E&I Technical Specification - Limestone Milling & Handling System

TATA CONSULTING ENGINEERS LIMITED
SECTION: B
EMISSION REDUCTION IN TSM BOILERS
LIMESTONE HANDLING SYSTEM
SHEET 1 OF 8
PROJECT INFORMATION
1.0 PROJECT INFORMATION
1. Owner :
2. Owner’s Consultant : Tata Consulting Engineers Limited,

73/1, St. Marks Road, Sheriff
Centre, Bangalore
3. Project Title :
4. Location : Odisha, India.
5. Latitude : 20 o 50" N
6. Longitude : 85 o 6”E
7. Elevation above mean sea level : 74 m
8. Road / Rail network :
9. Limestone Analysis : Annexure: 1
10. Key Parameters of Existing Boilers : Annexure: 2
11. Coal Analysis : Annexure: 3
12. Climatic Conditions :
(a) Ambient Temperature

Dry Bulb : 37.3 0C Max 25.1 0C Mean
Wet Bulb : 26.0 0C Max 21.8 0C Mean
0 0
Maximum : 44.4 C (Extreme 47.2 C) inside
shade
Minimum : 9.7 0C (Extreme 3.5 0C) inside shade
(b) Relative Humidity

Maximum : 83%
Minimum : 33%
(c) Rainfall
Maximum in 24 hrs : 257.3 mm/m2
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FILE NAME: TCE FORM NO. 329 R7

F329R7.docx
SPEC NO. SECTION: B
TSM-TSP-23-00- LIMESTONE HANDLING SYSTEM
01-14-002-60001 SHEET 2 OF 8
PROJECT INFORMATION
Maximum Monthly : 826.0 mm/m2
(d) Predomimant Wind Direction : West to east, North - West to South -

East
(e) Wind Speed : 44 m/s at 10 m height
(f) Seismic Zone : Zone - III - ( As per IS : 1893 Part 3)
13. Wind Load
Calculations for wind effect shall be in accordance with IS:875 (latest issue)
taking into account the following :
(a) Basic wind speed of 44 m/sec.
(b) Factor K1 shall be taken as 1.07
(c) Terrain category shall be 2 and corresponding values shall be taken for
K2
14. Seismic data (as per IS:1893 latest issue)
(a) Zone : Zone-III
(b) Importance factor (I) : Importance factor (I) As per IS 1893 for
civil structures, i.e 1.75
15. Auxiliary power supply:
Auxiliary electrical equipment to be supplied against this specification shall be

suitable for operation on the following system :
a) For motors rated > 200 KW 6600V, 3 phase, 3 wire, 50Hz medium
earthed AC
b) For motors rated upto 200 kW 415V AC, 3-phase, 4-wire, 50 Hz

effectively earthed
c) DC motor starters, DC solenoids, DC 220V DC, 2 wire, unearthed DC

alarm, control and protections of
Breakers
d) AC control & protective devices 240V, 1 phase, 50Hz, 2 wire AC supply.
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SPEC NO. SECTION: B
TSM-TSP-23-00- LIMESTONE HANDLING SYSTEM
01-14-002-60001 SHEET 3 OF 8
PROJECT INFORMATION
The single-phase 110V AC supply shall

be derived by CONTRACTOR by
providing 415V / 110V control
transformers of adequate rating with
MCCB / MPCB on the primary and MCB
on secondary sides
e) Uninterrupted power supply 230V, 1 phase, 50Hz, 2 wire AC supply
f) Lighting fixtures and space heaters 240V, 1 phase, 2 wire, 50Hz
g) Lighting fixtures and space heaters 240V, 1 phase, 2 wire, 50Hz
h) The above voltages may vary as follows :

All devices shall be suitable for continuous operation over the entire range of
voltage and frequency indicated below without any change in their performance.
AC supply Voltage variation  10%

Frequency variation  5%
Combined voltage & frequency variation
10%
DC Supply Voltage variation +10%
-15%
16. All the electrical equipment shall be designed for 50 C reference ambient
temperature.
17. The noise (sound) power level emitted by the generator shall meet the
requirement of Ministry of Environment and Forest (MOEF), Government of India.
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SPEC NO: TATA CONSULTING ENGINEERS LIMITED
TSM-TSP-23-00- SECTION: C6
EMISSION REDUCTION IN TSM & AEL BOILERS
01-14-002-60001
SHEET 1 OF 29
ELECTRICAL REQUIREMENTS
ELECTRICAL SYSTEM REQUIREMENTS FOR LIMESTONE HANDLING

SYSTEM
1.0 SCOPE OF WORK
1.1 The BIDDER scope shall include Design, Engineering, supply, packing,
forwarding, transportation, unloading at site, storage at site, erection, testing
and commissioning of the complete electrical system for the Limestone
handling system on EPC basis shall include the following but not limited to:
a. 6.6KV HT switchgear
b. 6.6KV/0.433KV Dry type transformers
c. 415V Limestone Handling PMCC and MCC.
d. Variable Voltage Variable Frequency (VVVF) Drives with suitable
bypass arrangement.
e. 6.6KV HT and LT Motors and actuators.
f. DC and UPS system
g. All HT & LT power and control cables.
h. Cable termination kit, joints, gland plates, glands, lugs, ties, etc.
i. Cable trays with all accessories, supports, support structures, etc. All
tray work from TG building upto and including Limestone Handling
area.
j. All Distribution boards, Control panels.
k. Local Starter cum control panels, Push button stations (LPBS) and
Junction boxes (JBs).
l. Indoor and Outdoor area Lighting system.
m. Above ground equipment earthing for all the equipments under the
scope of supply of the Bidder. Below ground earthing including earth
pits. Bidder shall also include interconnection of earthing system with
the Main plant's earth-mat minimum at two (2) separate points.
n. Lightning Protection system (as required).
o. DC and UPS system
p. Fire detection & Alarm system with interconnection with existing main
plant Fire alarm system.
q. Communication system
r. All the foundation accessories including base plates/channels,
foundation bolts, wall/column inserts/supports, anchor bolts, etc. as
may be required for all electrical equipments under the scope of
supply of Bidder.
s. All Power & welding receptacles.
t. All other equipments, accessories and services necessary for
successful operation of the project, whether specifically mentioned
herein or not, shall be under the scope of the Bidder.
u. All commissioning spares up to 72 hours of uninterrupted operation at
full load.
v. List of recommended spares for two (2) years trouble free operation
along with the unit rates.
w. All statutory clearances required from Electrical Inspectorate for
Bidder supplied system.
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01-14-002-60001
SHEET 2 OF 29
1.2 Terminal Point : Two numbers 6.6KV HT power supply feeders shall be
provided by Owner from the existing HT switchgear located at TG building for
Limestone Handling system area.
All further downstream power distribution for the Bidder's supplied equipment
shall be in the scope of the Bidder.
2.0 DESIGN CRITERIA AND EQUIPMENT SPECIFICATION
It shall be responsibility of the bidder to comply with the End user standard
and safety norms in addition to the requirements mentioned in
this specification.
2.1 HT Switchgear
2.1.1 The 6.6kV switchgear shall be rated for symmetrical fault current of 40kA for 1
second. The 11kV switchgear will comprise draw-out type Vacuum circuit
breakers housed in indoor, metal-enclosed cubicles. The switchgear will be of
two incomers and a bus-coupler with auto and manual changeover. The
switchgear shall have Aluminium bus bar and will be equipped with control,
protection, interlock and metering & communication features as required. All
relays would be Numerical type in compliance with IEC 61850 protocol. All
feeders shall be provided with multi-function meters, Ammeter with selector
switch.
2.1.2 All circuit breaker shall be of Motorized Vacuum Circuit Breaker with operating
duty of 0-0.3min-CO-3min-CO. The Circuit Breaker shall be fully draw out type
and it shall have test, service and isolated positions. At least 6NO+6NC spare
auxiliary contacts of circuit breaker and Master Trip Relay (86) shall be wired to
the terminal block for protection, interlocking, annunciation etc.
2.1.3 Each Circuit Breaker cubicle shall be provided with but not limited to the
following minimum standard accessories: (a) One two position “Local/Remote”
stay put type control selector switch (b) LED Indicating lamps – 5 min. (c)
electrical anti pumping relay (d) breaker operation counter (e) Mechanical
indication for spring charged/discharged status (f) Limit switches for test and
service position interlocking, (g) Required CTs/ PTs/ CBCTs (CBCT shall be
provided for all outgoing motor and transformer feeders for sensitive earth fault
protection) (h) Cubicle lamp, heater with thermostat and plug point (i) Suitable
labels/Name plates for feeders and cubicle mounted components (j)sufficient
terminal blocks (k) AC Supply On/Off switches with Short Circuit protection (l)
One double pole switch for DC control supply and spring charging (m) Aux
relay and contactors for multiplication (n) trip circuit supervision (o) DC supply
supervision (p) any other devices to meet the system.
2.1.4 All the doors, panels, removable covers shall be gasketed all around with
neoprene gaskets. All louvers shall have screens with filters. Each switchgear
shall be fitted with a label on front and rear of cubic.
2.1.5 Relay setting software for setting all the numerical relays, software for
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in a dedicated PC (Laptop) and provided along with the switchgear. All the
numerical relays shall be time synchronised with the GPS master clock. All
numerical relays shall be IEC61850 compliant. The minimum protections /
metering required for various typical feeders shall include, but not be limited to
the following
MV Switchgear Incomer:
a) IDMT over current (51)
b) IDMT earth fault protection (51N)
c) Under voltage protection (27)
d) Over voltage protection (59)
e) Local breaker Backup (50LBB)
f) Sync check (25)
HT Motor:
All HT motors shall be provided with numerical motor protection relays

covering thermal overload protection, overload alarm protection,
instantaneous over current protection, locked rotor protection, negative
sequence protection, bus under voltage, earth fault, etc.
Service Transformer:
a) IDMT Over current on HV side and LV side (51)
b) IDMT earth fault protection on HV side and LV side (51N)
c) Instantaneous over current protection on primary side (50)
d) Instantaneous earth fault current on delta side (50N)
e) Neutral earth protection (51N)
f) Local breaker Backup (50LBB)
Tie feeder and Bus coupler:

a) IDMT Over current (51)
b) IDMT earth fault protection (51N)
Bus PT:
a) Synchronizing check relay (25C)
b) Under Voltage relay & no voltage (27)
c) Over voltage relay (59)
2.1.6 The interface between the medium voltage switchgear and the station control
system shall be hardwired for control and trip/open feedback from the
DCS/PLC. Suitable interposing relay shall be provided based on DCS/PLC
voltage in the MV Switchgear. The MV switchgear protection trip shall be
hardwired to the breaker.
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2.1.7 Surge arrestors shall be provided for motor feeders and oil type transformer
feeders.
2.1.8 One (1) no. circuit earthing truck and One (1) no. bus bar earthing truck
suitable for voltage rating of the switchgear shall be provided.
2.1.9 At least 20% spare terminal shall be provided on each panel and these spare
terminals shall be uniformly distributed on all rows of terminal blocks
2.1.10 All MV panels shall be mounted on ISMC 100 channels embedded in concrete.
2.2 Service Transformer

2.2.1 The Service transformers shall be two winding, three Phase, 50Hz,
6600/433V, with off-circuit taps of + 5% to - 5% in steps of 2.5% and shall
Indoor Dry Type, with Dyn11 Vector group. Transformer LV side neutral shall
be earthed through knife switch arrangement as per end user standard.
2.2.2 Quantity and rating of Service Transformers shall be based on the loads to be
fed by the respective transformers and considering 100% redundancy, i.e.,
rated for 2 x 100% capacity. Uniformity shall be maintained in selection of
transformer rating so that spares can be reduced.
2.2.3 The sizing of the transformers shall be done, considering 10% margin on the
total load (1.1 of the total load) to be fed by the respective transformers,
rounded off to the nearest higher standard rating available. An appropriate
diversity factor with a minimum of 0.8 (or 0.9 as per the process) for
continuously running loads and 0.4 for intermittent loads like cranes, plug
points, sump pumps, elevators etc., shall be considered for load estimation.
The rating established shall also take into account the load variations that
may occur during the course of detail engineering.
2.2.4 The impedance of the Service transformers shall be chosen such that the
fault level does not exceed designed SC fault current at 415V switchgear and
voltage drop conditions mentioned above are met. In addition to this, MVA
rating & impedance of Service transformer shall be chosen such that the
largest 415V motor can be started under base load running condition maintain
voltage drop conditions.
2.2.5 The BIDDER shall submit transformer sizing and design calculations for
review. The Quantity and rating of service Transformers shall be subject to
OWNER’s approval.
2.3 415V LV Switchgear and Busduct
2.3.1 The LV Switchgear shall be provided with two incomers and one buscoupler
with suitable interlocks. MCC shall be completely fuse free. No fuses shall be
used anywhere in the installation.
2.3.2 The LV Switchgear will be of metal enclosed design with a symmetrical short
circuit rating of 50 kA for 1 sec. The 415V switchboard/PMCC/MCCs will be
compartmentalized and will be of single front execution. It shall be of fully
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including 630A and air circuit breakers will be used for rating 800A and
above.
2.3.3 All ACBs will be of electrically spring charged in addition to manual spring
charge facility and of manual draw out type. All ACB power feeders will be
provided with microprocessor based O/C, S/C & E/F protections. All MCCB
type power feeders will be provided with inbuilt O/C, S/C & E/F protections.
2.3.4 All LT motors shall be controlled by ACBs/MCCBs/MPCBs/motor protection

relays and contactors with all necessary protection.
2.3.5 Moulded case circuit breakers shall be used for motors rated less than
110kW. For motors rated 110kW and above will comprise circuit breakers.
2.3.6 All the equipment and associated accessories required for the PMCC/MCC,
cables from the switchgear to individual drives / feeders LT motors / actuators
& control cabinet shall be included in the bidder’s scope.
2.3.7 The enclosure for the LV switchgear shall be minimum IP52 and weather
proof.
2.3.8 Busbars shall be adequately supported on insulators. These insulators shall

withstand dynamic stresses due to short circuit currents.
2.3.9 MCCB terminals shall be shrouded.
2.3.10 Voltage transformers shall have continuous over voltage factor of 1.2 and
short time over voltage factor of 1.5 for 30 seconds.
2.3.11 The PMCC/MCC shall have one no. of module of each size and each type for
outgoing feeders only – motors & MCCB feeders.
2.3.12 All cable terminations shall be made with aluminium / tinned copper crimped
type lugs.
2.3.13 One LPB station shall be provided with each motor. Indicating lamps and
ammeters shall be provided on LPBS for motors rated 30kW and above.
2.3.14 In addition to above details Datasheet-A shall be referred for Low Voltage
PMCC/MCC details.
2.3.15 The PMCC shall be provided with 10% spare feeders with at least one of
each type and rating (per board). Additionally 10% spare cubicle shall also be
provided.
2.3.16 Necessary changeover arrangement shall be provided between the two

incomers to the PMCC.
2.3.17 Ammeter, Voltmeter and MW meter shall be provided for the incomers of
415V MCC.
2.3.18 20% spare terminal shall be provided in the terminal boxes.

