12/12/11

2.DISTRIBUTED

DIGITAL CONTROL,MONITORING

INFORMATION

SYST ...

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2.DISTRIBUTED DIGITAL CONTROL,MONITORING INFORMATION SYSTEM(DDCMIS) October 17, 2008
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2.00.00 DISTRIBUTED

DIGITAL

CONTROL,

MONITORING

AND

INFORMATION

SYSTEM

(DDCMIS)

The

microprocessor based distributed

digital

control,

monitoring

&

information

system(DDCMIS) shall

be

provided for the safe and efficient operation of SG, TG,

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balance

of plant and all auxiliaries in all regimes

of

Operation.

The following standards shall be followed for design, manufacturing, installation and commissioning of the Distributed Control System:

a) ANSI/ISA84.01

1996 - Application of Safety Instrumented

System.

b) lEe - 61151 - Functional Safety- Safety Instrumented

System for Process Sector.

c) IEEE - 1046 - IEEE Application guide for Distributed

Digital Control Monitoring for Power Plant.

d) ANSI/ ISA - 77.13.01_- Fossil Fuel Power Plant Steam

Turbine By-pass System.

e) NUREG - 700 - Human- System Interface Design Review

Guidelines .

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f) ANSI/ISA-18.1-Annunciation

Sequence and Specification.

2.01.00

GENERAL

REQUIREMENTS

2.01.01

The

requirements

for

distributed

digital

control

monitoring and information system(DDCMIS) are

indicated

on functional basis in this specification. Bidder

shall

be responsible for engineering, selection and connection

of

all

components and sub-systems to form

complete

system

whose

performance

is

in

accordance

with

functional, hardware, parametric and other

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requirements
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of this

specifications.

It is not

the

intent

or purpose

of this

specifications

to specify

all

individual

system

components

since

the bidder

has

full

responsibility

for

engineering

and

furnishing

of a complete

system.

2.01.02

SYSTEM CONFIGURATION

DDCMIS

shall

basically

consist

of

control

system

of

boiler,

turbine

& balance

of plant

(namely

SG-C&I,TG-C&I

&

BOP-C&I

including

their

respective

measurement

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system);

Man-machine

interface and

plant

information

system(MMIPIS);

system

programming

&

documentation

facility;

data

communication

system(DCS);integrated

sequence of events recording system(SERS);

Annunciation

system,

and

master & slave

clock system.

The basic configuration of DDCMIS shall be as

indicated

in the

DDCMIS configuration drawing No.CED/STP/I/821,822,

823 .

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2.01.03

SYSTEM EXPANDABILITY

Modular

system

design shall be adopted

to

facilitate

easy

system

expansion.

The

system

shall

have

the

capability

and

facility

for

expansion

through

the

addition

of

controller modules,

process

I/O

cards,

drive

control modules, hand/auto stations, and push button

stations, peripherals like CRT/ Keyboards, printers etc.

while

the

existing system is fully

operational.

The

system shall have the capability to add any new

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loops

groups/ sub-groups, in control system

while

the

existing system is fully operational.

2.01.04

ON LINE

MAINTENANCE

It shall be possible to remove/ replace on line

various

modules(like

I/O module) from its slot

for

maintenance

purpose

without

switching

off

power

supply

to

the

corresponding

rack.

System design shall

ensure

that

__ 1-.!

-1_'!

__

__

_ __

...l_,C.!

__

....1

_.!

,.!

.L..

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wnlle aOlng so, unaeIlnea

slgnallng

ana releases ao nOL

OCCur

and

controller

operation

in

any

way

is

not

affected(including

controller

trip

to

manual,

etc)

except that information related to removed module is not

available

to

controller.

Further, it

shall

also

be

possible

to

remove/

replace

any

of

the

redundant

controller

module without switching off the

power

to

the

corresponding

rack

and this will

not

result

in

system

disturbance Or loss of any controller

functions

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for main

controller.

The on line

removal/

insertion

of

controller,

I/O modules

etc.

shall

in no way

jeopardize

safety

of plant

and personnel.

2.01.05

FAULT

DIAGNOSTICS

The

DDCMIS

shall

include

on

line

self

surveillance,

monitoring

and diagnostic

facility

so that

failure/

malfunction

can be

diagnosed

automatically

down

to

the

level

of

individual

channels

of

modules

giving

the

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details

of

the fault on the

programmer

station

CRT

displays

supplies, sensor fault, any channel

fault

in

2V3 channels etc. These faults on CRTs as well as

local

indication

on

the

faulty

channel/module

and

on

corresponding

rack/

cubicle shall be

available.

The

diagnostic

system

shall

ensure that

the

faults

are

detected before any significant change in any controller

output

has taken place.

