INSTRUMENT & CONTROL PHILOSOPHY AND

Client Logo
DCS DESIGN CRITERIA

Gujarat Fluorochemicals Ltd

Dahej Complex
INSTRUMENTS & CONTROL PHILOSOPHY & DCS DESIGN CRITERIA
18 MW CAPTIVE POWER PLANT

DSCL ENERGY SERVICES COMPANY LTD.

2nd Floor, Kanchenjunga, 18, Barakhamba Road, New Delhi – 110001

Tel 0091 1123316801 Fax 0091 11 23319062

Client Name Gujarat Fluorochemicals Ltd. Document No. 5400-DE1-000-07
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 1 of 57
 INSTRUMENT & CONTROL PHILOSOPHY AND
Client Logo
DCS DESIGN CRITERIA

Client Name Gujarat Fluorochemicals Ltd. Document No. 5400-DE1-000-07

Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 2 of 57
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DCS DESIGN CRITERIA

Table Of Contents

1 BACKGROUND & EVOLUTION 3

2 ELEMENTS OF I&C SYSTEM 5

3 CONTROL PROCESSES 5

4 PACKAGE OF CONTROL SYSTEMS 9

5 LOGIC INTERLOCKS 19

6 REFERENCE DRAWINGS 20

7 INSTRUMENTS ACCURACY 21

8 CODES & STANDARDS 22

9 CALIBRATION & TESTING LABORATORY 26

9.1 CHEMICAL TEST LABORATORY INSTRUMENT 26

10 INSTRUMENTS PNEUMATIC AND ELECTRIC SUPPLY 27

12 SAMPLE MIMIC DIAGRAMS 44

Client Name Gujarat Fluorochemicals Ltd. Document No. 5400-DE1-000-07

Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 3 of 57
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1 Background & Evolution

Increasingly sophisticated instrumentation and control system are being used in all modern
industrial plants including power plants for achieving and maintaining:
 High operational efficiency
 High reliability and plant load factor
 Safety of plant and equipments
 High man-power productivity
 Environmental conformance

I&C system has evolved over a long period of time. Starting with simple mechanical control
system used mainly for control of feed water level in the drum to electro-mechanical,
pneumatic, electronic including PLC and PLC PC based system to the modern day DCS.
Introduction of DCS based control system makes it possible to achieve all of these objectives
from a common control system (depending upon the degree to which a plant wishes to
centralize and cost). DCS based system helps in developing good management information
system based on historic performance, trend analysis etc.-such system can also be interfaced
with overall business control system.

Even though DCS system has emerged as the preferred option for most of the power projects
being set up currently, it is still not uncommon to see some industrial boilers still equipped
with old mechanical system for control.

Following table shows a simple comparative evaluation of different types of control system:
Type Merits Demerits
Mechanical Very simple to install, Limited application
operate and maintain Limited range of control
Low cost Single element-non-
Does not require highly interactive
skilled professional Very slow response
Electro-mechanical Some interactiveness Slow response
possible Requirement of trained
Low cost man-power
Can be applied for most of Control logic has to be pre-
the systems ordained

Pneumatic Can control the entire Requires good quality air-

system additional equipments like
Good response air compressor system
Some interactiveness Response though better
possible than electro-mechanical,
Information generation still slower compared to

Client Name Gujarat Fluorochemicals Ltd. Document No. 5400-DE1-000-07

Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 4 of 57
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possible electronic
Control logic has to be pre-
ordained
Requirement of skilled
man-power
Electronic-PLC Relatively faster response Separate system (SCADA)
Interactiveness and required for information
integration possible management
Can operate without Difficult to integrate with
software processes outside the
present project boundary
Difficult to alter control
logic-limited flexibility

DCS Highest degree of Software driven-requires

interactiveness highly skilled personnel for
Modular construction configuration, operation
possible and maintenance
Can be integrated with
systems outside project Software hang up can create
boundary including for serious safety problem-
remote control from requirement of alternative
different location safety management system
Real time performance for critical areas like boiler
monitoring and analysis drum water level, turbine
Can be used for highest lubrication system
level of empowerment of
the operating level Requirement large space for
Possible to alter control I/O panels-space and air-
logic conditioning cost
Possible to build fuzzy
logic Most costly-cost of system,
Real time information cost of spares, cost of
management including O&M, cost of space and
generation of MIS for energy for space
different levels conditioning
Storage and retrieval of
history

Presently, only two options are exercised by most of the project developed-PLC PC based
control with SCADA or DCS. PLCPC based system offer the advantage of relatively simpler
software-earlier cost used to be lower. But now cost of DCS system has come down and more
or less is same as for PLC PC based system. Therefore, increasingly DCS is being used more
or less as standard system particularly for the boiler plant. Independent control system used in
other equipments and systems are usually hooked up partially or fully with the main DCS
system for development of an integrated management information system.
Client Name Gujarat Fluorochemicals Ltd. Document No. 5400-DE1-000-07
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 5 of 57
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DCS based system helps in developing good management information system based
on historic performance, trend analysis and event logging -such system can also be
interfaced with overall business control system locally as well as at remote locations.

The DCS provides a very high level of programmable control for managing
complexities, redundancy at power source, central processing and at field level. The
system has inherent supervision mechanism to continuously self monitor for correct
operation and fall back arrangement in case of problems.

The actual operations as Flow Chart and PID can be seen as mimic diagrams for
different packages. Sample mimic diagrams for some of the equipments have been
included in the section 12 for reference: (Actual mimic will be finalized at the time of
DCS engineering).

2 Elements of I&C system

The basic components of the entire system consist of following
elements/components:
1. Sensors: To act as primary elements and acquire information about status of
process variables and equipments. These cover all the basic sensing elements
like pressure, temperature, flow, displacement, chemical elements etc.
2. Transmitters: To act as secondary elements and pass on information
acquired by sensors to controller and sending controller decision to final
control elements. Transmitters can be both direct and indirect type. For
example pressure can be read directly using gauge and information processed
for control. However, such direct transmission is most of the time not feasible
due to physical and mechanical constraints. The information is therefore,
converted either into electrical or pneumatic signals for transmission to the
controllers, which are usually located at a central place.
3. Input/Output (I/O) devices-Required mainly for DCS system and PLC PC
based SCADA system for making the transmitter data compatible with the
protocol of the control/data management system
4. Controllers: Act as the brain of entire control system and help in decision
making based on built in programmable logic systems and execution of the
decision.
5. Final drivers: Act as tools to implement the decision of controllers and send
signal back for actions taken. Actuators, motors, power cylinders are some of
the commonly used field drivers.

3 Control processes
Of all the elements of an I&C system, it is the process control system, which is plays the key
role and provide opportunity for deriving the maximum value from the I& C system.

3.0 Controlling Operational Efficiency

The objective of the control system is to ensure:

Client Name Gujarat Fluorochemicals Ltd. Document No. 5400-DE1-000-07

Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
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 Monitoring & Control of designated parameters

 Provide Logic and Interlock systems
 Stability in case of process disturbances
 Low fuel consumption in the boiler by maintaining highest thermal efficiency
 Low steam consumption in the turbine by maintaining live steam, extraction,
bleed and exhaust pressure and temperature parameters
 Low auxiliary power consumption by optimizing power drawn by major
equipments like feed pumps and fans corresponding the load on the boilers
and TG sets

The control philosophy for maintaining each of the above objectives is illustrated with
few examples in the following summary table. Detailed requirements are worked out post
design of the P&ID system and optimization exercise on relative benefits.