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2.3.19 The BIDDER shall furnish the rating of all the power supplies.
2.3.20 All necessary protections as per end user standard shall be included.
Moreover, lockout relay and under-voltage relay with timer shall be separate
fast acting type. However, following minimum protections shall be provided as
detailed below.
INCOMER & BUSCOUPLER:

• IDMT over current protection (51).
• IDMT earth fault protection (51N)
• Trip Coil Supervision relay
• Relay shall be numerical type
LT MOTORS:
• Motor rated less than 15kW - Current display type EOCR.

• Motors rated 15kW to 30kW - 1 phase CT with ammeter +
current display type EOCR.
• Motors rated 30kW to 90 kW - 3 phase CT with ammeter
selector switch + ammeter + Current display type EOCR.
• Motors rated 90kW & above - Microprocessor based composite
motor protection relay.
2.3.21 All EOCR for motors rated 20kW and above will be provided with 4-20mA
analogue output for DCS/PLC connectivity.
2.3.22 Following details shall be furnished by the BIDDER during detailed

engineering for OWNER’s approval.
i. General arrangement, foundation / fixing layout
ii. One line diagram
iii. Schematic diagram, BOM, etc.
2.3.23 Aluminium, Non-phase segregated type bus duct is proposed for Connecting
Transformer to LV switchboard panel. Bus duct shall be suitable for 50kA for
1sec. Bus duct shall be sandwich type suitable for IP 55 for outdoor portion &
IP 52 for indoor portion. Outdoor portion of the Bus duct shall be provided
with canopy.
3.0 HT/LT POWER AND CONTROL CABLES
3.1 Power cables for 6.6KV system shall be of 6.6kV unearth grade, single / multi
core having stranded annealed copper / aluminium conductor, cross linked
polyethylene (XLPE) insulated, extruded black PVC inner sheathed,
galvanized steel flat armoured for three core or aluminium wire armoured for
single core and overall FRLS extruded black PVC sheathed cables
conforming to IS: 7098 part 2. These cables shall have phase identification
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3.2 All HT cable termination kit and jointing shall be heat shrinkable type.
3.3 Power cables of 1100V grade, stranded aluminium conductor, XLPE

insulated, inner sheath of extruded PVC compound type ST-2, galvanized
single steel wire or strip armoured for multi core or aluminium wire armoured
for single core and overall outer sheath of extruded FRLS PVC cables
conforming IS: 7098 part-1. Minimum conductor size for aluminium cables
shall be greater than 16 sq.mm.
3.4 The following abbreviations are used applicable to these cables
A: Aluminium conductor, stranded, grade H4, class 2 as per IS

8130
C: Copper conductor, stranded, class 2 as per IS 8130
W: Galvanised single steel wire
F: Galvanised single steel strip
AW/AS: Hard drawn aluminium single wire/strip
 Item required
X Item not required
3.5 The construction, performance and testing of the cable shall comply with IS
7098 -Part1 (cross linked polyethylene insulated PVC sheathed cables for
working voltages upto and including 1100 V).
3.6 For cable sizing, maximum allowable voltage drop during largest motor
starting is 15% with all other loads running as well as running 3% voltage drop
of the largest motor.
3.7 CONTROL CABLES
Control cables shall be 1100V grade annealed high conductivity stranded

copper conductor class 2 as per IS 8130, FRLS HRPVC compound type C
insulated, extruded PVC inner sheath, galvanized steel wire/strip armoured
and overall extruded FRLS PVC outer sheathed cables conforming to IS:
1554.
Cables for instrumentation applications shall be stranded high conductivity

annealed, tinned copper conductor, multi-core, extruded PVC compound type
C insulated flexible twisted pair/triplets, individually and overall shielded for
low level analog signals and overall shielded for digital signals, PVC inner
sheathed, GI wire /strips armoured and overall FRLS PVC compound type
ST2 sheathed cable.
In situations where accuracy of measurement or voltage drop in control circuit

warrants, higher cross sections as required shall be used. However all CT
cables shall be minimum size of 4 Sq. mm. copper cross-section.
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4.0 CABLING ACCESSORIES
4.1 All cable glands shall be of double compression brass/stainless steel type. All
lugs shall be of tinned copper type.
4.2 CABLE TERMINATIONS:
4.2.1 Cable termination lugs - Termination lugs shall be tinned copper brand for
copper conductors. All cable lugs and ferrules shall comply with IEC 61238
and/or relevant IS.
4.2.2 LV cable joints and terminations - Joints in underground cables, and
terminations, shall be made by means of approved epoxy-resin pressure type
jointing. Joints must be made by competent cable jointers and entirely in
accordance with the manufacturer’s instructions using only the materials
stipulated in such instructions. Each end of the cables to be jointed must have
a minimum of 1000mm of slack disposed in a loop without stress. Backfilling
under joints must be firmly tamped to prevent any subsequent settling.
5.0 CABLE CARRIER SYSTEM
Cable carrier system for laying of all power & control cables supplied by the
Bidder is in Bidder’s scope. Also supply and installation of cable carrier
system for cables from JBs/MBs/ABs to respective field equipment/drives is in
Bidder’s scope.
5.1 CABLE TRAYS:

5.1.1 Cable trays of ladder and perforated types and associated accessories such
as cable tray covers, coupler plates, tees, elbow etc. will be made up of
Galvanise Steel. Cable trays will be supplied in standard length of 2500 mm
and clear inside width of trays will be as follows:
a. Perforated type trays : 150, 300, 450 and 600 mm
b. Ladder type trays : 150, 300, 450, 600 and 750 mm
5.1.2 Fire proof Sealing of Cable penetration:
Cables/ cable tray openings in walls and floors or through pipe sleeves from
one area to another or one elevation to another will be sealed by a fire-proof
sealing compound.
5.1.3 MODE OF LAYING:
a. Cables from MCCs, control panels will be routed on prefabricated

ladder type galvanised steel cable trays supported on site fabricated
tray supports inside TG building. The cable routing from TG building to
the Boiler area shall be finalized during detail engineering. Cables can
run either in trenches, duct banks or overhead cable racks. Separate
cable trays will be used for 6600V, 415 V power, control and
instrumentation cables. DC cables shall be fire survival cables.
b. Cover for top cable tray will be provided where the cable routing is
outdoor and above the ground level.
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c. The cables will be laid in prefabricated galvanised steel, ladder /

perforated type cable trays, suitably supported by painted steel cable
tray supports. Power cables will be laid in ladder type trays. Control
cables will be laid in perforated trays. Separate cable trays will be
used for 415V power cables and control cables. Horizontal cable trays
will be supported at a gap of 1500 mm and vertical trays at every
1000mm from slabs/walls as found suitable. Vertical trays and all
outdoor cable trays will be provided with removable covers. Power and
control cables of various class of supply will be laid in separate trays
with minimum distance of 300 mm between the trays.
d. Any buried cable crossing a road will be laid in a Hume pipes at

minimum depth of 1000 mm.
e. Space factor/fill factor of 40% shall be considered for carrying cables

inside the conduits.
f. The Fire proof sealing system will be adopted for cables or cable trays
penetrating through wall and floor openings, or cables passing through
embedded conduits / pipes / pipe-sleeves. This constitutes a ‘fire stop
/ seal’, which is meant to prevent spreading of fire between areas
separated by fire-resistant barriers. The fire-break shall be provided by
applying a suitable fire-resistant coating on cables and cable trays for
the required length, with or without a fire resistant panel, at the point of
the fire break. Fire breaks in vertical trays & horizontal trays shall be
provided at intervals of 5 m & 15 m respectively.
g. The insulation and sheath materials shall be resistant to oil, acid and
alkali and shall be tough enough to withstand mechanical stresses
during handling.
h. Multi-core control cables shall have 20% spare core, minimum one
spare. Separate cables for each type of following services / functions
as applicable shall be used for each feeder. Same multi-core cable
using different services shall not be acceptable.
i. The material and design concepts shall incorporate a high degree of

operating compatibility between the cable and joints. The protective
outer covering (jacket) used on the joints/terminations shall have the
same qualities as that of the cable outer sheath in terms of
ambient/operating temperature withstand capability and resistance to
hazardous environments and corrosive elements. No joints shall be
allowed unless the cable drawn length is exceeded. For each joints,
BIDDER to take approval from owner.
j. Cable tray system should be designed in such a way that 20% space
remains empty post commissioning.
6.0 VARIABLE FREQUENCY DRIVES
6.1 The design, material, construction, manufacture, inspection, testing and

performance of AC Drives shall comply with all currently applicable latest
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standards (IEC 61800-2,3, IEEE-519 etc.), regulations and safety codes in the
locality where the equipment will be installed. Nothing in this specification
shall be construed to relieve the Bidder of this responsibility.
6.2 IGBT based VVVF drives shall be provided. Drives shall have an operating
voltage of 415V for motors rated upto 200kW and 690V for motors rated
above 200kW upto 1000kW. Selection of number of pulses shall be done by
the bidder based on the application.
6.3 The unit shall be pulse width modulation (PWM) type with either open loop
frequency control to keep the ratio of voltage and frequency (v/f) constant
throughout speed range to maintain constant motor torque or vector control
for closed loop speed control with or without pulse encoder feedback where
high speed accuracies and good dynamic performance of the motor desired.
6.4 The unit shall comprise incoming load-break isolator, line semiconductor
fuses, moulded case circuit breaker (MCCB)/circuit breaker (ACB), main
contactor if required, reactor, three phase rectifier as the line converter and
three phase inverter as load converter interconnected through DC link reactor
and capacitor unit. Input side line reactors shall be provided as per drive
manufacturer's recommendation. Drives up to 15 kW should be provided with
both input and output line reactors. Output chokes shall be provided as per
manufacturers recommendation where the cable length between drive and
the motor exceeds 150 mtr. to protect the motor insulation from drive faults.
6.5 The PWM inverter shall have fully digital microprocessor based regulation and
control system with suitable interfaces for communication with plant DCS. The
microprocessor based control shall carry out all the functions required from
the unit including triggering, protections, self diagnostics and operator
interface. Display of faults, alarms as well as diagnostic messages will be
available in plain text on the operator panel mounted in the drive cubicle. All
metering feature viz voltage, current, frequency for incoming and outgoing
side shall be included in the panel.
6.6 Drive panels for motors should have motor winding PTC thermistor
monitoring device. For PT-100 detectors, the converter cubicle shall be
equipped with electronic equipment for signal handling and tripping.
6.7 Suitable by-pass arrangement of VVVF Drive shall also be considered with all
protection and metering requirements.
6.8 AC Drives should be considered with built in DC choke for longer life of DC
link capacitors, minimize voltage drop at motor terminal & harmonic reduction
at the drive input.
6.9 Shielded power & control cables from drives to motor terminals shall be
provided by the Bidder until and unless special cables are recommended by
the drive manufacturer. Also, drive manufacturer shall indicate the maximum
distance limitations from drives to motors to avoid output choke.
6.10 Duty of AC drives (heavy duty or light duty) shall be provided based on
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6.11 Hardware & software tools of drive window for drive parameterization &
programming shall be provided.
6.12 Drives shall be selected based on rating & application of motors, duty class,
current, torque values, GD² value, speed range etc and ambient temp
derating factor & altitude derating factor. Speed range of the VVVF drive shall
be selected as per requirement of driven equipment application.
6.13 The inverter system suitable for three phase output shall consist of the
following subsystems:
i. The basic inverter circuit consisting of the switching device IGBT

connected so as to supply three phase power.
ii. The logic network to enable rapid transition of the main inverter
switching devices from on-state to off-state.
iii. Suitable feedback system to allow balance of reactive power flow
during load power factor fluctuation as well as regeneration.
iv. The filter system of the inverter output to suppress harmonics at the
output of the inverter to less than 5% of the fundamental amplitude for
voltage THD. However, individual frequency voltage distortion shall
not exceed 3% as per latest version of IEEE standard - 519.
v. The ripple control system to limit current ripple to 4% at the input
terminals of the inverter caused by distorted current output.
6.14 Power semiconductors of reputed make either in stud mounting form or

disc/flat pack type can be offered based on the duty to meet the technical and
functional requirements.
6.15 Unless otherwise stated, the inverter shall be capable of being temporarily
overloaded to 150% of its full load ampere capacity for sixty (60) seconds
beyond which a current limit action shall be initiated and an alarm contact
initiated for annunciation. Additional output filters as required shall be
provided based on cable distance between drive panels to motor terminal.
6.16 Short time voltage dips upto 80% of nominal (e.g. in case of large motor start-
up connected to same bus) shall not cause the control system to stop
functioning and shall not trip the drive system.
6.17 The drive motor shall be speed regulated corresponding to 4-20mA or 0-10V
reference input signal. Upon complete loss of users speed reference signal,
the drive shall automatically run at constant speed as determined by the last
speed reference available prior to loss of the signal.
6.18 The required provision for interfacing with DCS, including details of
communication module and data transfer facility, I/O details shall be furnished
by the Bidder.
6.19 The required provision of RTD inputs for motor winding and bearing
temperature shall be furnished by Bidder.The required provision of interface
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6.20 Local/Remote selection provision should be available in offered drive panel.
6.21 Each power semiconductor shall be protected against short circuit. All fuses
shall have a trip indicator to operate a suitable microswitch with at least 1 NO
+ 1 NC potential free contacts for annunciation and/or tripping.
6.22 PROTECTION FOR AC DRIVES
i. Fuses for all power semiconductors and/or other devices like