Failure

of any

I/O

modules,

,...nnt-rnl1,:::::::.r

,:::::d-,...

c::::h~ll

h,:::::::. qllit-~hlu

rrrr'lll"nAn

.:::Inri

.:::Innlln,...i.:::lt-~rI

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~~ .. ~~~~~~~

2.DISTRIBUTED
~~~.~

DIGITAL CONTROL,MONITORING
~~ ~~~~~~~.l ':l~~~.t'~~

INFORMATION
~ .. ~ ~ ....

SYST ...
~ .. ~~~~~~

.. ~~~

to annunciation facia and to OWS(Operator work Station).

2.02.06

FAULT TOLERANCE

The DDCMIS shall provide safe operation under all

plant

disturbances

and on component failure so that under

no

condition the safety of plant, personnel or equipment is

jeopardized. Control system shall be designed to prevent

abnormal

swings

due to loss of

control

system

power

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supply,

failure of any control system

component,

open

circuits/ short circuits, instrument air supply

failure

etc.

On

any

of

these

failures

the

controlled

equipment/parameter

shall either remain in last position

before

failure

or shall come to fully

Open/ Close

or

ON/OFF

state

as

required for

the

safety

of

plant/

personnel/

equipment and as finalised

during

detailed

engineering.

2.01.07

DDCMIS

shall

meet all

requirements

stipulated

under
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other

sub-sections/sections

of

the

specification

including

general

technical

conditions.

General

technical

requirements, quality

assurance,

parametric

requirements etc.

2.01.08

SIGNAL

EXCHANGE

All

the

signal exchange

between

various

functional

groups of each control group ( i.e. within SG, TG & BOP

C&I) shall be implemented through redundant main

system

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bus

{The

main bus connecting

various

sub-systems)and

local

system

bus

within

sub-system

as

per

the

standard

practice of the bidder.

It shall

be

ensured

that any single failure in electronics involved for such

communication,

e.g.

communication

controllers,

bus

interface

modules, physical communication

media,

etc.

does

not

result in loss of such signal

exchange

and

there

in no deterioration in specified system

response

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and

system

parametric

requirements.

In

case

controller

utilizes

some

inputs

generated/

processed

by

any

other

controllers/functional

group

and

the

requirement

of controller

response

time

as specified

in

Clause

2.04.02

is

not

met

due

to

inadequate

communication

rate/

procedure,

then

the

bidder

shall

provide

hardwired

signal

exchange

for

such

inputs.

Bidder

shall

furnish

documentary

evidence

through

its

standard

catalogues

and drawings

explaining

as

to

how
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this

requirement

is being met by them.

Bidder

shall

also

furnish

along with the above documents,

list

of

coal

fired thermal power stations where

the

proposed

scheme

for

such signal exchange

is

already

working.

Further,

bidder

to

note that if

his

offered

system

cannot

meet

the

above

requirement

of

communication

redundancy

and specified system response

&

parametric

requirements

then

all the

signal exchange,

analog

as

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well as binary among various functional groups shall

be

carried out through hardwiring only and not through

bus

system.

However,

if

in

the opinion of the

employer,

few

signal

exchanges are found required

to

be

hardwired,

the

same shall be

provided by the bidder.

Control

&

protection signal exchange between control systems of SG,

TG

and

BOP C&I shall be

hardwired

only .

Protection

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signals

like MFT/Turbine/Generator

or tripping of unit

shall

necessarily

be

hardwired and

redundant

even

for exchange within

the

same

sub-system, as stipulated

in NFPA 85. Signal to or from BOP shall be galvanized or

optically isolated.

2.01.09

No

single failure either of equipment or

power

source

shall

be

capable of rendering

any

part/

system/sub-

system of DDCMIS in operative to any degree.

2.01.10 SYSTEM

SPARE

CAPACITY

Over and above the equipment and accessories required to

meet

the fully implemented system as per

specification

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requirements.

DDCMIS

shall have

spare

capacity

and

necessary

hardware/

equipment/accessories

to

meet

following requirement for future expansion at site.

2.01.10.01

10%

spare

channels in each

of

the

input/output

modules, fully wired up to marshalling cabinets.

2.01.10.02

Wired in space for 20% modules in each of the

system

cabinets

for

mounting electronic modules

wired

up to

corresponding

spare terminals in marshalling

cabinets

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such that implementation of any additional control loop/

logic

can

be achieved only by insertion

of

necessary

electronic modules(s) in system cabinets,

configuration

of

corresponding

controller

and

connection

of

inputs/outputs

at

field end of

marshalling

cabinets/

logic cabinets as applicable.

2.01.10.03

MMIPIS shall be provided with capacity to handle

25%

or

at least

No.of

each

type

of

peripherals

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additionally, like CRTs, keyboards, printers, PCs etc.,

over and above already specified, without any additional

hardware or software.

2.01.10.04

each

controller shall have

30%

spare

functional

capacity

to implement additional function blocks,

over

and

above

implemented

logics/loops,

further

each

controller

shall have spare capacity to handle

minimum

20%

additional

inputs/outputs of

each

type(including

2.01.10.01

&

02

above), over

and

above

implemented

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capacity.

Each

of

the

corresponding

communication

controller

shall also have same spare capacity as

that

of controller.

2.01.10.05

The data communication system (including main

system

bus

and

other bus system)shall have

the

capacity

to

handle the additions mentioned in clause

Nos.2.01.10.01

to

2.01.10.05.

This will be in addition to

50%

spare

capacity specified under this clause .

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2.01.10.06

20% spare relays of each type and rating, mounted and