Item Parameters Control blocks DCS-priority

Thermal efficiency Feed water steam Deaerator pressure 1
of boiler temperature and temperature
HP heater flow-TG 1

Combustion control Auto combustion 1

control system
Fan draft controls 1
Exit flue gas Soot blowing 2
temperature
TG Efficiency Main steam pressure Auto combustion 1
and temperature control system
Exhaust pressure Condenser hot water 1
level
Circulation water 2
temperature
Auxiliary power Feed pump load VFD 2
consumption Fans load VFD 1
CW pump loads VFD 2
CT fan loads VFD 1

3.1 Maintaining Safety, Reliability & PLF

For achieving high PLF, it is necessary:
 To control operational parameters within safe limit
 To monitor equipment conditions on a continuous basis
Since DCS systems are software based and problems do appear sometime causing
hanging of the system, there are views that the critical safety systems like boiler drum
water control, safety of turbine should be managed by mechanical supervisory control.
The following table shows how DCS and individual system can be incorporated to
address to both efficiency and safety concerns.
Client Name Gujarat Fluorochemicals Ltd. Document No. 5400-DE1-000-07
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 7 of 57
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Item Parameters Control blocks DCS-priority Individual

monitoring
system
Fuel Quality Moisture 2 1
Flow monitor
Feeder load Conveyor load 2 1
Individual 2 1
feeder motor
load
Ash Ash RAV operating 1 2
hoppers accumulatio
n in ESP,
Eco & APH 2 1
hoppers
ESP
interlock
DM water Conductivity Conductivity 2 1
meter & drain
control system
Return Conductivity Conductivity 1 2
condensate meter & drain
control system
Feed water Conductivity Conductivity 2 1
meter & drain
control system
Flow Flow control 2 1
system
Boiler Temperature Steam 1 x
steam needs to be desuperheater
temperatur controlled to station
e avoid Combustion 1 x
stressing of control
the
superheaters,
steam pipe
and turbine
Boiler Draft profile Fan 1 x
fouling Gas side VFD/Dampers 1 x
temperature Combustion
control
Soot blowers 2 1
control

Boiler aux. FW Pump Temperature 3 2

condition bearings, ID Vibration 3 2
monitoring and FD fan
bearings
Client Name Gujarat Fluorochemicals Ltd. Document No. 5400-DE1-000-07
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
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Turbine Various Several 3 (TCP) 1

operational pressures &
safety mechanical
systems & electrical
Turbine Various Temperature & 2 1
condition bearings and vibrations
monitoring lube oil
system
Turbine Steam Pressure & 1 x
pressure pressure at pressure drops
drop different
profile sections

*Priority under 2 and 3 indicate that these items can be configured from their own local panels.
x-Not required

3.2 Manpower Productivity

Theoretically, it is possible to control the entire plant from centralized DCS system. However,
depending upon the type of fuel used and reliability requirement, it becomes necessary to
deploy man-power more from safety considerations. Minimum man-power as per statutory
(IBR, Electricity rule etc) requirement has to be deployed in any case. Some of the optional
deployment areas include
 Combustion control-one operator for observing and taking corrective actions in
case of choking of chutes or inadequate flow of fuel
 Water management-One person per shift for attending to emergency in the feed
water and condensate system
 Fuel handling-One person per shift or day time (depending upon the running
hours of the fuel handling plant) for monitoring of the conveying system.
 Ash handling-One person per shift primarily to maintain the area clean
 TG system-two persons per shift-one at the control room and the second covering
both the operating and condenser floor
 Electrical-One person per shift covering the power evacuation system
 Laboratory-two persons per shift-one for collection and second for preparation of
samples for analysis of coal, ash and water
Rest all monitoring and control can be done from the DCS. The arrangement
suggested above is the long term goal. A detailed organization chart for manning
would be prepared on finalization of P&ID and I&C philosophy.

3.3 Environmental Conformance

Basic objective is to ensure smooth and safe operation of the ESP and Ash Handling system on
a continued basis. However, in some sensitive plants, additional systems may have to be
incorporated for maintaining ambient quality in the process plant as per norm.

3.3.0 Environmental Control

It has been envisaged to install an Electrostatic precipitator for the purpose of removal of
coal dust and ash from the Boiler exhaust gas. The environmental requirements are driven
both by external and internal considerations. External considerations include design of the
Client Name Gujarat Fluorochemicals Ltd. Document No. 5400-DE1-000-07
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 9 of 57
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plant and installation of monitoring system for conforming to statutes on control of water
and air pollution.
There are many sensitive chemical plants, which require more stringent environmental
quality so that products remain free of contamination. In such plants, additional
environmental control systems are required for the monitoring of ambient conditions around
the sensitive plants.

4 PACKAGE OF CONTROL SYSTEMS

It is possible to procure and install the I&C system on a turn-key basis for the entire power
plant. However, it is better to procure the same as part of individual plant package. As
discussed earlier, this helps in better management of the contract system with vendors relating
to performance guarantee. Accordingly, individual instrument package is recommended for
each of the following plant components.
 Boiler
 Fly Ash System
 Turbine
o Auxiliary Drives Control
o Turbine Control
o Condensing Control
o Oil System & Lube Oil Control
 ESP Controls ( Described Under Environment Control)
 RO & DM Water Control
 Cooling Tower & Pumps Control
 Fuel Handling Control
 Common Steam Header & PRDSH Controls
 HT Electrical Panel Control

Following table shows a typical summary of how the overall picture would emerge
integrating all the components shown above. Brief detail of individual system has been
discussed in the following section.

Central Control Panel Local Control Panel

ystem/ Equipment Open Closed Open Closed
Monitorin Opera- Monitor-
Loop Loop Alarms Loop Loop Alarms Op
g tion ing
Controls Controls Controls Controls
er DCS DCS DCS DCS DCS -- -- -- --
m Turbine DCS DCS DCS DCS DCS -- -- -- --
erator GCP GCP GCP GCP GCP -- -- -- --
handling system DCS DCS DCS DCS DCS
er treatment plant DCS -- -- -- -- PLC Based Control cum annunciation pane
water system DCS DCS DCS DCS -- -- -- -- --
liary cooling water
DCS DCS DCS DCS DCS -- -- -- --
m

Client Name Gujarat Fluorochemicals Ltd. Document No. 5400-DE1-000-07

Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
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DCS -- -- DCS -- Stand alone Control Panel

protection system DCS -- -- -- -- Stand alone Control Panel

& Ventilation system DCS -- -- DCS -- Stand alone Control Panel

pressed air system DCS -- -- DCS -- PLC Based Control cum annunciation pane
rical system DCS -- -- DCS DCS -- -- -- --
Oil System -- -- -- --
handling system DCS DCS DCS DCS DCS -- -- -- --

Client Name Gujarat Fluorochemicals Ltd. Document No. 5400-DE1-000-07

Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
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1.1 Boiler Control

The major control of the boiler and its auxiliaries includes the
following:
1. Three element drum level control
2. Combustion control
1. Super heated steam temperature control
1. Furnace draft control
2. Soot blower steam pressure control
3. HP heater – level control
4. Deaerator level control
5. Deaerator pressure control
6. PRDS control
7. CBD level control
8. LP & HP Dozing Control
9. SWAS ( Steam & water Analysis System)

4.0.0 Three Element Drum Level Control

Purpose
To maintain constant level in the steam drum by controlling the feed water flow required for
safety of the boiler and steam purity. This is the most important safety instrumentation for the
boiler. Abnormal variation in the level can endanger both human and equipment safety.
The multivariable three element control strategy is implemented in DCS having
analog inputs and the software function blocks to achieve accurate drum level control

Measured variable
a. Drum level :
Drum level is measured using three nos. of level transmitters with compensation for
drum pressure. For Boiler protection, level switches for very high and very low will
be derived in DCS using same level transmitters. 2 out of 3 logic for high-low alarm
will be generated in DCS, very high and very low drum level will be used for trip
logic. The 2 of 3 block output signal will be used through analog output module of
the DCS for remote water level indication on the operating floor.
It is also advisable to provide supplementary mechanical level indication and alarm
system at the operating floor.

Control logic
For normal operation median signal from two level transmitters are used as control
input signals. In case of failure of any one of two level signals the other input is
taken for control. Here any two out of three logic is followed for drum level control.
The median signal of the two level transmitters received by level controller is
processed in two PID blocks.

Drum level signal is density compensated using the drum pressure signal. Steam flow
signal is compensated by steam pressure and temperature signal.