commutation chokes, capacitors etc. which are not adequately
protected against flow of abnormal currents.
ii. Under voltage and over voltage protection on the input side. Loss of
input voltage to inverter shall entail tripping of the inverter.
iii. Protection for all control cards, power supply stabilizers, filter circuits
etc. Protection shall be provided such that failure of a part does not
cause damage elsewhere in the system.
iv. Polarising relay to prevent reversal of polarity on the input side of the
inverter.
v. Protection of inverter IGBTs, commutating circuits and other inverter
elements during regenerative operation of the inverter and also during
sudden load throw-off.
vi. Besides the above, the following protective systems shall be supplied:
a) Current limit fuses at the output of the inverter.
b) Commutation circuit under voltage
c) Inverter over frequency
d) Programmable overcurrent
e) Phase sequence/loss of phase protection
f) Earth fault protection
g) DC link overvoltage protection
h) Specific motor protection
i) Incoming line surge protection
j) Ventilation Loss
k) Over temperature
l) Phase loss protection
6.23 Switching devices as circuit breakers, isolators, contactors; MCCB etc. shall
be considered in the scope of supply of the Bidder.
6.24 Power semiconductors shall be mounted on heat-sink which can be individual

or common to a number of devices. Cooling of power semiconductors shall be
natural air cooled. The power semiconductors shall preferably be double side
cooled.
6.25 Cubicles housing the power semiconductors and drive level control system
shall conform to IP 42 degree of protection to enclosures. The controller
should have modular construction to facilitate maintenance. All cubicles shall
have copper earth buses of adequate size running the entire cubicle height
along the sides.
6.26 All bus bars shall be adequately insulated for full circuit voltage by insulating
tapes and similar insulating material. In case aluminium bus bars are
specified, care shall be taken to ensure that bimetallic connections are
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6.27 Each annunciator window shall have two lamps connected in parallel which
operate at not more than 75% of their rated voltage.
6.28 There shall be a three tier system of protection and annunciation:
(a) Alarm both audible and visual.
(b) Warning with delayed shut down –time delay through a timer of range 0-
60 sec.
(c) Disturbance associated with failures of systems elsewhere.
6.29 Individual meters shall be provided for speed reference, speed feed back,
current reference, current feedback, pulse output, and regulated power supply
voltages. All meters shall conform to at least accuracy class 1.0.
6.30 Stranded, flexible copper cable of 2.5 sq.mm shall be used for C.T. circuits
and 1.5 sq.mm for other control circuits. However for PCB terminals 0.75
sq.mm may be accepted.
6.31 TESTS
Acceptance tests shall be conducted at the works of the Bidder‟s and/or his
sub-vendor to ascertain that performance stipulated in this specification has
been honoured (e.g. overcurrent capability, measurement of ripple voltage &
current, P.F. measurement, Audible noise, etc). Dummy loads as required for
the purpose of simulating the operation conditions at the VENDOR‟s works
shall be considered in scope of this specification. However, should this not be
possible, testing at site with the actual load shall be conducted to prove the
performance of the power converters.
TESTS ON POWER SEMICONDUCTORS

a) Off state voltage and reverse voltage
b) Critical rate of rise of off state voltage
c) On state voltage
d) Thermal resistance
e) Surge on-state current
f) Triggering data
g) Recovery charge and recovery time
h) Critical rate of rise of on-state current
i) Switching losses
j) Environmental Tests
TESTS ON CONVERTERS
a) Checking of the setting of the protection devices and their functioning.
b) Checking of the auxiliary devices and their functioning.
c) Speed regulation of the drive shall be observed at different output
voltage and frequency settings (for AC drives).
d) Determination of the power losses at specified loads (By Calculation).
(Type Test)
e) Insulation test
f) Temperature rise (Type Test).
g) Light load & Functional Test.
h) Observation of various wave forms i.e. current and voltage.
7.0 LIGHTING SYSTEM

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It shall be responsibility of the bidder to provide adequate illumination in the

area/rooms where their supplied equipment are installed. All luminaries shall
be LED type complete with all accessories. Outdoor type fixtures shall be
provided with outdoor type weather-proof box with IP 65. For outdoor yard
areas lighting cum lightning mast of suitable height shall be used. Lighting
system shall be fed from 1 Phase, 240V Lighting Distribution board through
adequately rated 2 x 100% capacity 415V/240V lighting transformers. Type of
fixtures for different areas with designed average lux levels are indicated in
table below:
Sl. Area/Structure Average Lux Type of Fixture to be

No. level used
(Designed)
1 General (auxiliary 200 Integral well-glass LED

equipment areas) Luminaire with 40 W LED
lamp
2 Cable vault 150 Integral well-glass LED

Luminaire with 40W LED
lamp
3 All switchgear room 200 Recess Mounted LED

area (including off-site Luminaire with LED lamp
building control room)
4 Control room / 300 Recess Mounted LED

Electronic equipment Luminaire with LED lamp
room/ Office areas
5 Roads 20 LED Road Lighting

Luminaire with integral
mounted driver with 120W
LED lamp
6 Corridors, walk-ways, 150 Surface / Suspended

staircase, etc. mounted luminaire with
LED lamp
7 Building periphery 50 Integral well-glass LED

lighting Luminaire with160W LED
lamp
8.0 EARTHING SYSTEM
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Above ground equipment earthing for all the equipments under the scope of
supply of the Bidder shall be done by the bidder. Below ground earth mat with
earthing pits shall also be scope of bidder. Bidder shall also include
interconnection of his earthing system with the plant's earth-mat minimum at
two (2) separate points. Bidder shall submit the earthing calculation based on
IEEE-80 for purchaser’s approval.
8.1 SPECIFIC REQUIREMENTS
8.1.1 The earthing system installation shall comply with IS-3043 and IE Rules.
8.1.2 The earthing system shall be so designed that the overall earthing grid
resistance is below 1 ohm.
8.1.3 All electrical equipment operating above 250V shall have two separate and
distinct earth connections.
8.1.4 All cable trays shall be connected to earth grid at minimum two (2) places, for
cable trays of longer lengths shall be connected to earth grid at an interval of
about 10m.
8.1.5 Metallic conduits and pipes shall not used as earth continuity conductors.
8.1.6 Earthing conductor running exposed on columns, walls, etc. shall be supported
by suitable cleating at intervals of 750 mm.
8.1.7 Equipment bolted connection after being checked and tested shall be painted
with anti corrosive paint compound.
8.1.8 All bimetallic connections shall be treated with suitable compound to prevent
moisture ingression.
8.2 MINIMUM CONDUCTOR SIZES FOR GROUND CONNECTIONS
BIDDER to carry out complete grounding system study considering maximum

fault current and select ground conductor sizes. However, the minimum
conductor sizes used should not be less than the values as follows:-
CONDUCTOR
SL. NO. EQUIPMENT
SIZE
1.0 6 Sq. mm stranded a) Motors and starters upto and including

GI wire 2.2kW
b) Light fitting, JBs etc.
c) Instruments and miscellaneous small

items protected by fuses of rating not
exceeding 15A.
2.0 16 Sq. mm a) Motors and starters above 3.7kW and

stranded GI wire upto and including 15kW
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3.0 25 X 3 mm GI flat a) Motors and starters above 15kW, and

upto and including 45kW
4.0 50 X 10 mm GI flat a) Motors and starters over 45kW.
b) MCC, VVVF Drive, DB
c) Cable trays all around
5.0 6.6 kV switchgear/ a) 50X6MM GS flat

415V switchgear/
Transformers
6.0 Below ground 32mm dia MS rod

conductor
8.3 SIZE OF CONDUCTORS

a) Main Earthing Conductors
The earthing conductor sizes shall be calculated based on IS 3043/
IEEE80 and the earthing system shall comply with Indian Electricity
Rules.
b) Rod Electrodes
Galvanised steel rod /pipe electrodes of suitable diameter and length
shall be used as per the recommendation of standards. For test pits,
electrode installed in the test pit shall have disconnecting facilities.
For treated earth pits, electrode shall be provided as per IS 3043.
Bidder has to provide chemical type earth pit. Necessary number
(minimum two no.) of treated earth pits shall be provided for LAs, and
neutral earthing of Power transformer and LV Service transformer.
c) Equipment Earthing Leads
The size of the earthing leads shall be decided based on the type of
equipment and structure to be earthed and shall be provided
generally as per IS-3043. Number of sizes shall be standardised to
simplify procurement.
d) Conductors for lightning protection system
The size of conductors for lightning protection system shall be
decided based on mechanical strength.
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9.0 LIGHTNING PROTECTION SYSTEM:
Lightning protection (if required) shall be designed as per IS/IEC 62305.

Lightning protection system shall comprise vertical air terminations, horizontal
air terminations, down conductors, test links and earth electrodes. Dedicated
earth electrodes shall be provided for the lightning protection system. Air
terminations, down conductors and test links shall be of galvanized steel
conductors and earth connection below ground level shall be of mild steel rod.
10.0 POWER & WELDING RECEPTACLES

10.1 Industrial Receptacles
The industrial receptacles shall be heavy-duty type rated for 20A, 240V,
1phase, 50 Hz supply, complete with plug and switch housed in galvanised
sheet steel enclosure having degree of protection of IP 55 for indoor use and
IP55W for outdoor use. These shall be of three-pin type with the third terminal
connected to earth. Receptacles shall be provided in all the indoor / outdoor
areas such that the any working point is accessible within 25 M of cabling
distance from the receptacle. The receptacles shall have safety shutters and
other safety interlocks for safe operation.
10.2 Welding Receptacles
The welding receptacles shall be industrial heavy-duty type with 5 pin (with
earth connection) rated for of 63 A, 415V, 3 phase, 3 wire, 50 Hz supply. For
outdoor area, necessary receptacles shall be provided as per requirement
with a minimum of one (1) number in each working area. The receptacle and
switch shall be housed in a sheet steel enclosure complete with gasket, cable
glands etc. All receptacle enclosures shall have 2 Nos. earthing terminals.
The enclosure shall be min. 2 mm. thick galvanised sheet steel and shall
conform to the degree of protection IP-55 for indoor use and IP55W for
outdoor use. All receptacles shall be provided with matching plug tops. The
receptacle and switch shall be interlocked with the plug such that it shall not
be possible to remove the plug with the switch in 'ON' position. The exact
number and disposition of all above receptacles shall be decided during detail
engineering and shall be indicated in approved layout drawings by Bidder.
10.3 SAFETY FEATURES
10.3.1 All design & sizing will be as per end user safety norms i.e. TPM standard,
Positive Isolation and PSRM (Process Safety & Risk Management).
10.3.2 Following features will be provided for meeting TATA STEEL’s requirement
for positive isolation :
a. On-Off switch /operating handle of the breakers will have pad-locking

facility at OFF position.
b. Pad locking facility at “Breaker Isolated” position.
c. Door interlock will be provided for breaker doors which will allow
opening of the door only in “Breaker Isolated” position.
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d. Metallic barrier will be provided between control transformer and bus

bar chambers.
e. Wire mesh will be provided for ventilation louvers of panels.
10.3.3 Danger boards will be provided on front/back of the panels.
11.0 HT Motors
11.1 Motors shall be capable of starting and accelerating the load with the
applicable method of starting, without exceeding acceptable winding
temperatures, when the supply voltage is 80% of the rated voltage. For mill
motors, starting and accelerating at supply voltage of 85% of the rated voltage
is acceptable if it is not possible to achieve starting at 80% of the rated voltage.
11.2 The locked rotor current / starting current of the motors shall not exceed the
following values which are inclusive of 20% tolerance.
i. 600% of full load current for motors upto and including 1500 kW,
except for mill motors
ii. 450% of full load current for motors above 1500 kW
iii. For mill motors, 600% of full load current exclusive 20% IS tolerance
is acceptable if it warrants.
11.3 All Motors shall have class F insulation but, limited to class B temperature
rise.
11.4 All insulated windings shall be of Copper. The winding insulation shall be
Non-hygroscopic, oil resistant and, flame resistant
11.5 All Motors shall be provided with eyebolts, lugs or other means to facilitate
safe lifting.
11.6 Motors shall be provided with drain plugs, so located to drain water, resulting
from condensation or due to other causes, from all pockets in the motor casing.
11.7 Noise level and vibration limit should not exceed as specified in relevant IS /
IEC.
11.8 Vibration pads shall be provided for all MV motors for mounting vibration
detectors.
11.9 At least six numbers duplex resistance type temperature detectors for the
stator winding each having D.C. resistance of 100 ohms at 0 degC, embedded
in the stator winding at locations where highest temperatures may be expected,
shall be provided. The material of the ETD's shall be platinum. One number
duplex RTD shall be provided for each DE and NDE of the motor bearing &
shall be wired upto the terminal box. The temperature detectors shall be of 3
wire, duplex type. RTD for heat exchanger shall be provided if required. All
RTDs shall be available for remote monitoring.
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11.10 Unless otherwise specified, motor bearings shall have an estimated life of
atleast 40,000 hrs.
11.11 For Motor above 1000 KW, separate neutral terminal box shall be provided to
mount three differential current transformers (CT of PS class). The neutral box
arrangement shall be such as to permit easy access for C.T. testing and
replacement.
11.12 The cable box design shall be suitable for any type of cable termination kits
available. Cable glands shall be double compression brass type.
11.13 Terminal boxes shall have a degree of protection of atleast IP 55 for out door
application.
11.14 Terminals shall be of push fit type & the terminal box shall be complete with
necessary lugs, nuts, washers.
11.15 When single core cables are to be used the gland plates shall be of non-
magnetic material.
11.16 The terminal box shall be capable of withstanding maximum system fault
current for duration of 0.25 sec.
11.17 For motors rated 3.3 kV and above, the induced shaft voltage shall be
measured at the manufacturer's works during shop testing. The maximum
value of induced voltage in the motor shaft shall not exceed 250mV.
TESTS ON MOTOR
11.18 Motor shall be subjected to all the routine tests as per applicable standard in
the presence of the OWNER'S representative. Copies of test certificates of type
and routine tests shall be furnished as specified in the distribution schedule, for
the OWNER'S approval. The BIDDER shall ensure to use calibrated test
equipment/instruments having valid calibration test certificates from standard
laboratories traceable to national/international standards.
11.19 Type test certificates for similar motors shall be furnished with the Bid. If type
tests have not been carried out on similar Motors, or if the type test reports
submitted are not found in order, then BIDDER shall carry out these tests
without any extra cost to the Owner.
11.20 The polarisation index test shall be carried out on all motors rated at 3.3 kV
and above. The minimum value of the polarisation index shall be 2 when
determined as per IS-7816.
11.21 Coils of MV motors shall be tested as per IEC-34-15. Dielectric tests to