wired in relays cabinets.

All contacts of relays

shall

be

terminated in terminal blocks of relay cabinets.

In

each

of

the relay cabinets 20% spares terminal

blocks

shall

be

provided

so that additional

relays

can

be

mounted and wired.

2.01.11

the spare capacity as specified above shall be uniformly

distributed throughout all cubicles.

The system

design

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shall

ensure that above mentioned additions

shall

not

require any additional controller/ processor/ peripheral

drivers

Power

supply

module, software

etc.

in

the

system

delivered

at

site.

Further,

these

additions

shall

not

deteriorate the

system

response

time/duty

cycle etc. from those stipulated in the specification.

2.01.12

DDCMIS

shall

meet system

performance

and

parametric

requirements as stipulated under specification .

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2.02.00

SYSTEM

DESCRIPTION

The

DDCMIS

shall

include

following

main

systems/sub-

systems.

The

DDCMIS

shall

work

in full

integration

&

conjunction

with

field

equipments/drives

like

pumps,

motors,

valves,

actuators,

dampers,

hydraulic

control

systems(eg.for

HP/LP

bypass

etc.)and

field

instruments

to

be

provided

by

the

Bidder.

The

DDCMIS

hardware

(controllers,

modules/

cards

etc.)shall

be

housed

in

cabinets

located

in

control

equipment
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room(CER) except for operation interfaces located in UCD

& UCP in unit control room.

2.02.01

CONTROL

SYSTEM

The

control

system along with its

measurement

system,

shall perform functions of closed loop control, sequence

control, interlock & protection of SG TG and auxiliaries

in all regimes of Unit operation.

The

measurement system of control system shall

perform

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the

functions of signal acquisition,

conditioning

and

signal

distribution of various types of

inputs/outputs

like analog (4-20 rnA DC, thermocouple, RTD)binary

pulse

etc. The inputs, which are required for only

information

& monitoring

purposes shall be distributed suitably

in

various groups of the measurement system.

2.02.02

MAN-MACHINE

INTERFACE

&

PLANT

INFORMATION

SYSTEM

(MMIPIS)

The MMIPIS shall perform control, monitoring & operation

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of SG,TG & auxiliaries in all regimes of unit operation,

interacting

with the control system.

For

this

MMIPIS

shall primarily perform following functions.

i)

Operator interface for control system.

ii)

Plant

Supervisory functions like

displays,

alarm

monitoring

&

reporting(reports

&

logs,

calculations,

trend recording, historical and long term data storage &

retrieval etc.) .

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2.02.03

SYSTEM

PROGRAMMING

& DOCUMENTATION

FACILITY

The

programmer

stations shall be provided for -

i) On line configuration & tuning of control system.

ii) On line program development/ modifications

in MMIPIS.

In addition, latest state of the art workstation

based

system documentation for the complete plant.

2.02.04

DATA

COMMUNICATION

SYSTEM

(DCS)

The

data

communication system shall be

provided

for

h.o.+-T.To.an

5:.

MMT"DTQ

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communication

&

signal

exchange

between

various

functional

groups

as

well

as

communication

between

various units & off site/ off line systems.

2.02.05

SEQUENCE OF EVENTS RECORDING SYSTEM(SERS)

The DDCMIS shall be

capable of carrying out sequence of

event recording function to

scan & record events in the

sequence of occurrence within a resolution of 1 milli sec.

2.02.06

MASTER AND SLAVE CLOCK SYSTEM

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Master

& slave

clock

system

shall

be

provided

to ensure

uniform

time

indication

throughout

the

various

plants

facilities

and

time

synchronization

between

controls

system,

MMIPIS,

switchyard

disturbance

recorder,

PLC's

etc.

2.02.07

ANNUNCIATION

SYSTEM

A facia

annunciation

system

shall

be provided

with

lamp

boxes

in the unit

control

room.

The annunciation

logic

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will

be

implemented as a part of DDCMIS through

which

the

lamp

boxes shall be driven.

However,

additional

facility

to drive stand-alone printer in case of

total

MMIPIS & system bus failure shall be provided.

2.03.00

MEASUREMENT FUNCTIONS OF CONTROL SYSTEM

2.03.01

All

the signals coming into/going out of

the

control

system

shall

be

connected either directly

or

routed

through

marshalling cabinets. The input/output

modules

employed

in the

control system shall be separate

from
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controller hardware.

2.03.02

ANALOG

SIGNAL

CONDITIONING

& PROCESSING

2.03.02.1

the

conditioning

and

processing

functions

to

be

performed as a minimum for the

analog input coming

for

control & information purposes are

i)

Galvanic isolation of input & output signals wherever

required.

ii) Transmitter

power

supply

with

per

point

fuse

protection

or

current limiting

and

power

supply

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monitoring.

iii)Transducer/transmitter

signal output limit check.

iv) Implementation of multiple measurement schemes.

v)

Square root extraction

vi) Pressure & temp. compensation.

vii)On line ADC gain & drift monitoring & correction

at

periodic intervals.

viii)Linearisation

of thermocouple signals.

ix) Reasonability check for all analog inputs.

2.03.02.2 all

analog

signals

for

control

purpose

shall

be

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acquired, validated, processed and their respective data

base

updated

at

maximum

interval

of

250

milli

secs.except for some fast acting control loops for which

the

above-referred

time

shall

be

as

per

process

requirement.

For signals required for information only,

the above functions shall be performed at an interval of

sec. The validated analog inputs shall be

converted

into engineering units on a per point basis.

2.03.02.3

The 4-20 rnA input analog cards shall be

suitable

for
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interfacing

transmitters giving 4-20 rnA analog

signal

along with super imposed HART interface signals. 4-20

