing HMI along with hook up of
existing Siemens S-7 300 PLC & New PLC at New Control Room over redundant Fiber Optic
communication under the vendor scope. Necessary hardwire & software like Network Switch, Fiber
Optic, Converter (if any) etc. shall be supplied by the contractor.

GTC-8 Control Room:

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CONTROL & INSTRUMENTATION Transportation System
DOC. NO. 14L08-000-DBR-I-001

Existing GTC-8 Control Room have redundant Rockwell Control Logix PLC with Flex I/O. Additional
I/O of the silo 5 & 6 area shall be accommodated in existing GTC-8 Control Room PLC. There is free
space in the GTC-8 Control Room to accommodate the additional I/O Panel. Vendor has to supply
additional I/O Panel with I/O card, Communication card along with all accessories like back plane PCB,
Terminal Block, interposing relay, Cable, Power supply module etc. to accommodate additional I/O.
Vendor to ensure that all I/O cards & accessories shall be from same make, family of hardware as that of
existing one. Graphics up gradation of existing HMI along with hook up of existing Rockwell Control
Logix PLC & New PLC at New Control Room over redundant Fiber Optic communication under the
vendor scope. Necessary hardwire & software like Network Switch, Fiber Optic, Converter (if any) etc.
shall be supplied by the contractor.

The purpose communication with existing PLC & New PLC is to get rid of the issues of any overlapping
of command regarding silo filling, necessary interlocks to be incorporated in the existing PLC as well as
new PLC.

Local panels, if at all offered for the drives like Air Blower, Compressor etc, will be placed near to drives.

Switchgear related input will be connected to New PLC for information of electrical system & report
generation. It is envisaged that IED will be connected to Network switch with Peer to Peer
Communication and MFM will be connected to PLC through RS 485 communication with daisy chain.
Hardwired electrical I/O will be connected to PLC directly through control cable.

Following facilities have been envisaged for the PLC system as minimum:

1) Real time automatic centralized control (starting and stopping) from control room for all
equipment in accordance with a pre-determined sequence (both for starting and stopping) for
normal operation of the plant so as to ensure safe and efficient operation of entire plant.

2) Stopping of any equipment from the control station located near the drive of respective
equipment under all conditions including emergency.

3) The wagon unloading control and silo selection shall be carried out from the new control room.
The signals indicating faults on the silos shall be visualized in the above of control room.
Selection of silo to be filled will be made by an operator MANUALLY according to Alumina
level in different silos. These levels will be indicated by devices designed to show at any given
time the level of alumina in storage. When wagons have been emptied, unit should be
stopped in reverse order i.e. equipment nearest wagons first. Any incident, equipment
stoppage or blocking will be reported to unloading station by audio-visual signal.

4) Stopping of conveyors in case of emergency by safety Switches etc. provided along the
conveyors. Tripping of any conveyor will trip upstream conveyors & downstream conveyors

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CONTROL & INSTRUMENTATION Transportation System
DOC. NO. 14L08-000-DBR-I-001

sequentially after a time lag. Safety switch has been envisaged both side of all
conveyors maintaining standard distance. Safety Switch status will be displayed in the HMI.

Each safety switch will be addressed to MCC. Hardwired multiplication will be done in the
MCC. One contact will be connected to PLC and other one will be connected to MCC for
hardware interlock.
5) Safety interlocks of the equipment should be provided hard-wired into the drive level i.e. in
MCC. All the drive safety related switches shall be multiplied in the MCC to make two contacts
other than that used in the scheme. One set of contact shall be sent to the PLC and the other set
of contact shall be used to MCC / Sw. Gr. to realize the drive safety interlock. This will ensure
minimum Drive Safety aspects of all the Drives. However the logic for the safe operation of each
equipment will be developed during detail engineering

6) Suitable material level sensor shall be provided in each Bin/Hopper.

7) PLC System will be communicated with VVF drives & other 3rd party system through soft
communication depending on the system protocol, if any.

8) Starting and stopping of any desired equipment can be done independently from local control
stations located near the respective motors / drives for maintenance / repair / testing by selecting
remote / local mode of operation from the LPBS.

9) Sounding audio alarm / warning system prior to starting of the plant for information to plant
personnel / maintenance staff to keep a safe distance from equipment under operation.

10) Special care should be taken so as to ensure availability of signal to & from PLC & field keeping
the furthest distance between PLC & field instruments in design consideration.

11) EEPROM / Non volatile Reprogrammable Flash ROM having sufficient capacity to store the logic
program along with the tag/symbol name.

2 12) 24 VDC power supplies (if any) used for PLC cards / I/O interrogation shall be
configured in hot redundant mode through diode bridge. DI shall be envisaged for
monitoring the health of these power supplies and corresponding alarm to be generated
in the HMI screen in case of failure.
13) Local hard I/Os are proposed in PLC-2 (Silo 1&2) and PLC-6 (Silo 8) control room located at
GTC 8 Control room. All necessary items(hardware and software if any) required shall be in the
scope of the vendor/system supplier.

14) All analog I/Os ( mA signal) shall be through signal isolators having gain adjustment feature.