Client Name Gujarat Fluorochemicals Ltd. Document No. 5400-DE1-000-07

Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
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4.0.1 Automatic Combustion Control

Purpose
To maintain main steam header pressure under varying steam demand and
simultaneously control combustion air flow and fuel feed so as to optimize
combustion to derive the desired fuel efficiency. This is the most important control
from economic consideration.
This control also serves the safety requirement by maintaining boiler steam pressure
within set limit.
Measure Variables:
a) Drum Pressure
b) Steam Flow
c) FD air Flow
d) Fuel flow

Control logic:
The measured header pressure value is compared with header pressure set point in
Master pressure controller. The master pressure controller will generate the fuel
demand signal for boiler. The fuel demand signal of master pressure controller is
wired as set point to individual fuel feeder VFD drives Steam load vs. air flow
requirement curve generate the air flow remote set point signal. Oxygen trimming
controller output is added with the steam load vs. air flow requirement curve
generated air flow remote set point signal, and send to the air flow controller (as a
remote set point. The FD air flow signal is sent to the air flow controller FIC-200 as a
process value. Final output from air flow controller will regulate FD air either
through inlet guide vane or through variable speed operation of FD fan. Either VFD
(more energy efficient) or damper driven by pneumatic power cylinders can be used.
IN case the load variation in the boiler is not much, later option can be used.

4.0.2 Superheated steam temperature control

Purpose
To maintain constant superheated steam temperature at the design temperature to
maintain the designed thermo-dynamic cycle efficiency and safety of metals.
This loop maintains a constant temperature of steam at secondary superheater outlet
for the control range of (usually 60-100%) of Boiler MCR load.

Measured Variables
a) Main steam line temperature is measured using a thermocouple.
b) The thermocouple’s output is connected to temperature transmitters.

Control Logic

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
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A cascade control strategy is followed to take care of secondary superheater response

to the spray water control provided at primary super heater outlet. The master
controller takes the input of main steam temperature and generates controller output
used as set point to slave controller. The slave controller gets process value of steam
temperature after attemperator and set point from master controller and regulates the
spray control valve through I/P converter Position feed back of spray control valve is
taken to DCS and displayed in CRT.
When the superheated steam temperature increases, the de-superheater spray control
valve opens and when the superheated steam temperature decreases. The
desuperheater spray control valve closes and thus maintains the temperature.

4.0.3 Furnace Pressure Control

Purpose
To maintain the furnace pressure constant at the desired value for the entire range of
boiler loads to maintain the desired combustion efficiency and safety of the furnace
chamber. This also ensures dust free working environment in the boiler house.

Measured Variables
The furnace pressure is measured by the transmitters with 1 out of 2 logic and is used
as process value signal to the controller

Control Logic
For normal operation median signal from two pressure transmitters are used as
control input signals. In case of failure of any one of two pressure signals the other
input is taken for control.
The output of controller will regulate furnace draft either through inlet guide vane or
through variable speed operation of ID fans.

4.0.4 Soot Blowing Operational Sequence Control

Purpose
This system automatically operates the soot blowers in a sequential manner for
maintaining cleanliness of the heating surface. Other advantages of this control
system are avoidance of sudden loading of the boiler and improved man-power
productivity.

Measured Variables
The controller can be set independently with a timer clock or from the measured
values of flue gas temperatures in the different sections of the boiler.

Control Logic
Fuzzy logic system can be incorporated for selective soot blowing in the different
sections of the boiler. Flue gas temperature and pressure drop in the section are

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
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monitored. The fuzzy logic system provides signal to the soot blower drive motors
in the sections requiring clean up as per the pre set protocol.

4.0.5 Soot Blowing Steam Pressure Control

Purpose
Soot blower steam pressure is maintained at the design value to have effective
removal of soot from the heating surfaces without endangering the safety of the tubes.

Measured Variables
Steam pressure pre and post PRV.

Control Logic
This is a simple conventional single element valve travel controller.

4.0.6 HP Heater Control1

Purpose:
This loop maintains HP heater level at a predetermined valve to maintain the heat
exchange performance.

Measured Value
Condensate level in the shell

Control Logic
This is a simple conventional single element valve travel controller.

4.0.7 Deaerator Level Control

Purpose:
The loop maintains the deaerator (D/A) level at a predetermined value.

Measured Value
The level is sensed by the level transmitters (LT-50A & LT-50B)

Control Logic
This is a simple conventional single element valve travel controller.

4.0.8 Deaerator Pressure Control

Purpose:
This loop maintains the deaerator pressure within a predetermined value to maintain
the temperature of the deaerator indirectly and safety of the vessel.

1
Not required for the GFL project at the moment but provision should be kept for future.
Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07
Distilleries, Ambala
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Measured Value
Pressure inside the shell

Control Logic
A single element pressure control can suffice-it is also possible to provide a cascade
control taking the secondary signal from deaerator temperature.

4.0.9 PRDS Steam pressure and temperature control

Steam Pressure Control:

This loop maintains the steam pressure at the PRDS outlet at a predetermined value. .
Steam Temperature Control:
This loop maintains the steam temperature at the PRDS outlet at a predetermined
value.
Spray Water pressure control:
This loop maintains the spray water pressure at the inlet of the PRDS injection point
at a predetermined value.

4.0.10 CBD Level control

The loop maintains the CBD vessel level at a predetermined value. This is required
only for very large capacity projects.

4.0.11 Feed Water System

4.0.11.0 Feed Water Transfer Pumps

4.0.11.1 LP & HP Dozing System Control

4.0.11.2 Feed Water Tank Level

These are optional systems, which can also be integrated with DCS.

1.2 ESP Controls

Purpose
This is required for maintaining emission level in the flue gas and also safety of
the ESP and the connecting ducts.

Measured variable
Mainly ash level in hoppers

Control logic
The control system comprises of operation control of the rapper system
and alarm annunciation for ash level.

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
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Impact rappers are individually adjusted for frequency, intensity and sequence.
This helps in modifying the intensity and impact of rapping depending upon the
nature of fuel and operating conditions like high moisture in rainy season. Inlet
fields can be operated at more frequent and higher intensity than outlet fields-
Helps in saving power.
Voltage controllers are provided in the TR sets for adjustment of the field
intensity depending upon the conductivity of the flue gas.

4.1 Fly ash handling system and control

Purpose:
Usually PLC based system is provided for extracting the ash in a sequential
manner from the various hoppers.

Measured variable
Level in hoppers. Usually not required as the system is set based on experience
and it is not necessary to automate the operation related to level logic.

Control logic
The controller is pre set with necessary timer devices.

1.3 Turbine Control System

Purpose

The purpose of the control system can be broadly categorized as follows:

1. Operational control
a. Speed
b. Load share
c. Extraction pressure for EC machines
d. Process steam load share for EC machines
e. Condenser vacuum
2. Safety
a. Over speed
b. Axial movement
c. Vibration

1.3.1 Governing and supervisory system

The operational control system is carried out by the governing system whereas the
safety system is controlled from the supervisory panel. The systems have been
more or less standardizes globally and not much inputs are required for
discretionary alternatives.

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
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Turbine manufacturers would provide the entire control system with additional
options for increased safety. This would be reviewed by the Consultant with the
client and freeze the control scheme.
For integration with DCS, it would be necessary to develop the philosophy so that
provisions can be kept be the TG set suppliers for interface of the required items
with the DCS.

1.3.2 Distributed control System (DCS)

Range of integration with the DCS system can be very wide. This includes:
a) Auxiliary equipment start / stop control logic and operations.
b) Turbine protection interlocks.
c) Alarm level computations.
d) Monitoring of all process parameters and fault event recording.
e) Sealing steam pressure control
f) Hot well level control
g) Turbine efficiency calculations
h) Real time trending of selected parameters

4.2 RO & DM water System Control

Purpose
To ensure right quality of water is delivered by the RO & DM plant to meet the
requirement of the boiler
Measured variable
The system has capability to measure following at different points:
1. Level
2. Pressure
3. Conductivity
4. pH
5. Internal Timers (Local PLC)

Control logic
The control system comprises of:
(a) Maintaining level in the tank
(b) Sequential start up and stoppage of the RO plant.
(c) Alarm and annunciation system

During the power on the process is repeated from the beginning as per above.

During the service cycle, intermediate flushing takes place for every 4 hrs. RO
Reject valve opens for 3 minutes after every 4 hours. While RO reject valves is
open PLC will ignore the pr. low signal.

In case of faults plant will stop as per given in valve opening sequence.

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 18 of 57
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4.3 Cooling Water & Pumps Controls

Purpose
The basic purpose is to maintain the quality and temperature of the cooling water
being supplied to the turbine and boiler sections.