rnA

DC signal will only be used for control purpose &

super

imposed

HART

signal will be

used

for

configuration,

maintenance

diagnostic

& record keeping

facility

for

electronic

transmitters

& analyzers etc.

2.03.03

BINARY

SIGNAL

CONDITIONING

& PROCESSING

2.03.03.1

The

changeover type contacts

(i.e.NC +

NO

together)

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shall be wired to the control system for all the

binary

inputs

required for control purposes, except for

input

from MCC/SWGR, actuators and inputs related to hardwired

signal exchange among various functional groups for which

non-changeover type contract(NC or NO) shall be wired

to

the

control

system.

The

binary

input

required

for

information

purposes

only shall be

wired

to

control

system in the form of non-changeover type contacts .

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2.03.03.2

The

conditioning

and

processing

functions

to

be

performed

as a minimum for the binary input coming

for

control & information purposes are

i) 24

V DC power supply for contact interrogation

for

all

potential

free contacts with

per

point

fuse

protection

or

suitable

current

limit

feature/

isolation

through optocoupler.

ii) Contact

bounce filtering delay time of 15 milli secs.

iii) Facility

for

pegging the binary

signal

to

logic
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one/zero or last correct value in case of failure of

binary input module.

iv) Binary

signal distribution to different user

shall

be in such a way so as to ensure that a short/ground

fault

on

one user is not reflected

to

the

other

user.

v) Implementation

of multiple measurement

schemes

for

signals for control purpose .

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vi) All

binary

signals

shall

be

acquired

validated

processed, alarm checked and their database updated

within

sec.

In addition

to

this

requirement,

binary

signals

required

for

SOE

shall

have

resolution of 1 milli sec.

vii)Checking for excessive No.of status changes for

all

binary/contact

inputs.

viii) Facility to delete any binary input from scan or

to

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return to scan on operator demand.

ix) The

non-coincidence monitoring shall

be

provided

for

binary

inputs

for

all

changeover

signals,

namely

process

actuated

switches

required

for

control purpose.

x) All relay contacts shall be hermitically sealed.

2.03.04

Two out of Three

Measurement

a)Triple

measurement scheme for analog

inputs

employing

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three

independent

transmitters connected

to

separate

tapping points shall be

employed for the most

critical

measurements used in analog control functions

including

the

following

but not limited to furnace

draft,

feed

water

flow,

throttle

pressure,

turbine

first

stage

pressure,

drum level, drum pressure,

deaerator

level,

turbine

speed.

Turbine control valve

position,

power

measuring

device

LP

&

HP

Heater

Level,

PA

Header

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pressure etc.

b) The three signals shall be auctioneered to determine the

median/average

value,

which will be

used

for

control

purpose.

In

case

one

transmitter

fails

or

shows

excessive

deviation with respect to others, it will

be

removed from computation of medium/ average value &

the

average

of the other two transmitter outputs

shall

be

used

for

controls.

The control loop

shall

trip

to

manual

when

any two of the three

transmitter

outputs
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shall be used for controls. The control loop shall

trip

to manual when any two of the three

transmitter signals

fail.

The operator shall be able to select any of

the

transmitters

or

the

median/average

value

from

the

control desk.

The outputs of the transmitters shall

be

continuously

monitored

for excessive

deviation

which

shall

be

displayed, logged &

alarmed.

c)

For MFT/ Turbine/Generator/Unit

tripping;Triple

Sensor shall

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be

provided.

d)

For auto starting of pumps, pump tripping due to

very Low

level of water, Triple Sensor shall be provided.

2.03.05

One Out of Two Measurement

a) Dual measurement scheme for analog inputs

employing two

independent transmitters, connected to separate tapping

points/

temp.

element

shall

be

employed

for

the

remaining measurements used for analog control functions .

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The

output

ot

the

redundant

transmitters

shall

be

continuously monitored for excessive deviation.

In case

the deviation is within limits, the mean value shall

be

used

for the control loop.

If the

deviation

becomes

high

(with

both transmitters remaining

healthy),

the

other

transmitter remains healthy, then the

output

of

the

healthy transmitter shall be used for control.

If

the

other

transmitter also fails, loop shall

trip

to

manual.

The

outputs

of

the

transmitters

shall

be

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continuously

monitored

for extensive

operation

which

shall be displayed and logged and alarmed.

Individual transmitter signal, their status and selected

value for control/measurement

shall be available on

OWS.

b) All sensor other than MFT (Boiler)Tripping, Turbine Tripping,

Generator Tripping etc. for

safety interlock.

c)

All pressure/ Temperature/Level

Switches in Control loop.

d)

All Water/ oil Tank level alarm for Very low .

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e)

All non critical Measurement

for Control loops.

f)

Any other service recommended by equipment manufacture or

IEC/ISA/ASME/Standard/

code .

2.03.06

For

Binary

and

analog inputs required

in

furnace

&

turbine

protection

triple

sensing

devices

shall

be

provided.

Binary and analog inputs which

are

required

for

protection of more than one equipment

(e.g.

flame

failure,

deaerator

level very low, etc.)

as

well

as

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devices

shall be provided.

For other

critical

binary

and analog inputs required for protection and

interlock

purpose

of

other

equipment,

dual

sensors

shall

be

provided.

2.03.07

Wiring