establish the insulation withstand level of Motors as indicated in clause 5.2
above shall be performed on a sample coil (identical to that to be used in the
motor quoted for) for each type of MV Motor.
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11.22 Loss tangent measurement of coils for motors rated 6.6 kV & above shall be
done as per IS-13508.
11.23 All other routine tests shall be carried out as per applicable standards.
12.0
415V LV MOTORS
12.1 Continuous duty LT motors upto 200 KW Output rating (at 50 deg.C ambient
temperature), shall be Premium Efficiency class-IE3, conforming to IS
12615, or IEC:60034-30. However, tolerance on this efficiency value shall be
applicable as per IEC 60034.
12.2 The motors for VVVF application shall have performance characteristics
matched with the driven equipment and variable speed requirement. These
should be designed according to IEC 60034-Part 25 or NEMA MG-1 part
30&31. Variable speed motors shall be derated as per NEMA/IEC standard
due to the reduction in cooling resulting from any reduction in operating
speed and the effect of additional losses introduced by harmonics generated
by the drive. VPI or improved insulation shall be provided which do not
degrade due to transient voltage spikes and have an adequate thermal
margin. Motor bearings shall be insulated as required to prevent shaft
current and resultant bearing damage.
12.3 The motor rating shall be arrived at considering 15% margin over the duty
point input or 10% over the maximum demand of the driven equipment,
whichever is higher. Motors shall be capable of starting and accelerating the
load with the applicable method of starting without exceeding acceptable
winding temperatures when supply voltage 85% for LV motors.
12.4 All Motors shall be capable of developing the rated full load torque even if
the supply voltage drops to 70% of the rated voltage. If such operation is
envisaged for a period of one second, the pull out torque of the motor shall
be atleast 205% of full load torque and It shall be 275% for crane duty
motors.
Motors shall withstand for 1 second the voltage and torque stresses
developed due to the vector difference between the motor residual voltage
and the incoming supply voltage equal to 150% of the rated voltage during
fast change over of buses. Locked rotor current of the LV motor shall not
exceed 600% of full load current inclusive of 20% tolerance.
12.5 Rating of all drive motors of conveyors shall not be less than 120% of the
power required at drive motor output shaft at specified design capacity. The
motor rating shall be at 50 deg Cent. Ambient. Single LT drive motors shall
be used for conveyor drive ratings up to 160 KW.
12.6 The locked rotor withstand time under hot condition at 110% rated voltage
shall be more than the starting time at minimum permissible voltage
specified above by atleast three seconds or 15% of the accelerating time
whichever is greater.
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12.7 Provision of speed switch shall be avoided to the extent possible.
12.8 The degree of protection for the motor enclosure shall be IP-55 and IP-54 for
outdoor & indoor respectively and terminal boxes shall be provided with
atleast IP-55. For single core cable termination, gland plates shall be of non-
magnetic material. All motors located in hazardous area shall have
flameproof design.
12.9 Continuously rated (S1). However, crane motors shall be rated for S4 duty,
40% cyclic duration factor. For 415 V motors, maximum double amplitude
vibrations upto 1500 rpm shall be 40 microns and 15 microns upto 3000 rpm.
12.10 All motors shall be either totally enclosed fan cooled (TEFC) or totally
enclosed tube ventilated (TETV) or closed air circuit air cooled (CACA) type.
12.11 The noise (sound) power level emitted from the outer surface of the Motor
shall meet the requirement of Ministry of Environment and Forest (MOEF),
Government of India.
12.12 Space heaters shall be provided for all LT motors of rating above 30 kW.
Heaters to be automatically ‘OFF’ when the motor is switched ‘ON’
12.13 All motors for outdoor duty shall have detachable metal canopy.
12.14 Each motor shall have two earthing terminals.
12.15 All motors above 37 kW shall have minimum 92% efficiency at full load
conditions.
12.16 Separate terminal boxes to be provided for space heater, RTDs for
windings/bearings, vibration monitors etc. All terminal boxes shall be
provided with two earthing studs for termination of protective earth
conductor. Double compression type brass cable glands and crimping type
copper lugs shall be provided for termination.
12.17 All LT motors terminal box shall be suitable for Aluminium cable connection.
12.18 Unless otherwise specified, motor bearings shall have an estimated life of
atleast 40,000 hrs.
12.19 The ratio of locked rotor KVA at rated voltage to rated KW shall not exceed
the following (without any further tolerance)
a. From 50KW & up to 110KW : 11.0
b. From 110 KW & up to 200 KW : 9.0
c. Above 200 KW & up to 1000KW : 10.0
12.20 LT Motors supplied shall be of type tested design. During detailed

engineering, the Contactor shall submit for Employer's approval the reports
of all the type tests as listed in this specification and carried out within last
ten years from the date of bid opening. These reports should be for the test
conducted on the equipment similar to those proposed to be supplied under
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independent laboratory or should have been witnessed by a client.
All routine tests shall be performed as per latest amendments of IS / IEC
12.21 RTD based temperature measurements with alarm contacts shall be

provided for the VVVF motors. 3 nos. 3-wire RTDs shall be provided in stator
winding of variable speed motors 55kW & above.
12.22 Voltage and Frequency variations: All motors shall be suitable for following
variations
Frequency variation (+) 3% and (-)5%
Voltage variation a. (±) 6% for 6.6kV
b. (±) 10% for 415 V
Combined variation of voltage 10% (absolute sum)
and frequency.
12.23 Paint shade shall be Shade 631 of IS:5 / RAL 7032
13.0 ACTUATOR MOTORS
13.1 The actuator motors shall be designed for short time duty (S2) in accordance
with IEC 60034-1.
13.2 Each actuator should have a hand wheel for emergency manual operation in
addition to motor drive. Clockwise operation of hand wheel shall cause
clockwise movement of the output drive. The hand wheel shall be clearly
marked with an arrow and the word CLOSE. The hand wheel shall
automatically disengage when the power to the motor is restored i.e., power
drive shall have a preference over manual drive.
13.3 The DC and AC actuator shall be provided with accessories viz., Torque limit
switch, end of travel switch, adjustable limit switch, hand wheel motor,
thermostat, integral starter, etc. Complete actuator shall be tested at factory
as per IS 9334.
13.4 Two normally open and two normally closed or two changeover potential free
contacts corresponding to open and close positions of the valve shall be
provided.
13.5 Actuator shall be weatherproof type with enclosure conforming to IP-67

degree of protection. It should be suitable for out-door use without the need
for canopy. If the IP-68 degree of protection is required due to occasional
submergence, the Owner / Project Manager will specify the depth and
duration of such submergence.
13.6 The actuator shall be suitable for installation in any position without
lubrication leakage or other operational difficulty.
13.7 The main gearbox of the actuator shall be special grease filled.
13.8 Each actuator shall have a local mechanical position indicator. It should be
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suitable to indicate 0 - 100% position of the valve (continuous type).
13.9 In order to minimise the amount of spare parts required, parts and sub-
assemblies limit / torque switches, limit switch counter gear assembly, torque
switch drive assembly, mechanical position indicator assembly etc.
individually interchangeable / replaceable throughout the models selected.
13.10 The actuator shall be painted with corrosion resistant epoxy resin paint.
Paint shade shall be RAL 7032.
13.11 In order to prevent condensation, a space heater shall be provided in the

switch compartment, suitable for continuous operation.
13.12 Actuator mounting dimensions shall be according to ISO-5210. For rising

stem applications, the design must allow the removal of actuator from the
output drive without disturbing the function of valve.
14.0 LIMIT AND TORQUE SWITCHES
14.1 Independent torque and limit switches shall be provided in the actuator. A
minimum of two position limit switches and two torque switches, one each for
each direction of travel, having 2 NO + 2 NC potential free contacts, shall be
supplied. If called for in the data sheet, two additional limit switches shall be
provided for intermediate positions.
14.2 Torque switch dial shall be graduated directly in “kg-m” for easy setting to
desired value within the range specified. Separate dials shall be provided for
CLOSE and OPEN torque switches.
14.3 The switches shall individually be enclosed to a minimum of IP-66 protection

class.
14.4 Torque and limit switches shall have only stainless-steel flaps for better
protection against environmental condition.
14.5 Limit switches shall be operated by gear driven cams, which are
mechanically linked to the driving devices. The counter gear used for
counting and tripping the limit switches shall be of metallic construction like
brass etc. No plastic gearing shall be allowed.
15.0 TECHNICAL SPECIFICATION FOR LOCAL STARTER CUM CONTROL

PANELS
15.1 The Local Starter Cum Control Panel (LSCP) is required to run, control &
interlock requirements of electrical equipment.
15.2 There shall be motor stating modules for each motor feeder compromising of
MCCB/MPCB, Contactor, Thermal Overload relay, start/stop push buttons as
required.
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components shall be 50 deg. C. The temperature rise of complete LT panel

shall be limited to 90 deg. C i.e., 40 deg. C above ambient temperature of 50
deg. C.
15.4 The system fault level shall be 50kA and all panel components shall be
selected to cater this fault level.
15.5 The LSCP shall be fixed type with compartmentalized execution. One (1) no.
415 V ± 10% 3 phase 4 wire 50 Hz ± 5% power supply feeder shall be
provided for each panel. Power shall be received through an incoming
MCCB having R/Y/B indication lamps, voltmeter with selector switch,
ammeter with selector switch.
15.6 LSCP shall be floor/wall/structure mounted (to suit site condition), fixed type
enclosure with a hinged front access door.
15.7 Degree of protection of enclosure shall be IP-55 and with canopy for outdoor
unit.
15.8 Individual motor feeder shall have their MCCB/MPCB, power contactor,
overload relay-cum-single phasing preventor (hand reset type), stop/ start
push button, auto/manual selector switch, Red/Green/Trip indication lamp,
auxiliary relays, timers, etc. as applicable.
15.9 Local starter cum control panel shall be fabricated of not less than 14 SWG
sheet steel free from all surface defects. Local control panel shall have
sufficient structural reinforcement to ensure a plain surface, limit vibration
and provide rigidity during dispatch and installation.
15.10 All doors, covers etc. shall be properly gasketed to make the panel
effectively vermin and dust proof. Door hinges shall be concealed type.
Special dust protection measures shall be taken for panels located in dusty
area.
15.11 All hardware for the complete installation of the equipment including
foundation and fixing bolts, nuts, washers etc. shall be supplied to suit the
requirement. All bolts, nuts etc. exposed to external atmosphere shall be
cadmium plated or zinc passivated.
15.12 All instruments, switches etc. mounted on the front face of the local control
panels shall be of flush or semi-flush type.
15.13 Panel shall be fully wired at the factory to ensure proper functioning of
control, protection, transfer and interlocking schemes.
15.14 Wiring shall be done with flexible, 1100V grade, PVC insulated switchboard
wires with stranded copper conductors of 2.5 mm2 for control & current
circuits and 1.5 mm2 for voltage circuits.
15.15 Terminal blocks shall be 660V grade box-clamp type with marking strips,
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15.16 Not more than two wires shall be connected to any terminal. Spare terminals
equal in number to 20% active terminals shall be furnished.
15.17 A ground bus, rated to carry maximum fault current, shall be extend full
length of the panel. The ground bus shall be provided with two-bolt drilling
with Cadmium coated bolts and nuts at each end to receive 50 x 6 mm GS
flat.
15.18 Each stationary unit shall be connected directly to the ground bus. The frame
of each circuit breaker and draw out modules shall be grounded through
heavy multiple contacts at all times except when the primary disconnecting
devices are separated by a safe distance.
15.19 For LSCPs, the partition between the feeder compartment and cable alley
made of FRP sheet may also be offered. It shall be of such construction as
to allow cable cores with lugs to be easily inserted in the feeder
compartment for termination.
15.20 The panel shall be finished in Siemens gray (RAL 7032) with two coats of
Epoxy Paint.
15.21 Nameplates for all circuit symbols, Local Control Panel instruments and
devices shall be furnished on the local control panel.
15.22 Engraving shall be made on sheets (20 x 75 mm) of anodised aluminium

material, with white letters in black background. The material of nameplate
shall be at least 3 mm thick and the nameplate shall be held by self tapping
screws.
15.23 Push button shall be heavy duty, push to actuate type with integral
escutcheon plate marked with its function.
15.24 Each push button shall have two (2) normally open and two (2) normally
closed contacts rated 5A at 240V A.C.
15.25 One (1) no. stop (Stay Put) push button and one (1) no. test button shall be
provided for each motor feeder.
15.26 Lamps shall be LED type with coloured lens. Lens and lamps shall be
replaceable from the front.
15.27 The push button station shall be provided with separate terminal blocks so
that outgoing cabling shall be terminated in these terminals and not directly
to the push button terminals.
15.28 All live bus bars shall be shrouded appropriately to avoid any accidental
contact.
15.29 The minimum clearance in air between phases 25.4mm and between
phases and earth for the entire run of horizontal and vertical busbars and
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components, the clearance between "two live parts", "a live part and an
earthed part", shall be atleast 10 mm throughout.
15.30 All the panels shall be supplied with necessary hardware like Bus bar bolts,
nuts, washers, spring washers, contact grease etc. Hardware shall be
corrosion resistant.
15.31 All the local control panels shall be accessible and located near their
respective equipment and shall be complete with all the required controls,
interlocks, annunciation’s etc
16.0 TECHNICAL SPECIFICATION LOCAL START / STOP PUSH BUTTON

STATIONS
16.1 The local start/stop push button stations shall be metal enclosed, suitable for
outdoor / indoor mounting on wall or steel structures. The enclosure shall be
die-cast aluminum sheet steel of at least 1.6 m thickness. The enclosure
shall be provided with a hinged guard at the front, covering full length, to
avoid inadvertent operation of push buttons. LPBS shall be painted to shade
which shall be furnished during detailed engineering. Support structure for
mounting the LPBS shall also be supplied by Contractor.
16.2 The local push button stations shall be dust and vermin proof and shall have
a degree of protection of IP -65 as per IS : 13947.
16.3 The push button stations shall be suitable for both top and bottom cable
entry (either of which may be used depending on cabling convenience) and
shall be provided with removable undrilled gland plates or knockouts.
Adequate space shall be available inside the push button station enclosure
for terminating external cables directly on pushbutton terminals. Overall size
of push button stations shall be subject to approval.
16.4 The push button station shall comprise of a latched type EMERGENCY
STOP push button with two (2) NO and two (2) NC contacts.
17.0 FIRE DETECTION & ALARM SYSTEM

This system shall be completely designed, supplied and installed by the
bidder, comprising of automatic fire detectors such as multi sensor smoke
detectors, rate of rise of temperature detectors with fixed temperature setting,
linear heat detectors etc. which shall provide continuous surveillance in an
area. Based on the type of fire expected in a particular area of application,
these detectors shall be chosen except for plant area and transformer yard
where only manual call points shall be provided. The detectors would be
grouped zone wise and alarm signals shall be transmitted to local and main
control panels to indicate the location of fire. Fire detection and alarm system,
on detection of fire by sensors, shall initiate shutting off air conditioning and
ventilation system and initiation of automatic fire protection system. The fire
detection system shall be interfaced with the main fire alarm panel complying
with fire safety standards and recommendations.
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18.0 PLANT COMMUNCIATION SYSTEM
For effective communication in the entire plant, public address system,

electronic private automatic branch exchange system (EPABX) shall be
completely designed, supplied and installed by the bidder with suitable
interfacing with the main plant communication system.
(a) Public Address System