Measured variable
Parameters to be measured
A. Transfer pumps
1. Pressure before discharge valve (local)
2. Pressure after discharge valve (local)
Above monitoring shows the pressure drop across piping system. It gives
data for VFD usage.
3. VFD – (local & DCS)
4. Common line pressure (Local & DCS)
B. Condenser cooling - to maintain vacuum in the condensing mode:
1. Inlet & outlet pressure – Pressure drop across condenser indicates the
fouling in the system ( local & DCS)
2. Inlet & outlet temperature – Temperature difference shows the cooling
pattern. It also gives indication of flow through condenser (local & DCS)
C. Auxiliary cooling – In each equipment
1. Inlet & outlet pressure ( local & DCS)
2. Inlet & outlet temperature (local & DCS)
3. BFWP requires maximum pressure (3.5 to 4.5 kgf/cm2). BFWP should
trip if cooling water pressure is less than the limit prescribed by
manufacturer. ( DCS)
Control logic
In addition to details mentioned above, VFD is used to optimize power
consumption by maintaining optimum temperature.

4.4 Fuel Handling Control

Purpose
For safe, efficient and stable operation of boiler, there should be continuous
feeding of required quantity of fuel in the boiler.

Measured variable
Following parameters are to be recorded and monitored:
1. Fuel conveying rate
a. Conveyor electric load
b. Coal flow
2. Fuel feeding
a. On/ Off indication of all the feeders
b. R.P.M of feeders

Control logic
Apart from indications, the system can also be hooked up with boiler combustion
control system.
Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07
Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 19 of 57
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4.5 SWAS (Steam & Water Analysis System)

Purpose
Being a relatively higher pressure system, it is of utmost importance that the boiler
delivers high quality and purity steam to the turbine.
.
Measured variable
Silica, pH and conductivity of Feed water, Blow Down water, Drum Steam and
Super heated steam, and Condensate

Control logic
The complete SWAS system has an independent microprocessor based analysis
system which is linked to the central DCS for purpose of monitoring the relevant
quality parameters.

4.6 HT Electrical Panel Control

All electrical systems are provided with their own individual control and
protection system including mimic on the panels. However, there can be option of
replicating some of the critical mimic and fault annunciation system in the DCS.

5 LOGIC INTERLOCKS
5.0 ID fan
ID Fan motor can be switched on, only when the following conditions are satisfied.
a) Normal water level.
b) ID fan suction damper closed (or) ID fan motor VFD in line.
c) ID fan winding / bearing temperature not high.

When ID fan motor comes to the rated speed, its suction damper can be opened. (or increase
the speed as per furnace draft while running on VFD)

The ID fan motor shall be wired, such that the motor can be started / stopped either
from DCS or from Local Push Button (LPB) or from MCC panel.

The ID fan motor shall be tripped, when the drum level is very high or very low

5.1 PA fan
PA fan motor can be switched on only when the following conditions are satisfied.

a) ID fan running.
b) PA fan suction damper closed (or) SA fan motor VFD in line.

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 20 of 57
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DCS DESIGN CRITERIA

When PA fan motor comes to the rated speed, its suction damper can be opened. (or
increase the speed as per furnace draft while running on VFD)

The SA fan motor shall be tripped; when the ID fan motor is tripped

5.2 SA fan
SA fan motor can be switched on only when the following conditions are satisfied.

a) ID fan running.
b) SA fan suction damper closed (or) SA fan motor VFD in line.

When SA fan motor comes to the rated speed, its suction damper can be opened. (or
increase the speed as per furnace draft while running on VFD)

The SA fan motor shall be tripped; when the ID fan motor is tripped

5.3 FD fan
FD fan motor can be switched on, only when the following conditions are satisfied.
a) SA fan running.
b) FD fan suction damper closed (or) FD fan motor VFD in line.
c) Furnace pressure not high.
d) FD fan winding / bearing temperature not high.

When the FD fan motor comes to the rated speed, its suction damper can be opened. (or
increase the speed as per furnace draft while running on VFD)
The FD fan motor shall be wired, such that the motor can be started / stopped either
from DCS or from LPB or from HT MCC panel.
The FD fan motor shall be tripped, when the ID fan motor is tripped (or) when
furnace pressure is high

5.4 VFD/Dampers of fans

These would be integrated with the boiler combustion control system

5.5 Main Steam Stop Valve (Manual) / MSSV Bypass Valve

(Manual) / Start-Up Vent Valve For Boiler
For industrial power plants, mostly manual operated valves are provided. However,
some clients prefer to motorize the staring and main steam stop valve. In such cases
start and stop buttons are provided for both local and DCS operation.

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 21 of 57
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DCS DESIGN CRITERIA

6 Reference Drawings
Important reference drawings for design and finalization of specifications of
the I&C system include:
1. P&I drawings
a. Master
b. Raw, treated and DM water system
c. Steam and water system
d. Boiler including feed water pumps, heaters and blow down
e. Chemical dosing system
f. Air and flue gas system
g. Cooling water system
h. Turbine lube oil system
i. Turbine condensate return system
j. Fuel handling system
k. Ash handling system
l. Fire water system
m. Instrumentation and compressed air system

2. Process flow diagrams

a. Master
b. HMBD
c. Boiler GA and flow sheets
d. Water and steam system
e. Fuel and ash handling
f. Compressed air system
g. Other utilities

3. Electrical
a. Single line diagrams

7 Instruments Accuracy
Accuracy

Flow / pressure / differential : + 0.1% of calibrated span

Pressure/temperature transmitters or better

Electro pneumatic converter : + 0.5% of span or better

Controller : + 0.25% or better

Panel mounted indicator / recorder : + 0.5% of full scale or

better

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 22 of 57
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Pressure gauges : + 1% or better

Temperature gauges : + 1% or better

Pressure switch : + 1%

Temperature switch : + 1% or better

RTD : Class B type

Response time < 20 secs
with thermo well

Thermocouple : Response time <30 secs

with Thermo well
Limit of error
+ 3 deg.C < 400 deg.C
+ 0.75% > 400 deg. C
Metering Basis

Following units shall be followed for metering different process

parameters

Pressure above 0.1 kg / sq.cm : kg / sq.cm

Pressure below 0.1 kg / sq.cm : mm WC

and draft.

Vacuum : mm Hg or mm WC

Differential pressure : mm WC
o
Temperature : C

Flow (gases) : N Cu.m /h

Flow (steam) : kg / h or t / h

Flow (liquid) : Cu. m / h

Flow (lob. Oil) : liters / hr

Level : %

Density : gm / litre

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 23 of 57
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DCS DESIGN CRITERIA

Conductivity : micro-mho /cm

Gas analysis : % by volume or as

prevailed
in the respective case

8 Codes & Standards

The design, manufacture, inspection, testing and installation of all
equipment and systems covered herein shall conform to the latest
editions of codes and standards mentioned below:

8.0 Temperature Measurement

i) Instrument and apparatus for temperature measurement - ASME
PTC 19.3 (1974).
ii) Temperature measurement - Thermocouples ANSI - MC 96.1 -
1982.
iii) Temperature measurement - Guide to electrical resistance
thermometry IS-2806. (1992)
iv) Industrial Platinum resistance thermometer - IS: 2848 (1986).
v) RTD Design code - DIN 43760, BS 1904 class II.

8.1 Pressure Measurement

i) Instrument and apparatus for pressure measurement - ASME
PTC 19.2 (1987).
ii) Bourdon tube pressure and vacuum gauges IS: 3624 (1987).

8.2 Flow Measurement

i) Instrument and apparatus for flow measurement - ASME PTC
19.5 (1972). Interim Supplement, Part-II
ii) Measurement of fluid flow by means of pressure differential
devices BS EN ISO 5167-1: 1992.

8.3 Instrument Switches and Contacts

i) Contact rating - AC services NEMA ICS-2 1978 (with revision
through
May 1983) Part - 2 - 125, A6000.
ii) Contact rating - DC services NEMA ICS-2 1978 Part-2-125,
A600.

8.4 Enclosures
i) Types of Enclosures - NEMA Std. ICS-6-1978 (with rev.1-4/80)
through 110.22 (Type 4 to 13)
ii) Racks, panels and associated equipment - EIA: RS-310-C
(R1983), (ANSI C 83.9 - 1972).
Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07
Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 24 of 57
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iii) Protection class for enclosures, cabinets control panel & desks
IS: 2147 - 1962 / IS: 13947 Part - I (1993).

