DDCMIS PG Test Procedure Revision: 03

Doc No: SI1-0-TG-G-71-OOO-0003/9518-108-21-RU-PVM-W-011 Issue Date 23-Apr-15

Project: 3X660 MW Sipat STPP NTPC Page No. 1

NTPC Document :9518-108-21-RU-PVM-W-011 Formatted: Polish

Customer:

OJSC “POWER MACHINES”

Project:

SIPAT SUPER THERMAL POWER PROJECT

Stage-I (3 X 660 MW)

EMERSON PROCESS MANAGEMENT POWER &

WATER SOULUTIONS

Order No.: SI1-0-TG-G-71-OOO-003

Title:

PG Test and System Acceptance Procedure

Rev. Date of Issue
Emerson Doc No. : 3 23-04-2015

3 Performance requirements for CLCS test

(TABLE 1) parameters had been changed
Revision Revision Details Date of Issue

Prepared By Checked By Approved By

Konstantin Belemenko Wieslaw Jedynak Wieslaw Jedynak
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INDEX

1.0 Purpose & Scope.......................................................................................3

2.0 Outline .......................................................................................................3

2.1 Reference documents........................................................................3

2.2 Test Equipment .................................................................................3

2.3 Pre-conditions for conducting the tests .............................................3

2.4 General conditions to be observed ...................................................4

. PART-1

3.0 Closed Loop Control System Tests ..........................................................4

3.1 Performance requirements for closed loop controls..........................5

PART-2

4.0 Parametric Tests .......................................................................................7

4.1 Definition of worst case loading ........................................................7

4.2 Controller CPU Spare Duty Cycle .....................................................8

4.3 MMIPIS Controller CPU spare duty cycle..........................................10

4.4 Spare Capacity of working & bulk Memory........................................11

4.5 Ovation Network Spare Duty Cycle ...................................................11

4.6 Display response time........................................................................12

4.7 System Accuracy Requirements .......................................................13

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1.0 Purpose & Scope

The Purpose of this document is to explain the testing procedure to be followed for the
Performance Guarantee test of DDCMIS to demonstrate the conformity of the supplied
systems to the parametric requirement stipulated in the technical specification, towards
acceptance of the system by the owner.

This Performance Guarantee Test Procedure is applicable for the Distributed Digital
Control, Monitoring & Information System as configured, customized and supplied under
this contract and in line with the specification requirement.

2.0 Outline

2.1 Reference documents

The following documents shall be used during the tests

 All approved documents
 All standard system and O&M Manuals
 All design inputs from PM (ZEP Engineering) & NTPC Engineering.
 All MOMs and protocols signed during engineering & commissioning for
reference(ATST Report).

2.2 Test Equipment

Test equipment shall be used to measure/simulate process variables. The

following Test equipment shall be used during the tests.
 General Tool Kit
 Engineering and Operator work stations

2.3 Pre-conditions for conducting the tests

The Performance Guarantee Test shall be carried out at the site upon
confirmation of the following.
 Completion of commissioning of the system and full load operation of the
unit.
 All erection, pre-commissioning checks have been completed.
 Trial operation tests are successfully completed.
 All control loops shall be in Auto mode and Loops pre-tuned before start of
test.
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 Healthiness of all measurement schemes for indicators/recorders is

ensured.

2.4 General conditions to be observed

 Any equipment, if required, for conducting PG test shall be arranged and

calibrated. Valid calibration certificates shall be submitted.
 Necessary adjustments and tuning of the control system shall be carried
out prior to the start of the PG tests done. No adjustments shall be carried
out between the tests.
 DCS trend records shall be used wherever required.
 DCS log may be used for generating the required information.
 Final settings of all control loops shall be made available prior to the start
of PG tests.
 Number of coal feeders in operation and the unit load at the time of test
shall be recorded. Oil flow shall be recorded in case oil support is there.
 Process or equipment limitations which may affect the performance of the
closed loop controls shall be noted.

3.0 Closed Loop Control System Tests

3.1 Performance requirements for closed loop controls

Outline
The closed loop Control System shall provide automatic control of the plant for
full applicable operating range of the unit. The closed loop Control System shall
permit the performances of the dynamic load tests (ramp test, steady state test &
step tests) while maintaining safe furnace conditions, major process parameters
and without endangering other equipment. All tests will be performed with the
system in automatic mode.

During the load variation/run back tests, if stability of furnace is endangered due
to the reduction of unit capability, then oil supportproper action will be taken by
customer manually/automatically.