The Public address shall be designed to serve the purposes of making
general announcement, emergency announcements, announce the fire tone
under fire condition, external interface announcements, etc.
The PA system shall be with automatic central control exchange (consists of
amplifier units, system controllers, terminal points, etc.,) modular type and
easily extendable. The system shall be complete with call stations and end
user equipment like loud speakers.
The PA System shall have provision for interface with third party systems such
as Fire Alarm system, PABX system etc.,
(b) EPABX System

The power plant shall be provided with an intercom telephone system to
facilitate intercommunication for general administration purpose. An Electronic
Private Automatic Branch Exchange (EPABX) shall be provided for the
complete plant and located in Plant Control Room.
Facilities shall be provided to link up the exchange with other similar types of
exchanges by tie lines and to originate direct calls to extensions on the other
exchanges.
19.0 DC SYSTEM
a) 220V DC supplies shall be provided for essential functions such as protection,
switchgear closing & tripping, alarms, control and emergency drives,
emergency lighting, etc
b) DC system shall consist of 2 x 100%, plante type lead acid Battery and
2x100% rated float cum boost chargers and DCDB. Ampere-hour capacity of
the batteries shall be based on two (2) hours supply to essential loads. DC
starter panel shall be provided for DC motors.
c) The plant battery shall be sized to safely shut down the power plant upon loss
of all AC power and supply essential DC loads for a minimum of 120 minutes.
The plant battery system shall be sized in accordance with IEC (or IEEE485).
Battery rating shall account for aging of the cells(25%), 10% design margin
and temperature differences. DC power supply system panel-boards shall be
provided with at least fifteen percent (15%) spare breakers for future use. The
DC power supply system shall be sized to include the maximum inverter
output for 1 hour back up.
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d) The battery shall be located in a ventilated area so that suitable temperature

can be maintained and thus helping to ensure long battery life.
20.0 UPS SYSTEM

20.1 Each UPS system shall generally include, but not limited to, the followings:
i). 2 x 100% static converters / inverters with isolation facility.

ii). 2 x 100% static switches with isolation facility.
iii). 2 x 100% manual bypass switch.
iv). 2 x 100% UPS system battery bank.
v). 2 x 100% Float-cum-boost battery charger.
vi). 1x 100% Step Down Transformer with associated switchgear
vii). 1x 100% Voltage Stabilizer and back up source static switch.
20.2 The UPS shall be of “Parallel redundant with static bypass to SCVS regulated
voltage supply” type with 2 x 100% inverters and 2 x 100% battery bank with back-up
time of 60 minutes on each battery bank. Batteries type shall be of maintenance free
Lead Acid type.
20.3 UPS system shall be provided with necessary bypass line transformer, Voltage
stabiliser, AC distribution board, other necessary protection devices and accessories.
20.4 The static switch shall comprise Thyristors connected in anti parallel configuration,
enabling loads on each branch circuit to be connected to the inverter of the other
branch circuit or to the stand-by regulated AC supply.
20.5 The current rating of the static switch shall be not less than the continuous full
load rating of the branch circuit and short time rating of 750% for 1.0 sec.
21.0 INPUTS TO BE PROVIDED ALONG WITH BID
Following shall be provided by the Bidder along with bid:

• Load List
• Power distribution SLD
• Power requirements
• Layout
22.0 INPUTS TO BE PROVIDED AFTER AWARD OF CONTRACT
Following inputs shall be provided by the successful Bidder after award of

contract:
• Load List
• Equipment Datasheet
• Design calculations for selection and sizing of Cables, lightning protection
system, Earthing, MCCs, etc. shall be carried out by the BIDDER and
submitted for approval.
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• All civil assignment drawings including cable tray support locations &
details, equipment foundation details, floor cutout arrangement, panel
fixing arrangement, all equipment loads (static & dynamic), cabling
details, etc. as required.
• Equipment Layouts, Cable routing layouts, Earthing and Lightning
Protection Layout drawings in editable AUTOCAD format for Purchaser's
further engineering.
• GA, BOM, Fixing / foundation details, weights and Vendor drawings etc.
for MCC, VVVF Drive, LPBS, Control panels (if any).
• Wiring diagram of complete inverter. This shall be based on approved
schematic drawing. The correctness of this drawing shall be the
responsibility of the VENDOR.
• Manufacturer's technical literature on VVVF Drive.
• Detailed drawing of converter showing layout of power semiconductors,
fuses, heat sinks, cooling system etc.
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INSTRUMENTATION & CONTROL SHEET 1 OF 21
1.0 SCOPE
1.1 The scope shall include design, engineering, manufacturing, shop inspection and testing,
supply, unloading, storage & handling, erection and associated civil works, field calibration,
testing and commissioning at site, performance testing at shop and site, submission of all as-
built drawings/documents, O&M manuals, obtaining statutory approvals, training of Owner’s
personnel, etc., and finally handing over a fully functional system / equipment covering all the
Instrumentation & control(I&C) equipment /services specified in this specification including
enclosed Tables and drawings. The system shall be designed suitable for automatic
operation. The following systems / services, complete with hardware and software and all
other accessories to operate the plant efficiently, reliably and safely are included in the
scope:
1.2 Necessary switches / sensors and local instruments such as level switches and transmitters,
pull chord switches, belt sway switches, zero speed switches, chute jam detector, over travel
limit switch, etc., as required together with associated erection hardware, junction boxes,
etc.,
1.3 Cables (Instrumentation, Control, power for I&C equipment, Data highway & pre-fabricated
cables as required) for all interconnections within the Bidder’s scope. Preparation of
Interconnection cable schedule for all the I & C cables is included in Bidder’s scope.
1.4 A Redundant PLC based system with cabinets, processor cards, complete with I/O cards,
remote I/O units, power supply modules, communication modules and other associated
hardware for Video Display Unit (VDU) based operation, control & monitoring of the entire
limestone handling system (LHS).
1.5 Dedicated PLC / microprocessor-based control system for the air compressors.
1.6 110 V AC, single phase redundant UPS (as specified in the electrical section) for I & C
equipment comprising the PLC system and associated HMI, vibration monitoring system,
remote I/Os, field devices, etc. Back up time shall be 60 minutes. UPS Battery shall be
2x100% redundant and sealed maintenance free type. UPS & battery shall be placed in Air-
conditioned room. Power other than 110 V AC required for the PLC shall be derived from the
UPS. 24V DC power required for the I&C system / instruments shall also be derived from the
UPS using redundant power packs, diode-ORing, etc. The Power supply feeders and the
distribution shall be redundant in hot standby mode. UPS shall have non-redundant
communication link to the LHS PLC system using OPC protocol.
1.7 Power supply (UPS and non-UPS) distribution including cabinets, distribution boards, etc. for
complete I&C system.
1.8 Control desk with VDUs and printers for the LHS. Control room furniture (chairs, tables, etc.)
is included in the Bidder’s scope.
1.9 All HT drives will be provided with bearing temperature & vibration monitoring for each
bearing of drive motor & driven equipment and motor winding temperature monitoring.
Vibration sensors shall be provided on X & Y directions on DE & NDE of drive & motor. If
Compressors (HT type) are multi stage type, then bearing temperature & vibration monitoring
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shall be considered for each stage. All vibration signals shall be interfaced with PLC system
for alarm/interlock purpose.
1.10 Air conditioning for control rooms that house any PLC / microprocessor-based control
systems.
1.11 Local Panels for hot gas generator, dust extraction, in line conveyor scales, magnetic
separator, metal detector, etc. as specified.
1.12 Two number (2) radar type bunker level transmitter with local indicator to be provided for
each of the bunkers to sense the level and the signal shall be used for automatic filling of
bunkers. The automatic filling shall be such that the Bunkers are uniformly filled without
forming any heaps.
1.13 Addressable type of belt sway and pull chord switches shall be provided. A belt watch panel
shall be provided to enable identification of the particular belt sway or pull chord switch that
has been activated.
1.14 Bidder to provide hardwired signal exchange with Purchaser’s DCS (for monitoring) and with
PLCs for compressors, (monitoring, interlock and protection) using potential free contacts
and isolated 4-20mA signals.
1.15 All hardware, software, engineering, etc. required for providing redundant, fibre-optic, bi-
directional communication link between the LHS PLC and Purchaser’s DCS using OPC over
TCP / IP protocol for monitoring important parameters/status of the LHS from the Main
control rooms of TSM & AEL.
1.16 The LHS PLC system shall be time synchronised with Purchaser’s existing master clock
system. Corresponding cables to Purchaser’s equipment is part of Bidder’s scope.
1.17 Factory acceptance test and site acceptance of the PLC system
1.18 Training of Purchaser’s personnel including classroom and on-site training for all I&C
equipment included in the Bidder’s scope to enable them to take over the proper operation
and maintenance of the equipment and to carry out engineering functions in the PLC system.
The training shall be for a minimum of one week of class room and two weeks of on-site
training. The structure of the training shall be decided by the Purchaser.
1.19 The Bidder shall include in his offer all special maintenance and erection tools and
tackles for the I&C equipment.
1.20 Spares as specified.
1.21 Any other I & C equipment not specified but necessary to meet the specified functional
requirements of the system.
2.0 SPARES
2.1 The Essential Spares shall be supplied as detailed below.
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a For all field Instruments, a min of one (1) or 10% of the quantity of each type or
range, whichever is higher is to be provided.
b For control / pneumatic valves, a min of one (1) or 10% of the quantity of each
type or range of valve positioned, packing and gaskets, actuator diaphragm,
pilot relay, O-rings and any other accessory or consumable.
c For solenoid valves, a min of two (2) or 10% of the quantity of each type or
range of complete valve set with coil (each rating and insulation), gaskets ,O-
rings, and any other accessory or consumable.
d For PLC system, minimum one (1) no. of each type of module or 10%,
whichever is higher.
e Spare I/O Channels: All types of I/O modules shall be provided with 10 %
spare channels. Spare channels shall be wired and shall be distributed among
the control processors.
f 10% hot spare I/O modules (installed) shall be provided.
g 10% spare slots for I/O modules distributed among the control processors.
h 10% spare rack space shall be provided.
i The spare capacity shall be uniformly distributed in the system
j For relay based local control panels, system and marshalling cabinets:
minimum one (1) no. or 10 % quantity of each & every type of hardware
(fuses, MCBS, terminals, indicating lamps, push buttons, selector switches,
relays, connectors of pre-fabricated cables, etc) used in the panel / cabinet.
3.0 OPERATION AND CONTROL PHILOSOPHY

3.1 The overall operation, control and monitoring of the LHS shall be performed from the
corresponding LHS control room located in the LHS MCC cum control room building through
video display units (VDUs) of a microprocessor based Programmable Logic Controller (PLC)
based control system. Signals of all conveyors and feeders, crushers, flap gates, etc. to be
connected to the PLC cabinets housed in the LHS control room.
3.2 Electrical switchgears/MCC, incomer’s, bus couplers shall be controlled from PLC.
3.3 Redundant, fibre optic, bi-directional, OPC communication links will be provided from the
LHS control system to AEL & TSM DCS/Control system to facilitate monitoring of important
parameters and status. Hardwired signal exchange will also be provided for communicating
major control / trip conditions.
3.4 The LHS control room shall house the control desk for mounting the following HMI equipment
of the LHS PLC system:
i) One (1) Operator Station (OS).
ii) One (1) Operator cum Engineering Station (OES).
iii) One A4 size colour laser printer.
iv) One 132 column dot matrix printer
3.5 A belt watch panel shall be provided in the LHS control room to enable identification of the
particular belt sway or pull chord switch that has been activated.
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3.6 The following equipment shall be operated and controlled from respective pre-engineered
local control panel with annunciation / status indication on the HMI of LHS PLC for important
signals. Also, signals required for interlocks are hardwired to the LHS PLC:
i) In line conveyor scales.
ii) Magnetic separators.
iii) Metal detectors.
iv) Sump pumps.
v) Dust extraction / ventilation fan (operation from local panel as well as from the LHS
control room).
vi) Compressed air system for Dust extraction system. (PLC based - operation from local
panel as well as from the LHS control room)
vii) Hot air/gas generator.
viii) The local control panels shall be provided with conventional operational hardware
such as push buttons, selector switches, auto/manual stations, local / remote selector
switches, indicating lamps, hooters, etc
3.7 For each set of bunkers, one local panel, mounted on the bunker operating floor, shall be
provided for the bunker level indication. Each bunker shall be provided with two no. of radar
type level transmitter. 4-20 mA signals, corresponding to the bunker level, shall be wired to
the LHS PLC.
3.8 Weighing scale indication (flow rate indication & Digital totalizer) in PLC as well as local shall
be provided.
4.0 GENERAL REQUIREMENTS
4.1 Measuring instruments/equipment and subsystems offered shall be from reputed
experienced manufacturers of specified type and range of equipment, whose guaranteed and
trouble-free operation has been proven. Further, all instruments shall be of proven reliability,
accuracy, repeatability requiring a minimum of maintenance. They shall comply with the
acceptable international standards.
4.2 All measurements shall be in metric units.
4.3 All transmitters shall be SMART type with integral local LCD indication and HART protocol.
4.4 Instruments used in non-safe (hazardous area) shall be intrinsically safe as per the
corresponding area classification. Corresponding barriers shall be provided in the control
system cabinets for these signals.
4.5 All Temperature sensors shall be Duplex type. Both the element leads shall be wired up to
junction box (as the case may be).
4.6 Smart positioners shall be provided for all control valves/dampers.
4.7 All outdoor field equipment shall be provided with suitable painting.
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4.8 Cable number tags and markings will be provided at every 30 meters along the entire
length of cable.
4.9 JBs shall not have top entry to avoid dust entry. No equipment shall have top entry for cables.
4.10 All the switches, wherever provided shall be provided with 2 nos. changeover contacts and
both shall be wired up to Junction Boxes.
4.11 All the cables in the Hot Zone (combustor region) shall be fire survival cable conforming to
IEC 331standard.The cables in other areas shall be FRLS, conforming to IEC 332 standard.
4.12 Under no circumstances field cabling to be directly terminated in PLC system cabinets.
4.13 All outdoor panels, cabinets, JB etc. shall be provided with protective cover canopy to
provide effective protection against dust, rain etc.
4.14 All temperature measurements shall be with temperature transmitters.
4.15 All field instrument shall be IP-65.
4.16 For cable laying, the cable trays shall be made of FRP. For Fire prone/high temperature
zones only hot dip galvanized steel to be considered. Each tray shall be provided with 20%
spare space in the number of layers specified.
4.17 Any I&C equipment required at any stage for the efficient/safe/reliable operation of the
system either during detailed engineering/commissioning/after commissioning shall be
installed and commissioned by the Bidder within the quoted price.
4.18 The ranges of the instruments shall be selected based on the philosophy indicated below:
a) For pressure and draft measurements, the maximum operating pressure
shall be within 70 to 80% of the maximum scale range.
b) For temperature measurement, the maximum operating temperature will be
within 80 to 90% of the maximum scale range.
c) For pressure switches, the set points shall fall within 40% to 70% of the scale
range selected.
d) For level measurement, the maximum of the range will cover the overflow
point or six inches from the top of the vessel and the minimum of the range
will be stacked with overlap to cover permissive, alarm and trip levels.
5.0 SPECIFICATIONS FOR INSTRUMENTS