8.5 Apparatus, Enclosure and Installation Practice in Hazardous

Area
i) Classification of hazardous area - NFPA 70-1984 Article 300.
ii) Electrical instruments in hazardous dust location - ISA-512.11
(1973)
iii) Intrinsically safe apparatus - NFPA 493-1978.
iv) Purged and pressurised enclosure for electrical equipment in
hazardous location - NFPA 496-1982.
v) Enclosure for instruments - IS: 2148 (1981) reaffirmed 1993.

8.6 Sampling System

i) Stainless steel material of tubing for sampling system - ASTM A
269-82 Grade 7P 316.
ii) Submerged helical coil heat exchanger for sample coolers
ASTM D-1192-1964.
iii) Water and steam in power cycle - ASME PTC 19.11.
iv) Standard methods of sampling system - ASTM D 1066-69

8.7 Control Valves

i) Flow equations for sizing control valves - ISA S 75.01 (1985)
ii) Valves - flanged, threaded and welding end: ANSI B 16.34
iii) Casting : ASTM A 216 / A 351
iv) Welded end connection : As per ASME boiler and
pressure vessel code /
ANSI B 16.34, B16.25,
B 16.11.
v) Forging : ASTM A 105 / A 182
vi) Defect removal : ANSI B 16.34
vii) Cleaning : ASTM A 380
viii) CV test : As per ISA procedure S 75.02
(1982).

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 25 of 57
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DCS DESIGN CRITERIA

8.8 Instrument Tubing

i) Dimensions of fittings - ANSI B-16.11.
ii) Code for pressure piping, welding hydrostatic testing - ANSI B
31.1.

8.9 Cables
i) Cable : IS 1554 Part - 1 (1988)
ii) Insulation : IS 5831 (1984)
iii) Sheathing : IS 5831 (1984)
iv) Armoring : IS 3975 Part-1 (1988) Reaffirmed
1992.
v) Fire retardant test : IEC 332 Part - 3
category A
vi) Oxygen index test : ASTM D 2863 - 1974.
vii) Color coding : IS 1554 (1988)
viii) Thermocouple extension cables : As per ISA standard.
ix) Elastomer insulated cables : IS 9968 Part - 1 (1988)

8.10 Instrument end connections

i) Threaded : NPT ANSI B 1.20.1
ii) Flanged : ANSI B 16.5
iii) Cable entry in junction boxes and instruments : NPT
ANSI B 1.20.1

8.11 Code Nomenclature

i) IEEE - Institute of Electrical and Electronics
Engineers.
ii) ISA - Instrument, Systems and Automation
Society
iii) NEMA - National Electrical Manufacturers
Association
iv) ANSI - American National Standards Institute
v) NFPA - National Fire Protection Association
Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07
Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 26 of 57
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vi) ASME - American Society of Mechanical Engineers

vii) IS - Indian Standards
viii) IEC - International Electrotechnical Commission
ix) ASTM - American Society for Testing Materials
x) EIA - Electronic Industries Association
xi) DIN - Deutsche Institute Normale

9 Calibration & Testing Laboratory

9.0 CHEMICAL TEST LABORATORY INSTRUMENT
It is proposed that the Client shall provide a suitable chemical test laboratory with
adequate facilities to carry out routine test round the clock for measurement of
various parameters of feed water, DM water, Coal, Condensate etc.
The equipments proposed to be procured are as follows.

9.0.0 INSTRUMENTS FOR WATER TESTING Qty.

1. Turbidity Meter 1 no.

2. pH Meter 1 no.
3. EC - TDS Analyser 1 no.
4. DO Analyser 1 no.
5. Spectrophotometer Meter 1 no.
6. Nessler Tubes 1 set
7. Electronic weighing scale - Digital 2 nos.
8. Electric Oven 1 no.
9. High temperature furnace 1 no.
10. Flame Photo Meter 1 no.
11. Desiccators 1 no.
12. Steam bath apparatus 1 no.
13. Hot plate 1 no.
14. Water bath apparatus 1 no.
15. Photoelectric Absorption Meter 1 no.
16. Glass wares 1 set
Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07
Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 27 of 57
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DCS DESIGN CRITERIA

 Conical flask of various sizes

 Pipettes
 Burrets
 Beakers
 Titrating Rod etc.
 Miscellaneous

17. Platinum / Nickel / Silica Dish & Crucible 1 set

Gooch Crucible 1 set
Borosilicate Glass beakers 1 set
Sintered Glass Crucible 1 set
Conical flask of Borosilicate Glass 1 set

9.0.1 INSTRUMENT FOR COAL ANALYSIS Qty.

1. Bomb Calorimeter (For CV) 1 no.

2. Electric Oven 1 no.

3. High temperature furnace 1 no.

4. Weighing scale - Digital 1 no.

5. Glass Wares 1 set

6. Sieves for sieve analysis of coal

a) 100 mm, 50 mm, 25 mm. 12.5 mm,

6.3 mm, leed & receiver. 1 set

b) 4.0 mm, 2.8 mm, 2.0 mm, 1.0 mm,

125 micron, 75 micron, lead & receiver. 1 set

7. Sieve Shaker 1 no.

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 28 of 57
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10 INSTRUMENTS PNEUMATIC AND ELECTRIC

SUPPLY
All Instrumentation system proposed to be designed for the following conditions

A. Pneumatic:

1. Instrument air supply pressure : 7 kg / cm2 (g)

Dew point – 40 oC

2. Pneumatic signal : 0.2 to 1.0 kg / cm2 (g)

B. Electric:

1. Instrument power supply : 110 V AC ± 5% 50Hz, 1

(UPS)
(For DCS)
2. Electric signal : 4 - 20 mA DC

3. Stand alone panels : 110 V AC, 1, 50 Hz

4. Annunciators : 110 V AC, 1, 50 Hz

5. Solenoid valves : 110 V AC, 1, 50 Hz

6. Any other : 110 V AC, 1, 50 Hz

Also refer enclosed annexure (Project information) for site condition.

Supplier shall indicate in the offer the total power consumption (kVA rating) and
total air consumption (Nm3/hr) for the plant

11 DCS -APPROACH FOR SPECIFYING

System specification for the DCS is usually jointly developed to match the
requirement arising out of the control philosophy annunciated by the client and the
requirement of various processes. This section provides a general overview to
sensitize the client on following aspects and design approach for the proposed
DCS system:
1. Design philosophy
2. System description
3. Design requirements
4. Redundancy requirement
5. Sub-systems
6. Operator inter-face
7. Engineering station
Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07
Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 29 of 57
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8. Storage
9. Performance monitoring
10. Communication
11. Plant performance monitoring
12. Sequential event recording

11.0 Design Philosophy

The system shall be modular & scalable in nature and facilitate easy expansion/up
gradation of modules to enhance its functionality or performance, if required, at a
future date. Offer shall indicate possible expandability of system.

The system shall be microprocessor based and shall use proven minimum 32 bit
processors for all the sub-systems. The microprocessor selected must be powerful
enough to execute the control and computational algorithms and fast enough to
meet the needs of the process to be controlled.

The system shall comprise of a standard library of control and computational

functions that are preprogrammed and stored in ROM. During the system
configuration, the user shall be able to select the appropriate functional blocks
from the library, link them together, set the various inputs and tune parameters
associated with each block.
Graphical user interface (GUI) shall be available as standard for programming
control loops.
The system shall have adequate memory capacity to store all the control and
computational algorithms and the database as required carrying out all the
functional specified. In addition the system shall have at least 40% spare memory
capacity (after commissioning) for application programming and configuration in
each sub-system for the exclusive use of the user. This spare capacity shall include,
but not limited to the following:

a) Control algorithms
b) Monitoring / alarming
c) Trend and historians collection Reports
d) Displays including user defined graphic displays.

System shall be such that in case of failure of any one CRT, it shall be possible to
perform its functions from other healthy CRT. Also CRTs shall fall back on each
other.
System I/O racks shall contain 20% installed spare I/O points. This shall cover all
types of inputs/outputs. These spare points in the I/O modules shall be wired up to
the terminals of the cabinets and ready for the usage in all respects. 20% spare rack
space (without installed modules) shall be provided & It shall be wired upto the

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 30 of 57
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terminals of the cabinets. Terminal blocks/ MCBs / Power supplies etc shall be
provided in the DCS cabinets for these spare also.