Objective

During transient conditions causing deviation of process variables, the control

system shall not permit causes deviations, which exceed those permittedsafety
operation limit bydefined by the manufacturers of controlled process equipment,
for load changes as per Table-1 below. The exact parameters to be monitored for
this test and the allowed deviation limits are given in the Table - 1 below, against
in theaccordance the applicable transient conditions.
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Procedure

Necessary fine tuning of the control system shall be completed and all the loops
shall be running in automatic operation.
Steady load operation definition is missing. (contract?). (the steady load means Comment [JW1]: I did not find it .,
that the load setpoint does not change within the last one hour ) Formatted: Right
(a) Drop 50% of maximum load capability from approximately full load at a rate of Formatted: Font: Italic
10% per minute.
(b) Drop load from full ratedBCR output to the lowest runback limit, at a rate
corresponding to the fastest run back rate.
(c) Pick up 50% of the maximum load capability (MCR) from approximately 50%
load at a rate of 10% per minute.
(d) Following runback conditions shall be proved without any oil support. Comment [JW2]: We
 FD/ID/PA Trip
 BFP/CEP trip (CEP Trip Not Applicable as as per page documents 9518-
108-11-KO-PVI-G-089 & 9518-108-28-RU-PVI-G-089 )
 Mill, feeder trip
 Turbine trip/Turbine load rejection.

PERFORMANCE REQUIREMENTS FOR CLOSED LOOP CONTROL SYSTEM

(TABLE -1)
Rate of
load Throttle Flue gas Furnace SH RH Steam
Sl. change Pressure O2 Pressure Steam Temp.
No Deviation Deviation Deviation Temp. Deviation
(% of MCR Deviation
per min.) Kg/cm2 % O2 mmwcl Deg. C Deg. C
A STEADY STATE CONDITION

90% to +2.0 +0.4 +8.0 +5.0 +5.0

1
100%
60% +2.0 +0.4 +8.0 +5.0 +5.0
2

B RAMP TEST (change For Max. Duration).

+3.0% +4.0 +0.6/-0.4 +20.0 +10.0* +10.0*
per
3
Max 3
min

+5.0% +6.0 +0.8/-0.4 +20.0 +12.0* +15.0*

4 Per
max 2
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min

+10.0 +4.0 +1.0/-0.5 +15.0 +15.0 +15.0**

5 %

C* STEP LOAD CHANGES

From 100% +5.0 +1.5/-0.5 +20.0 +15.0 +15.0
to 80% @
1 100% per
min.

- *: Applicable only for one side temperature.

- **: Point #5 is not applicable for Sipat boiler so far

- C*: The test is only possible with mills trip while the runback happened and never with
100 %/BCR min. That is clear if is runback. That is made switching to Turbine Follow 2.
That Boiler reduces the load with demanded rate and turbine follows the boiler. Comment [JW3]:

Primary control – unit’s frequency influence MW load change value would be defined Comment [JW4]: What is a Droop and
scenario. That was not clear the last time
as no more than 3 % and if it happens that the load changed between the values 2% to we did.
3% it can be repeated only once per 30 minutes.

Note:

1) Sufficient time shall be allowed between the tests as settling period between
conducting the tests. The test is to be made once per 30 minutes. 15 minutes
for test and 15 minutes stabilizing the technology.
1)2) The Online trend facility shall be used to record the deviation in the
process parameter from the set point.
2)3) Plant operating conditions will allow and performing not limiting the all test.
All those , i.e. main equipment status, availability of auxiliaries, operational &
equipment constraints, which can influence the tests, shall also be recorded.
3)4) Control system shall be running in the CMC mode i.e. Boiler master, fuel flow,
air flow, feed water & turbine control shall be in automatic mode. Load set
point, maximum & minimum load set point, rate of raise/lower of load shall be
set through the Operator Work Stations, Large Video Screen.

Acceptance criteria

The control system limited does not cause the transient disturbances and
controls them within the acceptable limits as per the table and returned the
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controlled variables to the set points within the shortest possible time, subject to
no constraints being imposed by process/equipment.

4.0 ParametricDCS parameters monitored during the Tests Comment [JW5]: My intention is that
they are not special test it is a part of the
parameters monitored during the tests.
4.1 Definition of worst case loading

The parametric tests shall be conducted during worst case loading of the system.

The worst case loading conditions for control system shall include the
following tasks.

 All process inputs coming to Control System including SOE/annunciation

inputs are being scanned, acquired, conditioned and processed.
 All closed loop controls are in operation during a disturbed (non-steady)
state of the process.
 All open loop controls of DDCMIS are in operation during a disturbed
(non-steady) state.
 All data being transferred between control system, system bus and
MMIPIS.
 Three (3) alarms are being generated per second from each of the
functional groups of Control System. Comment [JW6]: Konstantin who and
 Twelve control commands from MMIPIS are being executed in one when that was analysis and is it document
says that is good or not?
minute.
Comment [JW7]: I do not understand I
 All processors (including hot standby) health being monitored. guess it is to one device ?
 All standby processors status being updated.