5.1 Pressure Indicators/DP indicators-Direct reading, pipe mounted Pressure gauges of
Stainless Steel with 6 inch phenolic dial (white dial with black numerals), 316 SS Bourdon
tube, AISI 304 movements and micro meter type adjustable aluminium pointer an accuracy
of +/-0.5% of span including accessories like siphons for steam services, snubbers for pump
discharge applications and chemical diaphragm for corrosive and oil services and name
plate, etc. Material of accessories shall be SS. IP65 or equivalent degree of protection for
enclosure. Over range protection shall be 50% above maximum pressure. Armoured
capillary of 15 metres shall be provided as required.
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5.2 Pressure Switches/DP Switches-Non indicating type, field mounted Pressure Switches of
aluminium casing (epoxy coated), and 316 SS element and accuracy of +/-1% of span,
including accessories like siphons for steam services, snubbers for pump discharge
applications and chemical diaphragm for corrosive and oil services, name plate & mounting
brackets. Material of accessories shall be SS. Auto reset micro switch with internal
adjustment for set values with 2 SPDT contacts rated for 0.2 A at 220 V DC. IP 65 or
equivalent degree of protection for enclosure. Over range protection 50% above maximum
pressure. Scale for setting shall be provided.
5.3 Pressure Transmitters/DP Transmitters-Micro-processor based indicating type (LCD display),

rack mounted with accuracy of +/-0.075% of span, external zero and span adjustment, self-
diagnostics, temperature sensor for compensation. Power supply 24 V DC; output signal of
4-20 mA DC. IP 65 or equivalent degree of protection. Aluminium housing with epoxy
coating, Accessories like snubbers for pump discharge applications and chemical diaphragm
with 15 m PVC covered SS armoured capillary for corrosive and oil services, three-way
manifold, name plate etc. Material for accessories shall be SS. equivalent degree of
protection over range protection 50% above maximum pressure. Repeatability shall be +/-
0.5% FSR.
5.4 Thermometers-Indicating type, field mounted, filled system with ten (10) metres SS capillary
with SS armour and six (6) inch dial (white dial with black numerals with micrometre pointer)
housed in aluminium casing (epoxy coated) with an accuracy of +/-1% of span, response
time of 2-4 seconds, auto temperature calibration, linear calibration over the range and SS
bulb with 316 SS thermowell having a process connection of M33 x 2 thread or 150 RF
flanged. Material of accessories (name plates, mounting brackets, etc.) shall be SS. IP 65 or
equivalent degree of protection for enclosure. Thermowell with Hex head bar stock
assembly. The thermowell construction shall meet the ANSI 19.3-1994 (latest) requirements
5.5 Thermowells-Pipe/equipment mounted temperature test wells of 316 SS with a process

connection of M33x2 thread or 150 RF flanged. Accessories like name plate, plug with chain,
etc. shall be provided. Material of accessories shall be SS. Thermowell shall be hex head of
barstock assembly. In case flanged wells are required for any specific application, the same
shall be supplied as required. The thermowell construction shall meet the ANSI 19.3 (latest)
requirements.
5.6 Resistance Temperature Detectors (RTD)-Duplex type, PT – 100, with accuracy of +/-0.5%
of span, response time 1-2 seconds; Spring loaded mineral insulated three (3) wire RTD
assembly with 316 SS Thermowell housed in aluminium casing (epoxy coated) having a
process connection of M33 x 2 thread or 150 RF flanged. IP 65 or equivalent degree of
protection for enclosure. Material of accessories (name plate, etc.) shall be SS. Thermowell
with hex head with screwed cover & SS chain, barstock assembly. Element lead size shall be
18 AWG. The insulation resistance at 540 Deg C shall not be less than 5M ohms.
Repeatability over full range shall be better than 0.02%. RTDs shall be ungrounded. RTD
shall be supplied as an assembly complete with thermowells meeting ANSI 19.3 (latest)
requirements
5.7 SMART Temperature Transmitters -Non-Indicating type, field mounted temperature

transmitters with an accuracy of +/-0.075%, ref. junction compensation, span/zero
adjustment, burn out protection upscale, input/output isolation, circuit ungrounded, ambient
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temperature error 0.1%/10 °C to provide linear output of 4-20 mA DC (2 wire system). NEMA
4 or equivalent degree of protection for enclosure. Material of accessories (name plate,
mounting brackets, etc.) shall be SS. Power supply: 24 V DC. Housing shall be aluminium
alloy. Stability: +/-0.25% of FSR for 6 months.
5.8 Level Gauges-Tubular type level gauges for low pressure upto 7 kg /sq.cm & reflex type for
high pressure water & steam services & vacuum services with automatic ball check valves,
illuminator (240 AC), Pyrex/ borosilicate glass, mica shield, brass guard rods & brass
holders. Material of accessories (name plate, etc.) shall be SS. Tubular glass OD shall be
5/8”. Vent & drain valves shall be provided. Connection shall be screwed or flanged (ANSI
class 150 RF).
5.9 Flow Glasses-Online flow glasses for pipe size up to 6" with a rotary wheel (not a flapper
type) suitable for installation on vertical or horizontal pipe lines, material Pyrex tempered
glass. Body material shall be carbon steel; rotor & wetted parts shall be bronze. The material
of accessories shall be SS. IP 65 or equivalent degree of protection for enclosure. Upto 50
Nb size, connection shall be screwed & above 50 mm Nb size it shall be flanged - ANSI, 150
RF. Accessories like name plate, mating flanges with gaskets (neoprene), bolts & nuts, etc.
shall be supplied
5.10 Flow Switches-Indicating, Differential pressure, flapper type on line flow switches for line
sizes up to 80 mm with an accuracy of +/-0.5% of span and dial size of min. 50 mm having
316 SS flapper/SS 316 bellows housed in die cast aluminium. Micro switch with adjustable
range with 2 SPDT contacts rated for 0.2 A, 220 V DC. IP 65 or equivalent degree of
protection for enclosure. The material of accessories shall be SS. Repeatability shall be +/-
0.5% of span. Over range protection shall be 50% above maximum flow. Setting shall be
tamper proof external adjustment & scale shall be provided for setting. Range spring & orifice
plate shall be SS 316 for DP type. NPT for sizes below 2” & for sizes above 2” ANSI 150 RF
shall be provided. Accessories like name plate, mating flanges with gaskets, bolts & nuts,
pipe assembly with orifice plate, etc. 5 way mani-fold, pipe, fittings (DP type), etc. shall be
supplied.
5.11 Silo level Transmitter / Indicator-Radar type level transmitters top mounted with LCD
indicator shall be provided. IP-65 protection; +24 V DC supply; 4-20mA output with HART
protocol; Accuracy ±1%; Resolution 0.04”; Repeatability ±0.04”; Linearity ±0.01%; Beam
angle <20º; Accessories like integral cable between sensor and transmitter unit with
connectors on both side, gasket and cable gland, digital panel meter, name plate & metal
tag; the material of accessories will be SS. Switch – 2 nos. of SPDT contacts (1 NO and 1
NC) rated for 0.2 A, 220 V DC .
5.12 Junction Boxes (JB)-All JBs shall be Galvanised. Wall/column mounted junction boxes
having 32 (2x16) terminals and cable entry only at the bottom and sealed with fire proof
compound; Screwed terminal type; IP 65 or equivalent degree of protection for enclosure.
Separate terminal blocks shall be used for analog and digital signal and also for signals with
different voltages. Removable gland plate shall be supplied. JB shall have single lockable,
hinged type door with gasket, able to open sideways, with common keys. Shield bus for
screw connection shall be provided. Terminal size shall be suitable for 0.5 sq.mm to 2.5
sq.mm wire. Terminal blocks shall be vertical. JB shall have 20% spare terminals.
Accessories like metal tag (SS), clamps, fixtures, bolts (SS), nuts (SS), gaskets (neoprene),
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lock & key, fire proof compound for sealing, etc. shall be supplied. All JBs shall be provided
with individual canopies to avoid ingress of water
5.13 Pull cord, belt sway and zero speed switches
A canopy made of 5mm M.S. plate shall be provided over the lever of each pull cord switch
and for each belt sway switch so that spilled over coal lumps do not trip the belt by actuating
the lever. Enclosure shall be provided for pull cord and belt sway switches. The degree of
protection for all protection switches shall be IP-65. All switches shall have 2 NO & 2 NC
potential free contacts. The switches shall be addressable type.
Pull Chord Switch-Pull Cord (manually reset type) emergency stop switches shall be located
along both the sides of entire length of all conveyors. The spacing shall be at an interval of
not exceeding 30 meters. Adequate length of PVC coated wire rope and all accessories shall
be furnished. From either end of conveyor pull cord switches should not be more than 15m.
Also a local trip indication (Cluster of LEDs) shall be provided with each pull cord switch. Pull
cord switch shall have C.I. body with additional enclosure to prevent ingress of dust.
Belt Sway Switch-Belt Sway limit switches (auto reset type) shall be furnished in pairs at
periodic intervals of minimum 30m to limit belt sway to permissible extent. For any conveyor,
however, minimum two pairs of switches shall be provided. These switches shall be placed
not more than 15 m from either end of conveyor. Belt sway switch shall have C.I. body with
additional enclosure to prevent ingress of dust
Zero Speed Switch-Each conveyor shall be provided with a zero-speed switch (auto reset
type) at the tail end for sequential operation of the system. In case of belt speed falling below
the tolerable limit, the same switch shall stop the conveyor. The speed setting should be
adjustable. Necessary provision to be kept in control circuit to by-pass the switch during
starting.
Pull cord switch / Belt sway switch identification system -The system shall identify the one or
more operated pull cord / belt sway switch location and monitor the condition of the cable
connecting the switches in series for open and shorted conditions. The system shall
comprise sensor modules installed in the field switches and indicator / transmitter module to
identify switch operated / cable healthy condition. The system output shall be connected to
the PLC/DCS for identifying the operated switch location / cable condition to the operator on
the VDU.The system shall be provided to cover all the conveyors from the leading up to the
bunkers.
5.14 Air Filter Regulator (AFR)--Constant bleed type AFR with an accuracy of +/-0.1%, inlet
pressure range of 5-8 kg /sq.cm and suitable spring ranges (AFR) for use with positioners in
control valves, control damper, E/P convertors and shut off valves, transmitter purging lines
etc; Filtering particles above five microns having phosphor bronze filter element. Material of
accessories shall be SS. Built in blow down valve shall be provided. AFR shall have
automatic drain feature. All accessories shall be supplied. Degree of protection shall be IP65.
5.15 Solenoid Valves-Direct operated solenoid valves, pilot operated for higher sizes, body
material of SS-316, plunger material of SS316 rated for continuous duty. IP 65 class for
enclosure. Insulation class of 'H' for the solenoid. Body ratings shall suit the pressure and
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temperature conditions.
5.16 Pneumatic block valves -Balanced, on off, plug type, single ported, gate valve. Body material
shall be ASTM A 216 GR WCB with end connection socket welded for sizes 50 NB and
below & butt welded for sizes above 50 NB and flow direction shall be horizontal. Bonnet:
Std. type of material ASTM A 216 GR WCB & packing material GRAFOIL. Trim: Cage
guided, metal seated with flow characteristic of quick opening with stem, plug, seat and guide
material of SS 316. Actuator: Diaphragm (Nitrile) type with hand wheel & travel indicator and
adjustable stop. It shall be sized for shut off differential pressure. Accessories like air filter
regulator, solenoid valve, limit switch with Nema4 & enclosure, etc. shall be supplied.
Actuators & accessories requiring tubing shall be mounted and tubed
5.17 Cables-Individual pair shielded & overall shield twisted pair copper cables shall be used for
analog signals & overall shielded cables shall be used for digital signals. All these cables
shall be armoured. All the insulation including overall sheath shall be FRLS quality. The wire
size shall be minimum 1.0 sq.mm. Ferruling indicating terminal numbers on termination side
shall be followed. Colour coding shall be as per Purchaser’s standard. Only sleeve type
ferruling with printed terminal numbers shall be used. Cross ferruling shall be adopted.
Instrumentation Cables -Instrumentation cables shall be 600VAC grade, stranded high

conductivity annealed, tinned copper, twisted pair (with min. 20 twists for meter) PE
insulation with overall and / or individual screening, extruded PVC inner sheathed,
galvanized steel wire armoured, extruded outer sheathed with FRLS PVC compound. The
conductor size shall be minimum 1.0 sq.mm. Triplex cables similar to instrumentation cables
shall be used for RTDs. Instrumentation cables carrying digital signals shall have overall
screening along with drain wire and analogue signal carrying cables shall have each pair
screening and overall screening along with each pair drain wire and overall drain wire. Cores
to be identified by colour and coding.
Control Cables -Control cables shall be 1100V AC grade, multicore, minimum 1.0 sq.mm
cross section, stranded copper conductor having 7 strands, PVC insulated, inner FRLS PVC
sheathed of type ST-1, galvanized steel wire armoured, and outer sheath made of FRLS
PVC compound of type ST-1. In situations where accuracy of measurement or voltage drop
in control circuit, warrant, higher cross sections as required shall be used. For all the CT &
PT cables, minimum 2.5 sq.mm cables shall be used. Solenoid valve Power supply cables
shall be minimum 2.5 sq.mm.
6.0 PROCESS - DESIGN CONSIDERATIONS