Each installed communication network shall have at least 10% spare nodes
available for future expansion. The system shall be designed with additional 10%
spare capacity (in addition to spares capacity mentioned above, including, but not
limited to the following :

a) I/O rack capacity

b) Power supply capacity
c) Communications to support the spare I/O

The reliability and availability of the system shall be very high to ensure
continuous running of the process under safe operating conditions. The downtime
shall be reduced to the minimum. To achieve the above objectives, the System
shall be manufactured using highest-grade components of proven quality.
Extensive burn-in testing of the hardware shall be conducted and strict quality
control measures shall be adopted during the manufacturing process to increase
the Mean Time Between Failure (MTBF).

The design shall include a wide range of self diagnostic routines in the reporting
of the system functions to detect and warn the operator about impending or actual
system failures. Depending on the nature of the diagnostic, each test can be
performed at startup / during operation on a periodic or continuous basis.

A self-diagnostic program shall be provided for troubleshooting down to the card

level. Vendor shall furnish graphics showing system status down to card level.
The DCS shall include extensive self-checking to detect malfunctions and
appropriately prevent system upsets. Any non-recoverable malfunctions shall be
alarmed and provide flags necessary to locate and correct the problem.
Components of the DCS shall be capable of being removed and replaced on line
without disturbing the process. (i.e. cards shall be replaceable without powering
down the rack).

The list of self-diagnostics shall include but not be limited to the following:

a) Input Diagnostics: A/D converter check, sensor out of range check,

excessive rate of change check, open T/C / RTD detection.
b) Configuration Diagnostics: I/O hardware check, Memory check.
c) Memory Diagnostics: ROM/EPROM sum check, Memory check.
d) Output Diagnostics: D/A converter check, output register check.

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 31 of 57
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e) External hardware check: Using Watchdog timer.

f) Power System Diagnostics: Monitoring various voltage levels.
Once a diagnostic test has detected a failure, the failure shall be reported to the
operator in the form of an alarm message in the CRT. The details of the fault shall
also be printed with time of occurrence in the alarm printer.
LED for channel status on module is required.
Each device with a direct AC power input shall be protected by suitably rated
miniature circuit breaker.
Each AC electrical power circuit breaker shall be tagged with a permanently
mounted metal nameplate with service description.
I/O hardware must be designed to withstand high level voltage surges where the
field equipment is subject to lightning strikes or large induced voltage spikes.
AI/AO modules shall have signal isolators. Minimum isolation voltage required is
1500 V.
I/O hardware must be designed to render the installed system immune to Radio
Frequency Interference (RFI) caused by the presence of walkie-talkies / FM
stations or other EMI generating equipment such as motor starters or relays.
Any system hardware shall not generate radiated electromagnetic emissions
excess of 1 volt/meter/MHZ at 1 meter from the equipment enclosure. Design
shall incorporate such techniques as isolation, shielding, grounding and gasketing,
filtering and bonding as necessary to meet this requirement.
The system shall be provided with a shared communication facility over which the
various sub-systems can communicate with each other to meet all functional
requirements.
The communication facility shall be designed to operate satisfactory under heavy
traffic conditions, such as during a major plant upset. The message delay time and
undetected error rate of the network shall not degrade in any significant way
during these conditions.
The communication facility should be expandable for future applications without
requiring major restructuring.

The communication facility should be designed in such a way that the failure of
any one of its components will not affect the performance.
The communication facility must have provision for interfacing the DCS with
other personal computer systems, laptops and peripherals using Ethernet interface.
DCS system shall have the facility to accept the data from plant system & also it
shall have facility to transfer the data to other plant.
The operations for setting up, starting, or restarting the communication facility
should be simple and automatic. The facility should have self-diagnostic features

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 32 of 57
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to detect and announce the internal faults. It should be possible to replace the
faulty modules while the rest of the system is powered and operating.
The shared communication facility shall adopt STAR/RING topology for the
network communication protocol.
To improve the security of message transmission the following levels of protection
shall be provided as a minimum.
The shared communication facility should support Gateway/Computer Interface
Devices (CID) to interface general purpose computers and other external devices to
the DCS. These Gateway/CID shall have the following features.
It must be able to handle all types of messages transmitted over the shared
communication facility, These include analog and digital inputs from process
variables associated with control loops, control configuration and tuning data, and
the operational status of all the hardware in the system.
Information must travel across the interface at the speeds required by the
computer/external devices to perform its functions, consistent with the ability of the
shared communication facility to provide this information.
Time delay across the interface must be small in order to maintain the accuracy and
timeliness of the data.
Similarly, support of the interface should not place undue demands on the shared
communication facility.

DCS shall have capability to be hooked up to the Management Information

System (MIS) if required and installed by Client. Vendor shall check on supply of
required hardware / software and establish the communication with MIS.

Response Time
The system will have adequate speed of response through all regimes of system
loadings. The minimum conditions to be ensured are as follows.
For operator requested display, the response time will be 1-2 seconds under all
loading conditions. This time is defined as the time between pressing of last key and
appearance of last character on screen.
The digital input will be scanned and the database updated at an interval of 100
milliseconds.

Cycle time for open loop & close loop controls will be of the order of 200
milliseconds or better except the following which will be executed at a much faster
rate.
The interlock & protection control loop response time will be of the order of 100
milliseconds. The electro hydraulic turbine governing control loop response time
will be of the order of 100 milliseconds if controlled from the DCS.
Monitoring signals will be scanned every 500 milliseconds.

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 33 of 57
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On operator console, the dynamic parameters will be updated in one second

interval.
To avoid damage to the plant equipment in the event of a major failure in the DCS,
a safe shutdown of the plant must be guaranteed. The offer shall contain a detailed
description of the shutdown procedure.
The system shall be designed and implemented such that no single failure will cause
loss of other non-associated critical loops of control and the failure can be located
and repaired without taking the system off line or affecting the operation of the rest
of the system.
Reasonable facilities to permit maintenance and calibration shall be designed into
the system and equipment. All equipment shall be software programmable,
electronic, modular and of plug - in design. Client will accept delivery of the
system only after all components are mounted, wired and checked out in the factory
as a complete unit.
It shall be possible to make on-line and/or off-line program/configuration changes;
however, the main program/configuration stored in memory shall be protected
against unintentional destruction by power failure, tampering with operator's
controls, system generated commands, system malfunction or erroneous data or
program/configuration entry).
This system shall use standardized, module, plug-in construction so that any card
may be easily removed from the system and replaced without breaking or making
soldering connections. The number of types, kinds, categories, etc., of cards shall be
kept to a minimum in order to reduce the spare parts costs.

11.1 Redundancy

Redundancy shall be provided at following levels to improve system availability

and reliability.

(a) Controller level

(b) Power supply level.
(c) Communication level
(d) Client server level

11.2 Controller Sub-system

The automatic control functions of the system shall be executed by

microprocessor based controllers. PC based controllers shall not be accepted. The
design of the system shall adopt the following security objectives:

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 34 of 57
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a) Failure of a single control system element shall not shut down all automatic
control functions.

b) To ensure that the control outputs to the process are safe ones so that, if
critical automatic and manual control functions are lost, the operator can
shut the process down in an orderly and safe manner.

c) In the event of Power failure, configurations stored in the controller

sub-system shall not get lost up to a minimum of 1 year. Supplier to provide
sufficient battery to ensure proper back-up.

d) The loop cycle time for all closed loops in the controller shall not exceed
100 milliseconds. However electro hydraulic turbine governing control loop
response time will be of the order of 10 milliseconds if controlled from the
DCS.

e) The controllers shall primarily be used for regulatory control functions

only. However, the sequencing and interlocking capability of the
controllers can be used whenever specified during detailed engineering.
f) All controller racks shall be provided with redundant power supply.
Controller shall be able to operate in either manual, auto, cascade mode.
Mode change over in either direction shall be procedure less and bump
less.
g) It shall be possible to change set point, tuning constants, operating mode,
controller configuration etc., from operator's interface keyboard/ Engineer
interface keyboard.

h) The system shall be capable of sending the following messages to the

operator interface sub-system.

i) Self Diagnostic Alarms

j) Process Alarms

k) Loop status changes

l) The controller shall have facility for slow and fast ramping of set point and
output. Also all controllers shall have anti-reset wind up as a standard.

m) In cascade loops, the primary controller shall be able to track the set point
of the secondary controller while the secondary controller is not operating
in cascade mode.

n) The status values on various stages of Control algorithms being executed

by the Controller sub- system shall be visible on the CRT when the
Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07
Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 35 of 57
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Operator wishes to view the Control Loop Strategy. Supplier to furnish the
information possible to view and limitations in stages of the algorithms, if
any.

o) Controllers shall also be capable of being programmed from external PC.