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15) All PLC outputs to be routed through fuse terminal having LED type fuse blown
indication and interposing relay board having dual ended potential free relay contacts
having suitable contact rating.

16) All digital I/O interrogation shall be through Non UPS power supply only.

17) All the software licenses (PLC, Microsoft, Antivirus etc.) must be purchased in the name
of “ Smelter Plant, National Aluminium Company Limited, Nalconagar, Angul”. The
Documentary evidence in this regard must be submitted to Nalco.

18) All licenses should be paper based only.

19) All the HMI stations/CCTV servers shall be loaded with Antivirus software having 3 Year
license.
2

20) Software:
a) All Scada screens shall be developed in consultation with NALCO.

b) Application program MUST be developed in LADDER LOGIC only.

21) Local hard I/Os for the existing PLC is proposed in PLC-2 (Silo 1&2) and PLC-6 (Silo 8) control
rooms. If Existing space available in the existing panels is not sufficient, then extra panel to
house the local I/Os shall be in the scope of vendor along with all necessary items (hardware
and software if any) to communicate with the existing PLC shall be in the scope of the
vendor/system supplier.

22) Inter PLC communication-

The communication with the existing PLCs located in the control room – 2 and GTC-8 control
room shall be in the scope of the vendor. All necessary hardware, software, configuration,
services etc. shall be in the scope of the vendor.

23) The control of all equipment will be done from the New Control Room.

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 DESIGN BASIS REPORT Alumina Unloading and
CONTROL & INSTRUMENTATION Transportation System
DOC. NO. 14L08-000-DBR-I-001

5.0 DRIVE CONTROL PHILOSOPHY:

a) Local/Remote Selection

For every drive there will be a Local/Remote Selector Switch near the drive, preferable in the same
plague of Local Push Button Station. The Selector Switch is kept in Local position during testing,
commissioning only. Normally the Selector Switch will be kept in Remote position.

b) Remote Operation

Drives can be started from Remote Mode i.e. HMI stations provided there is no safety interlocks
active & Local/Remote Selector Switch kept in Remote position. Also in this type of operation, the
sequential starting of the drive can be performed by group selection mode as well as individual
selection mode provided there is no safety interlock active & process interlock are alive.

Drives can be stopped from Remote Mode i.e. HMI stations irrespective of any situation. The drives
will stop automatically in case safety interlock is active.

c) Local Operation Mode

Drives can be started from Local Mode i.e. through LPBS provided Local / Remote Selector Switch
are selected in Local mode.

Drives can be stopped from Local Mode i.e. LPBS irrespective of any situation. The drives will stop
automatically in case safety interlock is active.

d) Emergency Operation

One no emergency push button is envisaged for every drive. This push button will be physically
situated on the operator console in Control Room. The emergency push button will be directly
hardwired to MCC / SW GR for stopping of the drive irrespective of any situation.

e) Conveyor Operation Philosophy

In case of tripping of any intermediate conveyor in a chain of conveying system, the feed end
conveyor has to stop first. With a pre-set time gap adjacent downstream conveyor shall stop
sequentially.

In case of starting a chain of conveyor, the discharge end belt has to be started first. The adjacent
belts will be started with a preset time gap sequentially towards feed end.

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DOC. NO. 14L08-000-DBR-I-001

 Operation of Siren

A safety warning through siren/hooters near the drive for the field personnel & safety of major
drive a pre-set time followed by a definite time when drive will start.

6.0 UPS:

Redundant UPS (2 x 100%) with common Ni-Cad battery having state-of-the art technology (IGBT with
PWM) is envisaged for Control Room. The power supply of UPS shall be from emergency feeder and by
pass line shall be from raw feeder. This UPS power will also cater to CCTV system as required. Loading
of the UPS shall not be more than 80% of total load.

7.0 CCTV:

IP based CCTV cameras will be located for each plant section for the monitoring of relevant areas from
Control Room. Some of the cameras shall have facility of pan, tilt and zoom for selection of target area
and closer view of the area under observation. The numbers of cameras are as follows:

a) 10 nos. of PTZ Cameras

b) 10 nos. of Fixed Cameras

Location of the camera will be finalized during detail engineering. Cameras will be interfaced to the
control and monitoring system through video server. Two no of desktop mounted 24” LED based screen
will be there in the Control Room along with a 74” wall hanging screen for monitoring & control of
CCTV Cameras.

8.0 DRAWINGS & DOCUMENTS:

The following drawing and documents to be supplied

2 a) Control Philosophy.
b) I/O/F List
c) Electrical schematic wiring drg. (from field devices to PLC I/O card.)
d) Instrument loop drawing.
e) Instrument power supply drg.
f) P&ID drg.
g) All field instrument settings.

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CONTROL & INSTRUMENTATION Transportation System
DOC. NO. 14L08-000-DBR-I-001

9.0 Special Tools and Tackles

2 Any special tools/instruments required for communicating/parameter setting/viewing/diagnostics viz.

HART communicator, IR Cable (if any), special cable etc.. shall be supplied along with the instrument.

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