6.1 The design of the safety interlocking system shall be based on the following basic principles.
i To trip the minimum equipment in the sequence during abnormal operating conditions
leaving all the other equipment running which may safely be permitted to continue
operation
ii To annunciate and indicate initiating cause for an equipment which is tripped.
iii To prevent restarting of equipment until safe conditions are restored.
iv To retain as much flexibility of operation as is consistent with safety
v To prevent mal-operation of equipment on interruptions and restoration of control
voltage
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INSTRUMENTATION & CONTROL 21
vi The design of the control system shall be fail-safe in the event of Critical Process
disturbance.
vii Hooters are to be provided for each path of the LHS. These are to be sounded prior
to the starting of the associated path.
6.2 Annunciation on VDU – process requirements:
Individual point annunciation provided on the VDU shall include as a minimum, but not be
limited to the following:
i Annunciation for trip of individual belt conveyors
ii Annunciation for fault in individual conveyor drives / crusher motor screen trip on O / L
/ fault of HT motors
iii Annunciation shall be provided for all belt conveyors except belt feeders to
annunciate the tripping due to each of the following conditions separately.
-Pull cord switch operated
-Belt sway switch actuated
-Zero speed switch actuated
-Emergency Switch Operated
-Thrust Brake Fault in HT Drives
-Chute Position disturbed
-Any other causes
iv Annunciation for trip of individual crusher, screen and feeder.
v Annunciation for trip of feeder / conveyor drive due to overload / fault on LT motors /
core balance relay /under voltage relay / bi-metal relay.
vi Annunciation for all HT motor trip due to high bearing temperature and winding
temperature.
vii Annunciation for operation of low speed switch of crushers, eccentric disc screens.
viii Annunciation for trip of conveyor due to metal detection by metal detector.
6.3 The system shall include the following features for efficient operation from the VDUs-
i Individual overview, plant group displays, plant control displays for drives and all
electrical breakers, unfulfilled criteria display, individual face plate for drives.
ii Plant dynamic schematics (mimic diagrams), bar graph display, Electrical Single Line
Diagram, Switchgear status, All breaker On-Off conditions, Equipment status etc
iii Alarm displays
iv Trend plots
v Logs and reports
i Operation guidance for start-up and shut down.
7.0 REDUNDANCY & AVAILABILITY REQUIREMENTS

7.1 All the specified redundancies shall be achieved by duplication of hardware, cable etc., and
not through software.
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7.2 For the PLC system, 1:1 redundancy shall be provided for the processor modules, power
supplies, communication modules and communication bus (including remote I/O, operator
interface, Engineering station, History module etc.). I/O modules shall be non-redundant.
8.0 PLC SYSTEM

8.1 The PLC based control system shall provide automatic sequencing of start-up, running and
shutdown of the system along with protection and interlocks as required. The system shall
also comprise of data acquisition and historization functions of binary and important analog
parameters, dynamic status / parameter updating on graphic pages, trends, logs and alarm
annunciation.
8.2 The system shall be upgradeable, evolutionary in both hardware and software.
Manufacturers shall provide evidence on such upgrades in similar plants, along with the bid.
The hardware and software used shall be of the latest version.
8.3 The Latest system and system configuration available / being marketed in the international
market by the PLC manufacturer with minimum 3 years of proven performance record to be
provided.
8.4 The PLC system shall comprise of the processors, I/O cards, remote I/O units,
communication modules, power supply modules, racks, mounting accessories fully wired and
tested.
8.5 The PLC hardware shall include all electronics required to perform signal conditioning
functions required to process the various types of input / output signals such as digital inputs,
4-20 mA, RTD inputs, etc. It shall also be capable of implementing open and closed loop
controls.
8.6 The system shall be designed in such a manner that in the event of failure of the primary
controller, the entire configuration of the failed controller shall be instantaneously and
automatically transferred to the back-up controller without operator’s intervention. The
following requirements shall be fulfilled.
i) Mode changeover in either direction shall be bumpless and shall not exceed 50 ms
and in any case not more than one cycle time of the fastest loop in the processor.
Simultaneously, a message should appear on the video-monitors of the
Operator's/Engineer's work station indicating the failure.
ii) Automatic synchronisation of primary processor/controller of PLC with secondary
processor/controller.
iii) Automatic program and data equalisation in the event of any on-line program / edit
executed in the primary processor/controller of PLC.
iv) Automatic “Forcing Bit” update in the secondary processor/controller of PLC when
any “Forcing is applied in the primary processor/controller of PLC.
8.7 Data bus system shall have local bus, communication controller, main bus and remote I/O
bus to transfer the data between the function cards, remote I/Os, processors and VDUs and
printers.
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8.8 Complete licensed software for PLC based system including the communication software
system shall be supplied and implemented to meet completely the specification
requirements.
8.9 The PLC shall have extensive self-diagnostic feature to monitor completely the software,
hardware and communication faults in the system. Hardware diagnostics up to card level
shall be provided. The HMI shall have mimic diagram for displaying the status of each
component of the PLC System up to card level with status and identification of faults /
failures. It shall also have mimics to show the power distribution system.
8.10 Scan, response times and loading of the PLC system. PLC system performance
requirements shall comply with the following under the specified worst loading conditions,
spare capacity and grouping philosophy:
i) Scanning rate of analog inputs Max. 250 milli seconds

ii) Scanning rate of digital signals Programmable 25 - 50 milli seconds
iii) Scanning rate of pulse signals Maximum 100 milli seconds
iv) Loop execution time for CLCS Maximum 250 milli seconds (For all
(The loop execution time is the total loops) or faster if required by the
time required from input scanning to process.
output updating including processing
time of the control processor).
v) Loop execution time for OLCS Maximum 100 milli seconds (For all
loops) or faster if required by the
process.
vi) Controller output update for CLCS Every 250 milli seconds (For all CLCS
loops)
vii) Controller output update for OLCS Every 100 milli seconds (For all OLCS
loops)
viii) Update time of display 2 seconds or better
(Measurement)
ix) Update time of display OLCS / CLCS 1 second or better
x) Display call up time. Max. 2 seconds
xi) Command execution time from 1 second or better
keyboard to the field equipment
through output card
xii) Minimum trending scan rate 5 seconds.
xiii) Minimum trend display time 1 minute
xiv) Controller Loading Maximum 50% (under worst loading
conditions)
xv) Data bus loading Maximum 50% (under worst loading
conditions)
xvi) Memory Loading Maximum 50% (under worst loading
conditions)
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xvii) Overall system availability 99.7% or better
8.11 For the control system, the worst loading condition shall include the following tasks:
i) All process inputs scanning and processing is in progress and all the data is
transmitted over the main data bus every one second.
ii) All closed loop controls in operation
iii) All open loop controls in operation
iv) All output devices are in operation with rated performance/speed.
v) Control/information request is initiated on control VDU.
vi) Controller Loading: Maximum 50%
vii) Data bus loading: Maximum 50 %
viii) Memory Loading: Maximum 50 %
8.12 Spare philosophy for PLC I/O channels:

i) Spare I/O Channels: All types of I/O modules shall be provided with 10 % spare
channels. Spare channels shall be wired.
ii) 10% hot spare I/O modules (installed) shall be provided.
iii) 10% spare slots in each rack
iv) 10% spare rack space shall be provided.
v) The spare capacity shall be uniformly distributed in the system
8.13 The PLC system processor shall support the following functions and capabilities:
i) Data acquisition.
ii) Logic functions.
iii) Closed loop control functions.
iv) Generation of Boolean functions.
v) Self-diagnostic functions.
vi) Monitoring of ADC / DAC performance and alarming for analog inputs.
vii) Digital filtering.
viii) Validation of all inputs and outputs.
ix) Redundant communication with all I/O modules.
x) Redundant communication with all HMI equipment.
xi) Communication control and monitoring.
xii) Battery back-up of not less than 72 hrs.
xiii) Minimum 32 bit processor with floating point capability.
xiv) Minimum RAM capacity shall be 256 MB.
xv) Minimum non-volatile memory to be 12 MB.
xvi) Volatile memory to store dynamic plant data, control programs and self-diagnostic
routines
xvii) Non-volatile memory is required to store programs, standard software to perform
logic functions, data acquisition and diagnostic features.
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xviii) Watchdog facility.
8.14 The PLC system shall support the following design features:
i) Optical isolation for all digital inputs & outputs.
ii) Galvanic isolation/optical isolation for all analog inputs & outputs.
iii) Power supply to sensor / transmitter at +24V DC from the PLC AI card (loop powering).
For field instruments with high loads, 4-wire connectivity to be used.
iv) Contact interrogation voltage shall be 24VDC.
v) Contact bounce protection for digital inputs.
vi) Detection of open circuit for RTDs / thermocouples in RTD / thermocouple cards
respectively.
vii) Cold junction compensation for thermocouples – part of thermocouple card.
viii) Overall accuracy of measurement signals shall be 0.5%.
ix) In rush current limiter to driving circuit.
x) All circuits shall be short circuit and voltage surge proof.
xi) Modular type of cards.
xii) All cards shall be tropicalised.
xiii) Filters for noise rejection.
xiv) In analog input cards, transmitter monitoring for parity, wire break, live zero and end
limit values.
xv) Analog input card features - Monitoring of A/D conversion, test for substituted value,
Conversion to engineering units, Test for normal or extended range, Alarm limit testing
for high, low, high high and low low substituted values and Rate of change – positive
and negative dead band.
xvi) Analog output card features - Direct or reverse operation, D/A per output and power
regulator per output, loop back check of output, Default options upon failure, 5 segment
output characterization and ‘Go to zero current’.
xvii) Signal distribution of input signals to various devices within the PLC system shall be
through signal multipliers.
xviii) All card replacements shall be possible on power on conditions.
xix) At least 3 levels of hierarchical protection for operator & engineer functions.
xx) Output status on controller failure to be configurable in engineering station.
xxi) Output status on power supply failure to be configurable for switching to fail safe mode
xxii) LED indication for status for each channel in DI / DO card.
xxiii) LED indication for power supply healthiness status in all modules.
xxiv) Individual fuse for analog I/O channels and LED indication for fuse status.
xxv) Individual fuse for digital I/O channels and LED indication for fuse status.
xxvi) Fuse for maximum of 8 DI / DO channels; individual for analog signals.
8.15 Channel densities for AI, AO, RTD and Thermocouple cards – not more than 16 channels
per card; DI and DO – not more than 32 channels per card. Thermocouple / RTD (3 wire)
cards shall have maximum channel density of 16 channels.
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8.16 Grouping philosophy: The following concept for Grouping philosophy shall be followed:
i) I/O spares capacity shall be as specified elsewhere in this section.

ii) The following I/O assignment guidelines shall be followed:
• No two identical / similar equipment (eg. Pump A and pump B) shall be
grouped in the same I/O module.
• I/O assignment shall be identical for similar / redundant equipment, i.e., if
Pump-A ‘run’ is assigned to channel 4 of a card, Pump-B ‘run’ shall be
assigned to channel 4 of another card. Also, these cards shall be located
in identical slots in different racks.
• Redundant field devices shall be connected to different modules.
• Any one card shall have I/O related to only one equipment and auxiliaries.
Any spare channels available after such assignment may be used for
common signals. If any equipment and auxiliaries require more than one
card, I/O related to auxiliaries shall be in different cards.
• Inputs and Outputs shall not be combined in a single module.
• Independent measurement circuit for each measurement.
• Quantity of I/Os assigned to a CPU shall be such that the system scan and
response times and loading are as specified elsewhere in this
specification.
8.17 Interposing relays shall be mounted in separate relay cabinets that shall be located along
with the other PLC cabinets. Relay contact rating is to be 5A at 240 V AC. Interposing relays
shall be provided for all digital outputs from the system..
8.18 Provision shall be made for time synchronising of the PLC system with Purchaser’s master
clock signal.
8.19 Human Machine Interface requirements

a Operation and monitoring functions shall be possible from either the OS or OES
stations and the failure of any one of these stations shall not affect operation and
monitoring. Engineering functions in the OES shall be available only to authorised
personnel as governed by the hierarchy of the user’s password. Annunciation shall be
implemented as part of the HMI software.
b Each OS shall have independent electronics and shall be freely assignable. All the
printers shall be network printers and shall be functionally assignable from any of the
OS.
c The OES and OS shall be PC based stations with Windows latest proven operating
system and hardware, 32 / 64 bit, Dual core, 3.6 GHz processor, 4 MB shared L2
cache, 1333 MHz FSB, 500 GB Hard disk, min. 1 GB RAM, 4 nos. USB port and
Ethernet adapter or better processor, monitors as mentioned above, mouse and
QWERTY keyboard.
d The monitor shall be 24” TFT-LCD suitable for desktop mounting. The volume shall
be adequate to make the annunciation audible over the back-ground noise.
e The system shall include the following features for efficient operation from HMI.
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i Individual overview, plant group displays, plant control displays, individual

point data, equipment operating history, trend (real time & historical trending),
alarm displays, system status, logs/reports, group displays, assignable trend
displays, operator guidance messages, unfulfilled criteria display, Individual
Face plate for Drives and all Electrical breakers, etc.
ii Plant dynamic schematics (mimic diagrams), bar graph display, Electrical
Single Line Diagram, Switchgear status, all breaker On-Off conditions,
Equipment status etc.,
iii Alarm displays.
iv Trend plots.
v Logs and reports.
vi Operation guidance for start-up and shut down.
vii OPC links to DCS, Proven serial links to Numerical relays, serial links to
compressor, etc., as required
f Plant Control Displays-
Control displays shall facilitate normal plant operation. These displays shall be
organised in the form of plant overview display, group displays, individual input/output
point displays and logical function displays. It shall be possible to perform open loop
control from these displays.
g Plant Schematics: (Process Mimics)-
Facility for overlaying displays with other displays on mimics, performing control
actions through touch panels in mimic diagram (graphics) shall be provided. Display
call up time and updating of dynamic information shall be specified above as part of
the PLC system performance requirements. ISA standard graphic symbols library for
generating mimics shall be provided
h Alarm Notification / Actions –
Minimum 3 levels of process alarm prioritising facility shall be provided. The alarm
messages shall be printed on dedicated printer on occurrence of fault or on demand
strictly in chronological order. Provision shall be made for display of alarm messages
on OS/OES in the order of occurrence.
i Alarm display functions –
Alarm displays for equipment malfunctions, control deviations of process variables
indicating High-High, High, Low, Low-Low limits and change of states (0 to 1) or (1 to
0) shall be provided. Automatic inhibition for "Bad" and "Out of service" points from
limit checking shall be provided.
j Alarm Summaries –
Alarm summary shall be provided for existing alarms, bad-inputs, points out of scan, I
& C faults, Lock-out alarms. Alarm summary in the order of priority and chronological
order within priority shall be possible.
k Individual Point Data –
The display of analog / digital inputs shall contain the following data: -(i) PID number
(ii) Point description (iii) Current value/status (iv) Sensor / transmitter / instrument tag
number (v) Scan status (under scan/out of scan) (vi) Data quality (type status) (vii)
Scan frequency (viii) Current alarm status (ix) Alarm limits.
The display of analog / digital outputs shall contain the following data:(i) PID number
(ii) Point description (iii) Current value/status (iv) Drive/device tag number (v) Update
status (active/blocked) (vi) Up date frequency
l Trend Plot features –
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Configuration of upto 4 pens per trend plot for real time and historical trending with a
minimum sample time of 1 second should be provided. Bidder to state the maximum
number of configurable trend groups and max. no. of historical points supported by
the system. The operator may view both real-time and historical trend displays.
Operators shall be able to build specific trend groups from a pre-defined set of points.
Trend comparisons between archived, real-time and historical data between the
same points offset in time or different points should be possible. It shall be possible to
view historical trends in operator stations in the same format as real time trends.
m X-Y Plots-
Facility to plot up to five (5) variables on vertical axis against one variable on
horizontal axis shall be provided. Minimum configurable scan rate to be 1 second.
Bidder to state the no. of X-Y plot variables configurable on a display page.
n Logs/Reports -Event activated logs/reports, time activated report consisting of daily
report of fuel receipt, fuel despatch to bunkers, fuel storage availability status, calorific
value, daily power consumption, Shift report etc.
8.20 Data Bus System