Display ports shall be available on controller card to display various
programs/status.

p) Controller sub-system shall also perform the functions of data acquisition

system and protection/interlock system.

11.3 Input / Output Modules

Digital input (DI) modules shall be used to convert external binary signal (potential
free) from field to internal signal level DCS.

Input interrogation voltage shall be 110 V AC.

Each input shall be optically isolated to 1500 V DC and be provided with individual
fuses.

Not more that 16/32 inputs shall be connected to each card. Number of cards
required shall be worked out based on this.

Card should accept both NO & NC contacts (potential free).

All card failure status shall be reported on computer monitor.

LED indications shall be provided for fault status indication on the front panel and
individual input status indication on each module.

DI card should be capable of taking forced inputs.

Digital output modules

Digital output modules shall convert the internal voltage level of programmable
controller in to external binary signal level required to operate actuating / indicating
devices.

Digital output modules shall be able to source sufficient current while energising
field outputs. Outputs shall be 110 V AC. 5 A. Potential free contacts shall be made
available to motor START / STOP signal. Necessary interposing relays are included
in the Suppliers scope.

Digital outputs shall be short circuit proof.

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 36 of 57
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Each output shall be optically isolated to 1500 V DC and be provided with

individual fuses.

Digital output modules shall have 8/16 outputs (max.) per card. Total number of
cards required shall be worked out based on this.

LED shall be provided to indicate the status of output on the front panel and fault
status indication.

Output status simulation facility shall be possible on line.

Analog input modules

Analog input (AI) modules are used to accept field analog signals.

Modules shall be capable of accepting 4 – 20 mA DC or 1 – 5 V DC signals and

shall provide 24 V DC power to field transmitter. However when 4 – wire
transmitters are used Analog input cards shall be capable of accepting 4 – 20 mA
DC isolated signal.

AI modules shall be capable of accepting RTDs (3 wire, pt 100). Each channels

shall be individually configured. AI modules shall also be compatible for
thermocouple devices. Each channels shall be individually configured for J, K, T, E,
B, R, S or N thermocouples cold junction compensation shall be internal.

AI modules shall have maximum 8/16 channels per card. Total number of AI cards
required shall be worked out based on this.

Modules shall have cable break fault indication.

Analog output modules

Analog output (AO) modules shall be used to give input to the final control
elements.

Modules shall be capable of driving upto 700 ohms total loop resistance at 4 – 20
mA DC or 1 – 5 V DC selectable.

AO modules shall provide 1500 V DC isolation, field wiring to system black plane.

AO modules shall have maximum 8 channels per card. Total number of AO cards
required shall be worked out based on this.

AO modules shall have following two default option upon failure of the card to
receive fresh output from processor module
Hold last state.

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 37 of 57
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Predefined value.

Module shall have cable break fault indication.

11.4 Operator Interface

General
The Operator Interface Sub-system (OIS) shall be a well-engineered human
interface system to permit error-free interactions between the user and the
automated process control system.
The OIS shall be designed to permit the three distinct groups of plant personnel
(instrumentation and control system engineers, plant operators & MIS engineers)
to freely interact with the automated control system on a regular basis.
The instrumentation and control system engineers are responsible for setting up of
the control system initially and adjusting and maintaining it from time to time
afterwards. The plant operators are responsible for monitoring, supervising, and
running the process through the control system during startup, operation and
shutdown conditions. The MIS engineers are responsible for only monitoring the
process parameters. He should not be able to access the operator function.
Each Operator Station shall be configured for Operating a particular Process Unit.
In the event of failure of any Operator Station, the system shall be designed such
that the other Operator Station which is already configured for operating a different
Process Unit shall be used On-line for operating two Process Units. In addition all
CRTs shall fall back on each other.
The OIS in CCR shall be configured as indicated in Drawing No. 20-6965-I-351
The Operating system shall be well proven, multitasking and multi user type.
OIS in CCR shall be equipped with requisite number of:

a) Operator Stations with function keyboard and mouse.

b) Engineering Stations with function keyboard and mouse / MIS.
c) Dot matrix High speed printers.
d) SOE PC with 1 no DMP.
e) Color desk jet printer
f) B/W Laser printer
g) Hard disk drive units, floppy diskette drive units & CD ROM drive for each
operator console and engineering console.
h) Magneto optical disk drive (640 MB)/CD-Rewritable (650 MB) type for
Operator consoles and engineering consoles.
i) Sound cards.

All the above peripherals shall be functionally assignable & interchangeable

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 38 of 57
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OIS shall perform the following operator's and Engineers functions.

Operator’s functions

a) Plant graphic display

b) Alarm display
c) Plant control/Operation display
d) Logs and report generation
e) Real time and historical trend display
f) Plant performance calculations
g) Equipment characteristic monitoring.

Engineer's Functions

a) Generation & modification of graphics/displays/logs & reports.

b) Modification/addition of control loops
c) Controller configuration
d) System diagnostics
e) Maintenance logs
f) System configuration

The format for graphic displays shall be developed by the SUPPLIER based on the
P&I diagrams and also based on the philosophy framed up by the Client/Consultant
to cater to operation requirements. These formats generated by the vendor shall be
sent for CLIENT'S/Consultants comments/approval prior to the generation of
application software for the same.

Operator Console Displays

Available display pages shall include on a minimum 10 area displays and 12

group displays per area, all preformatted and 50 unformatted graphics pages.

Area Display
Area display shall provide an overall view of the alarm status and the group
organization of tags in a given area. Each area display shall accommodate at least
12 groups.
Group Display
Group display shall have loop displays in groups of 8. Group displays shall show
information pertaining to the loops associated with a group in the form of
controller or indicator face plates. Through these displays operator shall be able to
obtain loop information and manipulate loop parameters by using key board.

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 39 of 57
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Capability to assign any loop or variable to any group as well as to multiple

groups shall be provided.
The group shall be presented in a combined digital/graphic format. As a minimum
following information shall be indicated:

a) Input
b) Output
c) Set point
d) Tag nos.
e) Set point status
f) Control status (Auto/manual)
g) Drive status (Local/Remote, Running/Stopped/Tripped)
h) Service description

Operator shall be able to manipulate following minimum parameters. These

functions shall have dedicated keys on the key board.

a) Control mode (Auto/Manual)

b) Set point
c) Output (if control mode is manual)
d) Drive (Start/Stop/Reset)

The keyboard shall be designed to minimize the action required on part of

operator in performing a function. This shall include calling up displays,
acknowledging alarms etc. The use of dedicated function keys shall be
maximized.

Trend Displays
The format for these displays shall be capable of supporting simultaneous trends
of minimum eight variables. The trends shall be selectable as either historical (24
hour minimum) or real time with automatic updating. Each console shall support
historical trending for at least 200 points. These displays must be continuous type.
Bar charts type trends are not acceptable.

Alarm Overview & Alarm Summary Display

Alarm shall be displayed in chronological order in a table format with the most
current alarms appearing at the top of the display page. The alarm summary shall
handle at least 200 alarms.
When viewing the alarm page, incoming alarms must be displayed immediately
upon receipt.
Acknowledged process variable alarms returning to normal condition will be
erased from the alarm display page and the alarm page will be updated to remove
blank. Alarms must be able to be acknowledged from the alarm page directory.

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 40 of 57
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Status Display
Operator's console shall be capable of displaying system status displays, giving
operational status of the system on communication network status of each module
shall also be displayed. Interlock dynamic displays shall be generated with bypass
functionality.