scheme for inputs to control system shall be

as

follows

2.03.07.1

Each

of

the dual triple redundant

binary

&

analog

inputs

shall

be wired to separate input

modules.

In

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addition,

for functions employing 2V3 controllers

like

BMS/Turbine

protection, each of the redundant binary

&

analog signals shall be

wired to separate input modules

associated

with

each

controller

in

line

with

configuration drawing of BMS & TPS & meeting requirement

stipulated

under

clauses

2.04.01

of

this

section.

Similarly

each

of the dual redundant binary

&

analog

inputs shall be

wired to separate input modules.

These

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redundant

modules shall be placed in

different

racks,

which

will

have

separately

fused

power

supply

distribution.

Implementation of

multiple

measurements

scheme

of

these

inputs

will

be

performed

in

the

redundant

hardware loss of one input modules shall

not

affect the signal to other module and also other channels

of these modules can be used by other inputs of the same

functional group.

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purposes shall be wired as follows

i) The

limit

&

torque

switches

and

the

MCC / SWGR

check backs

shall

be

wired to

drive

control

modules

wherever

provided.

For the drives where

OCM

are

not

provided,

these

signals shall be

connected

to

input

module only.

ii) Other

single analog & binary inputs shall be

wired

to

single input modules .

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2.03.08

The binary and analog outputs from one sub-system of the

control

system

to other which are

required

in

these

systems

for

control purposes shall be

made

available

from

triple/dual

redundant binary

and

analog

output

modules.

However, redundancy in binary & analog outputs

to

indicators/ recorders, SERS and

Annunciation

facia

lamps are not required.

2.03.09

The

signal

conditioning

functions

like

multiple

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measurement

schemes

square root

extraction

for

flow

signals,

pressure

&

temperature

compensation,

limit

value

computation

can

be

performed

either

in

the

controllers

or in signal conditioning

and

processing

hardware outside

controllers.

2.03.10

The

maximum No.of inputs/outputs to be

connected

to

each type of module shall be as follows:-

1.

Analog input module

16

2.
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...

16
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3.

Binary input module

32

4.

Binary output module

32

5.

Analog input & output(combined)-

16

6.

Binary input & output(combined)-

32

(Note:- For Binary inputs, one changeover contact is

counted as 2 inputs)

Further,

minimum 10% spare channels shall be kept in

each of the input/output modules.

2.03.11

The following requirements shall be met

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2.03.11.1 Input filters to attenuate noise shall be provided.

2.03.11.2

All analogi binary

input

shall

be

capable

of

withstanding

500 V DC common mode and 500 V AC peak

to

peak.

All analog outputs shall be short circuit

proof.

2.03.11.3

Common

mode noise rejection for analog inputs

shall

be

minimum 120 db at 50 Hz.

2.03.11.4

Normal

mode

noise rejection for

all

analog

inputs

shall be 60 db at 50 Hz .

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2.03.11.5

Surge Switch stand as per IEEE 472.

2.03.11.6

Any single sensor/transducer/transmitter

failure alarm

shall

be provided on I&C maintenance or

program

CRTs

for

all

sensors/transducers/transmitters.

Similarly

sensor break alarm for thermocouples etc. shall also

be

displayed on the CRTs.

2.04.00

CONTROL SYSTEM REQUIREMENTS

2.04.00.1

The

control system shall be broadly divided

into

SG

C&I, TG C&I and BOP C&I as already elaborated in

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2.01.02.

2.04.00.2

The SG C&I system shall perform the following

i)

Burner

Management System(BMS)including

control

&

protection of coal mills, fuel oil system etc.

ii)

Analog

control functions pertaining

to

secondary

air

damper

control,

Aux. PROS

pressure

&

temp. control etc.

iii) Soot Blower Control .

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2.04.00.3

The

TG

C&I

system

shall

perform

the

following

functions.

i) Turbine Protection System function (TPS)

ii) Turbine Governing System for main Turbine

iii) Turbine Stress Control System (TSCS)

iv) Automatic Turbine Testing

(ATT)

v) Automatic Turbine Run up System (ATRS)

vi) HP/LP Bypass Control System

vii) Turbine Generator Control System

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2.04.00.4

The

balance

of plant C&I system

shall

perform

the

following functions:

i) Analog control functions performing to the

other plant

areas

like coordinated master control,

furnace

draft

control, FW flow control etc.

ii) Binary

control

functions

pertaining

to

other

plant

auxiliaries

like FD/ID/PA/APH/BFP

etc.

and

electrical

breakers etc.

2.04.00.5

The No.of Functional groups (FGs)shown in elsewhere

in
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the

specification,

these

are

the

minimum

required.

However, splitting of any functional group in

more

than

one FGs due to any

limitation

in

bidder's

system

shall

be

acceptable,

subject

to

employer's

approval.

For

each

of

the

FGs,

separate

sets

of

controllers,

I/O

modules,

communication

controllers,

power

packs/modules etc. shall be provided.

Mixing

of

hardware

of

two or more FGs shall not

be

acceptable .

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2.04.00.6

The minimum functions to be

realized in each

of the above-mentioned controls systems shall be

as per

requirements specified

under subsequent clauses of this

specifications.

The

bidder

shall

provide

all

hardware/software,

whether or not specifically indicated

in

this

specification

to

fully

meet

operational/

maintenance/

safety requirement as well

as

statutory/

international standard and proven practices .

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2.04.00.7

The

control system shall function reliably under

the

environmental

conditions

as

specified

under

Part-C

ftGeneral Technical Requirement" of this