a The data bus system comprises the following:
i Main data bus for communication between Controller, OS and OES /
ES).
ii Communication controller
iii I/O bus to the Controller
b Coaxial or fibre optic data bus redundant in hot backup mode with a minimum
transmission rate of 100 Mbps or better shall be provided. The minimum transmission
rate shall be such that, the specified response time and update time are met
c Both the buses shall be active, and in the event of failure of one bus, the same shall
be annunciated and the other bus shall be capable of meeting the functional
requirement
d Provision for 25% expandability for connecting additional nodes after the completion
of engineering. Also, spare bus loading capacity shall be as specified under worst
loading conditions. The data bus system shall facilitate on-line addition/removal of
controllers without affecting the continuous operation of the plant. The communication
protocol shall have direct connectivity with Ethernet.
e Two types of buses shall be available in the PLC. The local bus which shall
communicate between the different modules / cards of the same station / system and
extensions. The main data bus shall communicate with the HMI. The bus
communication cable, bus couplers, bus interfaces, etc. shall also be redundant. The
data transmission rate on the HMI bus shall be commensurate with specified system
response requirements. The bus system shall be insensitive to external disturbances
(noise, electromagnetic fields, walkie-talkies etc,) and shall possess high security of
data transfer.
f All the communication bus cables shall be laid through separate (bus 1 and bus 2 in
separate) box type cable trays with covers/flexible metallic conduit with glands on
both the ends. Trays/conduit routing shall be complete covered including bends,
corners and cable entry points in panels.
8.21 Annunciation Functions: Annunciation functions shall be part of HMI software of the PLC
system. Speakers shall be provided in the OS / OES of the PLC for audible annunciation.
Based on the criticality of the alarm, the volume/tone of the annunciation shall vary. For
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those equipment controlled from the local control panel, hooters, indicating lamps shall be
provided for annunciation.
8.22 Engineering Tools: The tools should facilitate both Online and Offline Engineering of the
system. The functions consists of facility to generate control software through logic diagrams
without any programming knowledge, facility to generate graphic display and control
displays, facility to change/enter all the attributes of analog and digital I/O points, calculated
and boolean variables and constants like scan rate, process range, facility to perform all
functions of OS with locking facility, facility to test, configure/reconfigure process interface
modules/cards, facility to accumulate I&C faults to analyse downtimes and time to repair,
facility to run offline system diagnostic programmes, facility for on-line fault detection through
diagnostics and other maintenance engineer’s functions. Graphics/Database tools shall
comprise of easy use of GUI Icons/Menus to facilitate faster implementation.
The PLC system availability shall be 99.7% or better and the same shall be demonstrated
based on a procedure to be submitted by the Vendor during detailed engineering stage.
8.23 System diagnostics shall be capable of identifying locating and reporting the following faults
as a minimum
a) Processor fault
b) Communication fault
c) I/O module fault
d) Power system fault
e) Over temperature fault
f) Permanently close/open (stuck on or off) fault
g) Scan timer failure
h) Memory fault
i) Single redundancy fault.
Any other additional diagnostic alarm if available as standard shall also be provided by bidder
8.24 Input/ Output Module

a. Each I/O Module shall have its own processor working asynchronocally w.r.t to control
processor and other I/O processor.However I/O module configure in redundant
configuration, shall have their processor properly synchronized.
b. Each I/O Module shall be galvanically isolated from external control circuit by suitable
means, the minimum isolation level between I/O module and logic circuit shall be 1000
Volts DC.
c. Each I/O module shall be protected against reversal of polarity of the power voltage to
I/O.
d. Each input shall be provided with filters to filter out any noise in input line and contact
bouncing noise, as applicable.
e. All the inputs shall be double ended i.e. two wires per input and not with common
return for all inputs.
f. The interrogation voltage to the input and power supply for two wire instruments shall
be powered from separate redundant power supply / supplies.
g. Each I/O module shall have LED per channel to indicate the status of each
input/output
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h. When specified, input module shall be capable of monitoring the input contacts for any
wire open fault (i. e 4-20 mA)
i. The communication of I/O system with central processor shall be carried out
redundant with complete error checking.
j. Where inputs or outputs have multiple field devices for the same measurement or
device, the output shall be configure to separate I/O module .
k. Input module shall be suitable to accept input from proximity switches.
l. Digital output module shall provide output contact rated for 110V AC-5 Amp or 110V
DC 0.5 Amp.
1. input fault such as open circuit, short circuit and earth fault shall be detected IO
modules.
m. System shall provide 24 V Dc for loop powered 2-wite transmitter and shall also loop
power the 2-wire outputs.
9.0 TESTS FOR PLC & INSTRUMENTS
9.1 PLC
a Functional test (simulated) for the complete system (Refer Note-1), System
performance & tests for monitoring functions (Refer Note-2), Surge withstand
capability test as per ANSI C37.9A/ IEEE 4721 BE MMA 219, Damp heat
cycling test as per is 2106, part 1I- 1962 or equal, Dielectric strength test
(high pot tests as per NEMA ICSI. part ICS-109) ANSI C39.51/UL 508, Radio
frequency interference test as per SAMA PMC 33.1, Immunity to noise test
as per IEEE SWC test 587, Burn in test & temperature rise test for 120 hrs,
Continuity test & short circuit test for current limiters, Under voltage and over
voltage test (Refer Note-2), Simulation test for all control loops (Refer Notes-1
& 2), Factory Acceptance Test as per FAT Test Procedure submitted by
Bidder and approved by Purchaser.
b The following tests shall be performed: (refer notes 1 and 2)
i Demonstration of proper functioning of hardware
ii Demonstration of diagnostic features
iii Performance check of all redundancies, fail safe and fault tolerant
features of the system
iv Simulation and checking of all inputs, outputs, control loops and
protection and interlock functions.
v Checking spare system capacity and various scan time/response time.
vi The interface fiber optic cables which are part of Bidder’s scope shall
be used for testing with the as required lengths for site connection
vii Power consumption and power failure protection checking.
9.2 Field Instruments-Calibration test, Hydro test (1.5 times max. Pr.), contact rating test for
switches, over range test, accuracy test, leak test, Bore concentricity test : +/-5% of
wall thickness & material test for temperature instruments, Insulation test (< =
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500M at 500VDC) as per ISA for RTD/T/C, seat leakage test & ball check for level
gauges, hysterisis test.
9.3 Solenoid Valves-Hydro test/Seat leakage test/CV test/Coil insulation test
9.4 Junction Box-Test for IP65 or equivalent/Material test
9.5 Interposing relays- Functional test, Temperature rise test, High voltage test, Limits of
operation test, Insulation test
9.6 Bunker Level sensors-Functional Test, Accuracy etc.
9.7 SITE ACCEPTANCE TEST (PRE-COMMISSIONING FUNCTIONAL TEST)

a Site Acceptance Test (SAT) shall be executed after all the PLC and other I&C
equipment are installed at site, during pre-commissioning period.
b The Bidder shall present SAT test schedule and activities to the Purchaser or its
representatives 4 weeks before actual SAT starting date.
c The preliminary requirement for the SAT to start is submission of compliance report
for the FAT punch list to the Purchaser. Implementation of all the FAT comments shall
be duly verified during the starting of the SAT.
d The functional checks shall be verified during SAT using simulated inputs / outputs
and after the completion of the SAT and SAT is cleared by Purchaser. The PLC shall
be ready for pre -Commissioning loop checks.
e It is the responsibility of the Bidder to ensure that the contract schedule for PLC and
other associated equipment shall be such that all the above activities are completed
in time to meet the Overall Project schedule.
f Testing at site shall include the following:
i Complete loop checking with switches, instruments, actuators and other
accessories connected
ii Checking of sequence and interlocks
iii Software Communication between PLC's and DCS.
iv Pre commissioning trial and start-up tests
v PLC system performance tests
9.8 INSTRUMENTS FOR PERFORMANCE TESTING

a All instruments required for performance testing to prove the guaranteed performance
of the Instrumentation and Control Equipment shall be provided by the BIDDER for
the duration of the Performance Test. All the documentation shall be provided in CDs
in addition to the printed documents. All the software to retrieve online documentation
shall be supplied.
b All required maintenance tools and inspection devices shall be included in the
system.
c Access stairs, maintenance platforms and ladders as required shall be provided for all
instrument, transmitters, analyzers, etc near the respective tap points.
d All the I &C equipment and systems covered in the specification shall be derived for
maximum reliability and availability.
ISSUE
P0

01-14-002-60001
SHEET 21 OF
e The I &C system should be designed with extensive self-diagnostics and

troubleshooting features. Facilities shall be provided for quick repair/maintenance and
on-line replacement of faulty modules.
Notes: -
1. Bidder will furnish in his proposal the test facility and details of the simulation
test available in their factory including their previous experience.
2. All these tests will be witnessed by PURCHASER or his representatives.
3. These tests will be conducted based on approved FAT procedure witnessed

and certified by PURCHASER / ENGINEER.
4. For equipment not listed above, the tests shall be as per the approved QAP.
ISSUE
P0

E&amp;I Technical Specification - Limestone Milling &amp; Handling System

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TATA CONSULTING ENGINEERS LIMITED

1.0 PROJECT INFORMATION

2. Owner’s Consultant : Tata Consulting Engineers Limited,

(a) Ambient Temperature

(b) Relative Humidity

Maximum in 24 hrs : 257.3 mm/m2

FILE NAME: TCE FORM NO. 329 R7

Maximum Monthly : 826.0 mm/m2

(d) Predomimant Wind Direction : West to east, North - West to South -

(f) Seismic Zone : Zone - III - ( As per IS : 1893 Part 3)

13. Wind Load

(a) Basic wind speed of 44 m/sec.

(b) Factor K1 shall be taken as 1.07

(a) Zone : Zone-III

Auxiliary electrical equipment to be supplied against this specification shall be

b) For motors rated upto 200 kW 415V AC, 3-phase, 4-wire, 50 Hz

c) DC motor starters, DC solenoids, DC 220V DC, 2 wire, unearthed DC

d) AC control & protective devices 240V, 1 phase, 50Hz, 2 wire AC supply.

FILE NAME: TCE FORM NO. 329 R7

The single-phase 110V AC supply shall

e) Uninterrupted power supply 230V, 1 phase, 50Hz, 2 wire AC supply

f) Lighting fixtures and space heaters 240V, 1 phase, 2 wire, 50Hz

g) Lighting fixtures and space heaters 240V, 1 phase, 2 wire, 50Hz

h) The above voltages may vary as follows :

AC supply Voltage variation  10%

FILE NAME: TCE FORM NO. 329 R7

ELECTRICAL SYSTEM REQUIREMENTS FOR LIMESTONE HANDLING

1.0 SCOPE OF WORK

FILE NAME: F-329-Rev-R6.docx TCE FORM NO. 329 R6

2.0 DESIGN CRITERIA AND EQUIPMENT SPECIFICATION

FILE NAME: F-329-Rev-R6.docx TCE FORM NO. 329 R6

All HT motors shall be provided with numerical motor protection relays

Tie feeder and Bus coupler:

FILE NAME: F-329-Rev-R6.docx TCE FORM NO. 329 R6

2.2 Service Transformer

2.3 415V LV Switchgear and Busduct

FILE NAME: F-329-Rev-R6.docx TCE FORM NO. 329 R6

2.3.4 All LT motors shall be controlled by ACBs/MCCBs/MPCBs/motor protection

2.3.8 Busbars shall be adequately supported on insulators. These insulators shall

2.3.9 MCCB terminals shall be shrouded.

2.3.16 Necessary changeover arrangement shall be provided between the two

2.3.18 20% spare terminal shall be provided in the terminal boxes.

FILE NAME: F-329-Rev-R6.docx TCE FORM NO. 329 R6

INCOMER & BUSCOUPLER:

• Motor rated less than 15kW - Current display type EOCR.

2.3.22 Following details shall be furnished by the BIDDER during detailed

i. General arrangement, foundation / fixing layout

ii. One line diagram

iii. Schematic diagram, BOM, etc.

3.0 HT/LT POWER AND CONTROL CABLES

FILE NAME: F-329-Rev-R6.docx TCE FORM NO. 329 R6

3.3 Power cables of 1100V grade, stranded aluminium conductor, XLPE

3.4 The following abbreviations are used applicable to these cables

A: Aluminium conductor, stranded, grade H4, class 2 as per IS

C: Copper conductor, stranded, class 2 as per IS 8130

W: Galvanised single steel wire

F: Galvanised single steel strip

AW/AS: Hard drawn aluminium single wire/strip

X Item not required

3.7 CONTROL CABLES

Control cables shall be 1100V grade annealed high conductivity stranded

Cables for instrumentation applications shall be stranded high conductivity

In situations where accuracy of measurement or voltage drop in control circuit

FILE NAME: F-329-Rev-R6.docx TCE FORM NO. 329 R6

E&I Technical Specification - Limestone Milling & Handling System

E&I Technical Specification - Limestone Milling & Handling System