The worst case loading conditions for MMIPIS shall include the following
tasks. Comment [JW8]: That text is
duplicated? why

 Continuous data transfer between System Bus & MMIPIS.

 All calculations including performance calculations being performed at the
specified rates. Comment [JW9]: What rate? One per
 Alarms being reported at the rate of three (3) alarms per second for each hour?

of the Control System functional groups. Comment [JW10]: SOECIFIC RATES? I

guess range. It should be precisely defined
 Two control operator commands for control/ information within a base
Comment [JW11]: It is already above
period of one minute from each OWS & each LVS.
 OWS/LVS displays are in operation as follows:
o LVS – 1, 4 - Sequence chain display with maximum number of Formatted
dynamic data items.
o LVS - 2, 5 - Individual display with maximum number of dynamic
data items.
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o LVS – 3, 6 - Plant mimic display with one hundred and twenty (120)
numbers of dynamic data items.
o OWS (DROP211) - Overview display with max. no. of dynamic data
items.
o OWS – (DROP212) - Group display (twenty points, current data).
o OWS – (DROP213) - Alarm display of twenty (20) points.
o OWS –(DROP21 4) - 4 Nos. Windows each running current trend.
 All PC Stations- X-T plots are displayed & updated on Station LAN and
unit LAN.
 Data collection for all logs/reports in progress.
 All printers connected to MMIPIS are in operation at rated speed.
 MMIPIS processors and all peripherals health being monitored.
 Data collection for trend function and historical data storage in progress.
 Four alarm acknowledgements within a base period of one minute from
each OWS & LVS.
 Calculations for long term storage of data being performed.
 SOE Printing in Progress.
 Data transfer with other DDCMIS sub-systems, all PLCs and SG/TG C&I
Systems in Progress for Controls (commands) as well as for information.

The Worst Case Loading Conditions for Ovation Network

 The worst case loading condition shall mean continuous data transfer
between the distributed modules (Control System/MMIPIS), at their
individual worst case loading conditions defined above.

4.2 Controller CPU Loading, cycle time/controller reaction time,

memory spare capacity during control loop PG tests
(a) CPU Loading

Outline

The Controller CPU load is verified to determine the spare duty cycle. Spare duty
cycle is defined as the accumulated spare time available over a period of one
minute after the execution of all control and monitoring algorithms. CPU load
shall be verified under worst case loading condition.

Objective

To confirm 20% spare duty cycle when measured over any one minute period.
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Procedure

Under worst case loading conditions, the controller CPU load is monitored on the
engineering station.

Acceptance criteria

The CPU load is within 80% when measured over 1 minute period.

(b) Cycle time/controller reaction time

Outline

The Controller Cycle time/reaction time is verified to determine the execution

time of various logics.

Objective

To confirm that controller cycle time for each task area is properly defined as per
NTPC logic requirements.

Procedure

CLCS

1. Select a CLCS control loop configured for required scan rate.

2. Hardwire a square wave signal from a signal generator to the analog input
point (PV), Set P,I &D values of the loop to default.
3. Connect the analog input and the analog output from the loop to
oscilloscope.
4. Observe the time interval between the changes in input to output change
5. Verify the following
a) For fast CLCS loop : 250msec
b) For other loops : 500 msec
c) Main turbine and TDBFP EHG loops execution time - 50 msec.
OLCS

1. Simulate a trip signal through a Digital input and observe the digital input
and digital output (stop command) with two channels of oscilloscope.
2. Observe the time interval between the changes in input to output change
3. Keep start permissive avialble and give start command from DI & observe
DO issued. Indicate loop reaction tim expected for Electrical and other
OLCS logics, which will be demonstrated.
4. Verify following
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a) Electrical Sync/ Tie breaker : approx 100msec

Acceptance criteria

The task area cycle time settings are as per the various logic requirements
implemented in that particular task.

(c) Controller spare memory capacity

Outline

The controller spare memory capacity is defined as the accumulated spare

function block memory available after implementation of all control and
monitoring algorithms.

Objective

To confirm 20% spare function block memory is available (free).

Procedure

Each controller has a capacity for 999 sheets. The utilized no of sheets is noted
for each controller and spare available is calculated.

Acceptance criteria

The function block memory usage is not more than 80% of the control capacity.

4.3 MMIPIS controller CPU loading/spare duty cycle, spare

memory capacity

4.3.1 : Duty Cycle

Outline

The MMIPIS controller CPU load is verified to determine the spare duty cycle.
Spare duty cycle is defined as the accumulated spare time available over a
period defined below, after the execution of all control and monitoring functions of
MMIPIS. CPU load shall be verified under worst case loading condition.