specification.

It shall be immune from the interferences resulting

from

disturbances

in

power

supply

feeders

signal

lines,

inputs,

outputs

etc. as experienced in

coal

fired

power station.

2.04.00.8

The

control system shall have

on line

simulation

&

testing

facility.

Further, it shall be possible to

on
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line configure & tune controllers through

configuration

& tuning station for control system.

2.04.00.9

The

system

shall have

the

flexibility

to

easily

reconfigure any controller at any time without requiring

additional

hardware or system wiring changes &

without

disabling

other

devices from

their

normal

operation

mode.

Modifications

shall not require

switching

off

power to any part of the system .

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2.04.00.10

The remote manual operation from

hardwired

back-up

AIM

stations

&

push

button (PB)stations (wherever

provided) shall

be

independent

of

availability

of

controllers & power supply to controllers.

2.04.00.11

The executive

programs for the

controller

modules

shall be

firmware based, which shall be non-volatile

&

shall

not be alterable except by replacement of

parts.

The application programs for the

functional controllers

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shall

be

software based which

shall

be

maintained

through

power supply failure.

The application

program

shall be

alterable through the configuration and tuning

station

for

all configuration and

strategy

changes,

etc.

and

through

the

operator's

console

for

set

point/

bias

changes,

device

selection,

etc.

Parts

replacement

or parts removal shall not be

required

in

order

to

accomplish changes

in

application

programs

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including system tuning.

2.04.00.12

All the 100% hot/redundant

back-up controllers shall

be identical in hardware and software implementation

to

their corresponding main controllers & shall be

able to

perform

all

its tasks. The

back-up

controller

shall

track its corresponding main controller.

There shall be

an

automatic

and

bump less switchover

from

the

main

controller

to its corresponding back-up

controller

in

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resulting

in any change in control status.

In case

of

switchover from main controller to the 100% hot

back up

controller,

the

back-up controller shall work

as

the

main controller.

Facility

shall also be provided for

manual

switchover

from main to 100% hot back-up controller and vice

versa

from the programmer's console.

2.04.00.13

The control system hardware design shall be such that

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it is able to withstand power line disturbances.

2.04.00.14

The

control system for

SH/RH

Attemp.

Temp. control

shall be

state controller with observer.

2.04.00.15 The hardware design shall be such that

it is able to

withstand power line disturbance.The

system shall conform

to ANSI/IEEE C 62.4 (Immunity to power supply line disturbance).

2.04.01

BURNER

MANAGEMENT

SYSTEM

(BMS)

2.04.01.1

Fully

proven microprocessor based system,

based

on

hardware

and software specifically designed and

proven

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for

Burner

Management application for the

same

being

offered

for

shall be provided to

achieve

the

Boiler

protection action e.g.master fuel trip(MFT), control

of

mills

&

fuel

oil

systems etc.

BMS

shall

meet

all

applicable

relevant safety requirement including

those

stipulated in NFPA- 8502.

2.04.01.2

The

BMS

shall

be

provided

with

automatic

self

monitoring

facility.

All modules to be

used

in

this

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system

shall be of fail-safe design.

Any single

fault

in

either

primary sensor, I/O

modules,

multifunction

controllers

etc.

should not result in loss

of

safety

function.

All

faults

should be

annunciated

to

the

operator

right

at the of its occurrence

and

also

for

alarm annunciation facia.

2.04.01.3

The MFT

functions shall be

implemented

in

fault

tolerant 2 out of 3 triple redundant configuration. Each

of

the

three independent channels shall have

its

own
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dedicated

processors,

multifunction

controllers,

communication

controllers, I/O modules, interface

etc.

All

safety related process inputs shall be fed to

each

of

the

channels.

All

the

primary

sensors

for

unit/boiler

protection shall be

triple

redundant.

2.04.01.4

The

acquisition and conditioning of binary and

analog

protection criteria signals for MFT shall be carried out

in

each of the three triple redundant

channels.

Each

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channel

shall compute

the 2 out of 3 voting logic

and

issue

trip command.

The trip signals of

the

three

channels

shall

be

fed

to a fail 2

out

of

relay

tripping

unit for each drive. The

protection

criteria

for tripping shall be executed by a

program which shall

be

identical in each of the triple

redundant

channel.

The

check back contact signals of each relay of

the

out of 3 relays tripping unit shall be

fed back to

each

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DIGITAL CONTROL,MONITORING

INFORMATION &

SYST ...

of

the

triple

redundant

channels

shall

be

continuously monitored for equivalence in each of them.

2.04.01.5

The functionality of operation of mills. oil etc.shall

be

similar to that of

OLes

described in clause

2.04.03

below.

2.04.02

TURBINE PROTECTION SYSTEM (TPS) FUNCTIONS

2.04.02.1 Fully

proven

microprocessor based

system,

based

on

hardware and software specifically designed for

Turbine

protection

application

for

the

same

turbine

being
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offered

for this project, shall be provided to

achieve

the turbine protection action.

2.04.02.2

The

Turbine

protection

system

shall

meet

all

applicable safety standards/requirements

including those

stipulated.

The system design shall be such that safety function

of

the

total system must not be jeopardized on

occurrence

of

fault.

Any single fault in either

primary

sensor,