11.5 Engineering Station

The Operator Station shall be used for engineering functions also and shall have
provisions for configuring, tuning and maintaining the DCS system. The Operator
and Engineering functions shall be separated out in a key lock. This shall have
provision for performing the following engineering functions.
a) Database configuration including configuration of all displays and loops for
various sub- systems.
b) Automatic downloading of the configurations in each sub-system.
c) Configuration of various Control functions or Control blocks to implement
various control strategies and downloading the same into the respective
Control stations.
d) Configuration / reconfiguration of alarm settings, their values,
addition/deletion of alarm from groups, controller tuning like changing
P,I,D values, dead time values etc.
e) Defining the key lock functions or Engineer keyboard functions.
f) On-line compilation of all types of dynamic graphic displays.
g) Setting of real time clock.
h) Disk/Floppy initialization.
i) Plant/group alarm inhibit function.
j) Start/Stop of each sub-system, including printers.
k) Enabling/disabling of different instruments/ peripheral connected to the
system.
l) Scan/off-scan of different tags connected to the system.
m) Preparation and compilation of logs/reports/ historical trend points.
n) Calling of detailed self diagnostic displays for maintenance aid.

o) Loading, editing, compiling and executing of all programs written using

High Level Languages supported by the system.
p) Online configuration changes shall automatically update all modules, tags
and subsystems affected by the change. Online configuration changes shall
follow a prompt validation sequence requiring a final acknowledgement
step before the change is transmitted.
q) It shall be possible to save all database and configuration data on both
removable and non- removable media for back up purposes without taking
the system off line.
r) It shall be possible to down load the data bases and configuration data to
all modules from a single location.

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 41 of 57
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Each analog input/output and analog control block shall be assigned as

engineering unit designation. Engineering unit shall be a minimum of 6 free
format alphanumeric characters. Engineering unit shall be automatically displayed
along with the variable. System shall accommodate at least 50 user configurable
engineering units.
If the operator station is not capable of doing engineering functions, a separate
engineering station shall be provided.

11.6 Mass Storage

Mass storage system shall be an integral part of the system. It shall be offered with
necessary hard disks, controllers and back up devices.
The Mass Storage System offered shall be capable of storing Process Events,
Alarm Events, Graphics, Logs, and Reports in addition to the functional
requirements of the system.
It shall be possible to store the trend for at least 400 process variables with one
sample every 1 minute for a minimum of 8 days. The sampling frequency will be
selectable from 1 second to 1 minute.
Historical recording shall also be possible for storing hourly, shift, weekly,
monthly averages for at least 100 process variables.
It shall also be possible to record the alarm events. Supplier to furnish in his offer
the alarm storage capabilities.
All events (such as changes in set points , Computer/Auto/ Manual mode changes,
alarm inhibits, changing over from one key lock position to another etc.) alarms
and messages shall all be stored as Historical messages and presented to the
Operator as and when required. This data storage shall also be for one week.
Supplier to furnish the maximum number of free format logs and reports the
system can store with the offered hard disk.

Supplier to furnish hard disk sizing calculations for the above requirements.

11.7 Performance Monitoring

The OIS shall perform calculations for performance monitoring. The above shall
include all required custom programmed software for performing the calculations.
All the calculations shall use high level language based on C++/ VISUAL C /
VISUAL BASIC. Calculations shall be made using floating point arithmetic.
These equations shall be changeable on-line at job site. An extensive set of steam
parameter subroutines based on the 1967 ASME steam tables shall be included.
The calculations results shall automatically be quality coded according to the
worst quality of any of the inputs to each calculation. The results of these

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 42 of 57
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calculations shall be available, through the data base, for appropriate logs and
operator displays as determined by the Client.
If performance monitoring calculations are not possible to be done in OIS, a
separate PC based performance monitoring subsystem with necessary gateways
shall be offered.
The Performance Monitoring package offered shall be a common unit connected
to the LAN acquiring data available on the LAN shall make all the calculation
results available on all Operator Stations.
The Engineering functions software offered shall be used for editing and
modification of calculation programs available on the Performance Monitoring
Sub-system.

Performance Calculations

Calculations for monitoring the performance of the various units and

auxiliaries shall be performed.
The calculations shall include those calculations that are required to determine the
performance of individual items of equipment and the overall unit. The
calculations shall be performed using averaged data over a period which shall be
selectively adjustable. The operator shall be able to input coal fuel analysis data
into the computer and initiate the calculations.
Boiler efficiency shall be computed by the heat loss method and the input output
method. Percent deviation between the two methods shall be calculated as
recommended in DIN 1942 standards, for Steam Generating Units. If the test
codes require measured data that is not actually available in the process, manually
substituted values shall be used.
The following calculations shall be performed:
a) Turbine heat rate
b) Boiler efficiency
c) Condenser performance
d) Turbine enthalpy drop efficiency
e) Aux. steam consumption
f) Aux. power consumption
g) Deaerator Performance etc.

The values of the above parameters shall be stored into memory each time these
are calculated, for a period of one month. Analysis shall be performed at the end
of the month to determine the long term deteriorating trends.

11.8 Communication

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
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The communication sub-system shall be a digital communication bus that

provides a high speed data transfer rapidly and reliably between the various
sub-systems.
Communication sub-system shall be equipped with adequate redundancy,
consisting of separate communication bus and communication interfaces for each
node. A minimum Ten mega baud (throughput) data highway shall be provided.
Communication speed on the communication bus shall be sufficient to update the
OIS data base minimum once every second. The overall system performance
including display update time shall be independent of the loading of the bus.
Healthiness of each bus shall be automatically tested periodically at regular
intervals without affecting system operation.
Failure of a particular node shall not be treated as failure of Communication Bus.
Transceiver failure at a particular node shall not be displayed as Data Highway
failure. Bus and node devices shall be optically isolated.
It shall be possible to connect or disconnect any device from the system without
disturbing the operation.
In general, the transmitting message shall identify the transmitting and the
receiving device. The transmitting device shall receive a reply from the receiving
device on the receipt of correct message. Lack of response shall be considered as a
receiver failure.
The mechanism used by the communication system for error checks and control
shall be transparent. Error checking on all data transfer shall be done by cyclic
redundancy check and / or any other advanced codes.
Supplier shall indicate the maximum no. of redundant nodes the data highway can
handle. However the data highway offered shall have 50% spare nodes without
highway extender for future expansion.
Gateway sub-system (GSS) shall provide communication link between foreign
devices and DCS and converts data and protocol between the DCS and foreign
device.

Supplier shall furnish the details of all available communication protocols and
hardware information for interfacing with foreign devices.
GSS shall store configuration data, tag status and provide necessary data
conversion, buffering and sequencing necessary to perform an efficient
interchange of information between DCS highway and foreign device.
GSS shall acquire all defined programmable controller data and provide a cutout
function that suppresses unnecessary alarms from a secondary point.
It shall be possible to write/read any input/output tag to/from foreign device from/to
the DCS.
Supplier shall clearly bring out the maximum number of tags the gateway can
handle and time taken for the operator action to get effected in the field, if

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
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operator simulates a particular output in DCS. Supplier to indicate the time taken
to view in the CRT after an input change is effected.
The number of GSS shall be as per system configuration drawing.
The GSS shall provide communication link between DCS data highway and other
foreign devices. The details of protocol will be given to the vendor later.

11.9 Plant performance Monitoring

One (1) No. Plant performance monitoring console shall be provided with CRT
and Printer. It shall acquire the input data from turbine, boiler and other
auxiliaries. Based on the inputs it will generate the set points which shall be given
to boiler/turbine control. This master control system shall be developed and
implemented in the plant performance monitoring console which shall optimise
the load on turbine. The necessary software and hardware for carrying out above
functions shall be provided by the Supplier.

11.10 Sequential Event Recorder (SER)

SER shall be part of the DCS with 1 ms resolution. It shall be suitable for 128
points. Memory shall be considered as per the requirement. It shall be possible to
take the printouts in the chronological order in auto/manual mode.
The complete time shall be printed out in hours, minutes, seconds and milliseconds
with each sequential event contact status change.
The system shall be capable of recording and storing a minimum of ten separate
sequence of events logs without data loss. When the event is completed, a sequence
of events recording (SER) log shall automatically print on the printer after a time
delay. The program shall operate to type out the events on a first in, first out basis
and shall print the sequence of events log in its entirely.

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
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12 SAMPLE MIMIC DIAGRAMS

Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
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Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
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Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
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Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
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Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
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Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

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Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

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Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
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Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
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Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
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Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

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Client Name Gujarat Fluorochemicals Ltd.NV Document No. 5400-DE1-000-07

Distilleries, Ambala
Project Name 18 MW Captive Power Plant at Dahej Complex Rev. 00
Prepared by: JH Chkd by: GCDR Date: 13.05.08 Issue Version: 02 Page 57 of 57