Objective
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To confirm
(i) 40% free time when measured over any two second period
(ii) 50% free time when measured over any one minute period.

Procedure

The CPU usage on the controllers shall be monitored through the Performance
monitoring tool of windows.

Acceptance criteria

The MMIPIS controller CPU load is within 60% when measured over 2 seconds
and 50% when measured over one-minute period

4.4 Spare Capacities of working & bulk Memory

Outline

The MMIPIS RAM and HDD usage to be checked for EWS/OWS.

Procedure & Acceptance

Standard windows utilities of PCs will be used to check spare capacity of the
following.

a) Bulk memory (Hard-disk Utilization) of EWS/OWS

Acceptable limit = 50% loading

b) Working Memory (CPU load) of OWS/EWS

Acceptable limit = 75% loading

4.5 Ovation Network Spare Duty Cycle

Outline

The system network load is checked to determine the spare duty cycle. Spare
duty cycle is defined as the accumulated spare time available over 2 seconds
period, after the transmission of control and monitoring information over the
network. System bus load shall be verified under worst case loading condition.

Objective
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To confirm 50% free time when measured over any 2 seconds interval.

Procedure

 Using Web access user interface(SNMP) or Cisco utility

 Observe the network utilization of the active LAN Port bandwidth.
 The offered LAN architecture delivers 100Mbps bandwidth, and hence the
spare capacity can be verified.

Acceptance Criteria

The Network load is within 50% when measured over any 2 seconds interval.

4.6 Display response time

Outline

Various displays of the operator station should appear without considerable delay
after the display command is issued. To check this selected display screen shall
be called and the time taken for the screen to appear may be noted. The display
response time is defined as the time interval between the pressing of the last key
by the operator for demanding a display and completion of requested display on
CRT with full foreground and background information. The display response time
shall be checked under the worst case loading conditions.

Objective

To confirm operator station display response time as per the table below.

S.No. Display Description Response Time

1 Control Related Display (Faceplate) 1 sec
2 Point Details Display (Single Point) 1-2 secs
3 Bar Chart Display (20 points, current data) 2-3 secs
4 Operator guide/plant start-up guide message 1-2 secs
display (full screen of alphanumeric information
and a maximum of ten numbers of dynamic data
items).
5 Plant mimic display of fair complexity with a 2-3 secs
minimum of 120 numbers of dynamic data items
e.g. values, macros, line segments etc.
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6 Group review display (current values of twenty 2-3 secs

points)
7 X-Y plot display ( 2 X-Y plots and a single 3-4 secs
display requiring both historical as well as
current data)
8 X-T plot display (Trend of 6 analog points and a 3-4 secs
single display requiring both historical as well
as current data)
9 Plant summary display (e.g. bad point summary, 3-4 secs
limit check removed point summary, Assume
the whole data base search is required and the
summary display contains ten points only).
10 CRT display update rates (Input to be simulated 2 secs
and screen update to be checked on random
basis)

Procedure

Selected operator displays of above types are called by pressing the navigation
button or a key on the key board and the time taken for the selected display or
faceplate to appear fully, after the command shall be measured using a stop
watch.

Acceptance criteria

Operator station display response checked and confirmed as per the table.

4.7 System Accuracy Requirements

Analog Inputs :

Outline & Objective

The overall system accuracy from the signal input terminals to output
presentation on display and printers for the least accurate input range and
maximum scan rate shall not be worse than +0.1% of full scale of the engineering
process / measurement range of the channel/module. The accuracy is measured
as the error in %.

Since the accuracy tests are conducted for all the channels during hardware
testing as part of Factory tests, channels will be selected at random for each type
of module and accuracy reconfirmed as part of PG tests.
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The display of the parameter under testing shall have a display resolution of 2
decimal places.

Procedure

The selected channels shall be simulated using analog simulators (mA, mV). The
display on CRT shall be noted in a table. The simulation shall be done at 0%,
25%, 50%, 75% and 100% of the range configured. For each type of input (mA,
thermocouple, RTD), one channel per card in ten different cards will be checked
for different engineered measurement ranges.Format for accuracy test is
attached shall be similar to ATST format (Annexure 1).

Acceptance criteria

The overall channel accuracy (expressed as error) of the selected channels shall
be within +/-0.1% of the engineering process range of the channel/module.

SOE inputs :

Outline & Objective

Time stamping of SOE inputs shall be checked by generating SOE inputs

generated at 1 msec interval connected in 4 different drops selected at random.

Acceptance criteria

The report shall contain the simulated SOE points in same chronological order
(of their occurrence) with 1 ms time difference.
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Annexure-1

Log Format for Accuracy test

S.No. Tag 0% 25% 50% 75% 100%

Exp Act Exp Act Exp Act Exp Act Exp Act