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input/ output modules, controller

module etc. shall

in

no

way

jeopardized

the safety of

the

turbine.

All

modules to be used in this system shall be of fail

safe

design.

~.04.02.3

Bidder

shall provide two independent

trip

channels,

each having

its

dedicated

processing

module with

hot back up. Two out

of

three

voting

logic

will

be

implemented

in

each

of

the

channels

and

the

output of each channel to be

fed

to each of the

two

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turbine trip relays.

2.04.02.4

All

the

input signals

(trip signals

etc.

from

the

field

devices)

shall

be fed in parallel

to

all

the

three/ both the redundant channels of protection

system

as

mentioned

above

via

signal

conditioning

cards

designed for such application.

Further, the computation

of field input voting logics i.e. 2 out of

3 etc. shall

also

be performed in the controllers of all the

three/

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two

channels

of

protection

system,

which

will

then

perform

the

computation of field input

voting

logics

i.e.

out

of 3 etc. shall also be

performed

in

the

controllers of all the three/two channels of

protection

system, which will then perform the computation of 2

out

of 3 voting logic independently.

2.04.02.5

Bidder shall provide all the required primary

sensors

etc. required for protection system as per his

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standard
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and

proven practices.

All trip signal input

required

for the safety of the turbine shall be be based on 2 out

of 3 logics.

2.04.02.6

The

system

shall include

turbine

lock-out

relays,

redundant turbine trip solenoids and

necessary hardware

required for testing.

The tripping devices shall be designed to operate on

DC

supply.

The trip coils shall be monitored

continuously

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for healthiness and failure

shall be alarmed.

2.04.02.7 Turbine

Protection

System shall meet

all

applicable

relevant safety

requirement including those

stipulated

in ASME- TDP-1, VDE 0116, SecS.7; VDE 0160 etc.

2.04.02.S

TURBINE STRESS CONTROL SYSTEM (TSCS)

Bidder

shall provide a proven Turbine

Stress

Control

system

which

will

work in

conjunction

with

turbine

governing

system

and ATRS and

achieve

the

following

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2.DISTRIBUTED

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functional requirements.

a) Continuous

on-line monitoring of thermal stress

levels

in

all critical parts of the turbine such as main

stop

valves, control valves, HP casing, HP shaft and IP shaft

etc.

b) Continuous

on

line

computation

of

stress

margins

available for the above mentioned critical components of

the

turbine

during various regimes of

operation

i.e.

run-up,

synchronization,

loading,

load

maneuvering,
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2.DISTRIBUTED

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INFORMATION

SYST ...

normal operation, run backs, unloading, shutdown etc.

c) Computation

of

the limits of speed and

load

changes

allowable

at

any

particular

instant

before

synchronization and after synchronization respectively.

d) Carry

out

fatigue

analysis

for

all

affected

components

of

the

turbine and also

to

compute

the

percentage service life consumption of the turbine.

e) Display the stress margins etc. on a separate dedicated

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2.DISTRIBUTED

DIGITAL CONTROL,MONITORING

INFORMATION

SYST ...

colour

VDU/

Printer

as well as on

OWS

for

operator

guidance

and

storage

of

necessary

data

such

as

percentage service life consumption etc.

f) Store

long

term

data

&

carry

out

Residual

Life

Analysis.

The

system

shall

be

complete

including

measuring

transducers

for generator load and wall temp.

measured

value

processing

modules,

microprocessor

based

.L.

_..L...!

..L..

,_.! __

.!

~-

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2.DISTRIBUTED

DIGITAL CONTROL,MONITORING

INFORMATION

SYST ...

conLro~~ers

Ior

SLress ca~cu~aLlons ana

LurDlne

~lIe

calculations etc. dedicated colour

CRT monitor etc.

2.04.03

BINARY CONTROLS/OPEN LOOP CONTROL SYSTEM(OLCS)FUNCTION

2.04.03.1

The

OLCS shall include sequence control, interlock

&

protection

for

various

plant

auxiliaries/

valves/

dampers/ drives etc.

The sequence control shall provide

safe and

automatic

startup and shutdown of plant

and

of

plant

items

associated with a

plant

group.

The

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2.DISTRIBUTED

DIGITAL CONTROL,MONITORING

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SYST ...

interlock

and

protection

system

shall

ensure

safe

operation

of

plant/ plant items at all times

&

shall

automatically

shut down plant/ plant items when

unsafe

conditions arise.

2.04.03.2

The

OLes

shall

be

arranged

in

the

hierarchical

control structure consisting of unit level group

level,

subgroup level & drive level (as applicable).

It shall be possible to perform automatic unit startup &

shutdown by issuing minimum No.of command from the

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Thus,

the

unit

level shall control

all

the

control

system

blocks and issue appropriate startup &

shutdown

commands to various blocks of control system.

The

group level shall control a set of functional

sub-

groups

of

drives. Appropriate start-up and

shut

down

commands

shall

be issued to the

sub-group

control

&

various check backs shall be received from

sub-groups or

drives.

Each

sub-group shall execute

the

sequential

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start-up

and

shut

down

programme

of

set

of

inter-related

drives

along with system

interlocks

and

protections

associated with that sub-group as

well

as

basic

interlocks

& protections

related

to

individual

drive

falling

under that sub-group.

The

drive

level

shall accept commands from the sub-groups, push

buttons

etc.

&

transmit them to the

respective

drive,

after

taking into account various interlocks & protections and

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the safety of that particular drive.

2.04.03.3

Sequence Control

2.04.03.3.1

A sequence shall be

used to move a set of

groups,

sub-groups

from an initial steady state

(for

instance

'OFF') to a final steady state (for instance 'ON').

The

sequence

initiating command for the

unit & group level

shall be issued from CRT/KBD.

2.04.03.3.2

A sequence shall be

made of steps. The steps

shall

be

executed in predetermined order according

to

logic
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criteria and monitoring time consisting of the interlock

& protection

requirements and check back of previous step

which

shall act as preconditions before

the

sequence

control

can

execute

the

command

for

that

step.

2.04.03.3.3

Each step shall have a "waiting time" implying

that

the

subsequent

step would not be executed

unless

the

specified time elapses.

A monitoring time shall also be

defined as

the maximum time required

in executing

the

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commands

of

any

step

and

the

time

required

for

appearance of checks backs signals.

In case, this is

not

completed within the

specified time, a message shall be

displayed and program will not proceed further.

2.04.03.3.4

Manual intervention shall be possible at any

stage

of operation and the sequence

control shall be able

to

continue at the correct point in the

program on

return

to

automatic control.

Protection commands

shall

have

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priority over manual commands, and manual commands shall

prevail over auto commands.

2.04.03.3.5

Open or close priority shall be

selectable for each

drive.

2.04.03.3.6

The

sequence

start-up

mode

shall

be

of

the

following types.

i) Automatic Mode

In this mode of operation, the

sequence

shall progress

without

involving

any action from the

operator.

The
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INFORMATION

SYST ...

sequence

start/stop command shall be

issued

from

the

CRT/KBDs.

ii) Semi-Automatic Mode

In

this

mode

of

operation,

once

the

sequence

is

initialized,

the

step progressing shall be

displayed

on

the

CRT.

But the step execution command

shall

be

prevented

and

shall be

sent by the operator

via

the

keyboards .

It

shall

be possible to

bypass

and/

or

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simulate

one or more criteria to enable the program

to

proceed.

This facility shall allow the program

to

be

executed even if some criteria are not fulfilled because

of

defective

switching device, etc. while

the

plant

condition is satisfactory. It shall be

possible to

put

the system on the Auto-mode after operating it on

semi-

automatic

mode

for some steps or

vice-versa,

without

disturbance to the

sequence operation .

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DIGITAL CONTROL,MONITORING

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SYST ...

iii)

Operator Test Mode

It shall be

possible top use the sequential control in

operator guide model test mode i.e. the complete

system

runs

&

receives

input

from

the

plant

and

the

individual

push

button

stations

(where

provided)/

keyboards

but its command output is blocked. the

whole

program,

in this case shall run in manual

mode.

This

mode

shall

allow

the

operator

to

practice

manual

operation

using

step and

criteria

indications.

The
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actual

protection should remain valid during this

mode

of operation also.

2.04.03.4

The sequence shall be

started by putting the sequence

on 'Auto' and on receipt of 'Start' command from the OWS

or

from

higher level group/

protection

action

as

defined.

The sequence shall then progress as

per

the

defined

logics.

It

should

be

possible

to

select

alternative operation in the same sequence depending

on

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certain process/ equipment condition.

Some step can

be

automatically

bypassed also based on

certain

process/

equipment

condition.

When the expected results of

the

sequence is reached the sequence is considered as 'End'.

2.04.03.5

If

during

sequence

initialization

or

sequence

progressing

or

during normal running of the

drive,

shutdown

criteria

is present, the

sequence

shall

be

stopped and the shutdown sequence initiated .

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2.04.03.6

For

the drives, the command shall be provided

through

redundant

olp module and inputs (Status, SWGR

& process)

shall

be acquired through input modules.

The inputs

&

output

modules used in relation to drives shall not

be

mixed

with

inputs

&

output

modules

for

other

applications.

The drive logic shall be implemented

in

the

redundant controller.

The

status

of the HT drives and some

other

important

drives (total approximately 40 Nos. per unit) shall

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be wired in parallel to redundant input modules so

that

on failure of the single input modules, the

information

regarding

the

status of the

affected

drive

remains

available in OLCS.

2.04.03.7

The

output

modules

shall

have

the

feature

that

ensures

that

in case of failure, all the

outputs

are

driven

to zero.

The 24 V DC command outputs to

drives

for

ON/

OPEN,

OFF/

CLOSE

shall

be

separate

and

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independent

and

inverted

outputs

shall

not

be

employed.

For

inching

type

of

drives,

position

transmitter

power

supply and

monitoring

of

position

transmitter

signal

shall be provided.

2.04.03.8

The termination for OPEN/ CLOSE command for the

drive

actuator

shall be performed in the actuators

specified

elsewhere

in the specification.

However,

OPEN/

CLOSE

and disturbance status as a minimum shall be

monitored

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in OLCS.

2.04.03.9

The sequence interlock & protection requirements shall

be

finalised during detailed engineering and the

same

shall be subject to employer's approval.

2.04.03.10

The

OLCS

shall

also

include

the

control

of

electrical

systems

in addition to the

auxiliaries

of

boiler

&

turbine performing functions such

as

OPEN/

CLOSE or ON/ OFF etc. of various electrical systems such

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