Adani Power Dahej Limited 4x660 MW Thermal Power Project

EPC Technical Specification

VOLUME II PART - E SECTION I SCOPE AND CONTROL DESIGN CRITERIA FOR BTG PACKAGE

Volume II, Part E, Section I Scope and Control Design Criteria for BTG Package

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Adani Power Dahej Limited 4x660 MW Thermal Power Project

EPC Technical Specification

1.00.00
1.01.00

INTRODUCTION This specification is intended to cover all aspects of the design, engineering manufacture, assembly, testing & inspection at manufacturer's works, delivery at site and erection and commissioning of the complete Instrumentation and Control System for the BTG Package of (4 units of 660MW) Thermal Power Station being put up at Dahej,Bharuch, Gujarat. In the event of any conflict between the requirements of any two (2) clauses or documents forming a part of this contract the owners decision will be final and binding in all such cases. DESIGN OBJECTIVE C & I System shall be provided to enable the power plant operation to be carried out in a safe, effective and reliable manner, without invoking plant or system operational limits and to provide the quality of control to support the overall performance guarantees detailed in the other sections. The main objective of centralised control room operation for the plant is for the following actions a) b) All routine unit operations (including all normal, emergency, start-up , shut-down operations and operations when on load) Any non-routine operation for which there is not ample time for plant attendant to accomplish.

1.02.00

2.00.00 2.01.00

2.02.00

The design of the indication, alarm and control for equipment shall be such as to employ recognized ergonomic principles leading to: a) b) Minimization of incidence of operator error. Maximization of efficiency of operator.

The principal design objective for the C & I System shall be of minimization of station personnel (both operation and maintenance staff). 2.03.0 The general design philosophy for the control & instrumentation system shall meet the following objectives. 1. High degree of overall system reliability, Low MTTR/downtime & high MTBF 2. Enhanced availability of plant, taking into consideration proper redundancies at various levels like hot dual redundancy for Input module, output module, Bus/Data highway system, internal bus system, processor/controllers for Interlock and protection functions. 3. For critical functions like BMS, Boiler Protections, FSSS, Turbine protections Tripple Modular Redundancy (TMR Fail safe 2 out of 3 logic) configuration right from Field sensor through I/O modules, Bus system, Controllers/Processors, interposing relays, Interposing Relay contacts) shall be provided which is TUV approved and part of the DCS family. If the offered DCS family does not have TUV approval TMR configuration then Stand-alone TUV approved system shall be provided for these critical services.

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EPC Technical Specification

4. Use of Process Transmitters is encouraged for all applications and use of field process switches like Pressure Switch, Level Switch, Flow Switch, Temperature Switch, Differential Pressure Switch etc is discouraged. All the interlock and protection contact shall be derived in the DCS from the acquired 4-20mA in the DCS by using Limit Value Monitoring (LVM) tool. However, if any main equipment manufacturer recommends or insists for the use of field switches the same shall be discussed during detailed engineering. 5. All the temperature signals from RTD and Thermocouple shall be acquired in DCS through field transmitters in the form of 4 20 mA signal. Both the elements of the RTD or Thermocouple shall be wired up and engineered in DCS. 6. The temperature sensors shall be mounted on the process pipes or vessels with using proper size, material thermowells designed to meet the applicable international standard. These thermowells shall be either threaded type or Weld-in type depending on the pipe or vessel thickness and the services. The bidder shall ensure that all the thermowells are fulfilling the wake frequency calculation requirements. Bidder must furnish the sizing calculations and wake frequency calculations for each thermowell. 7. All the Process Transmitters shall be SMART and based on HART principle. All the process transmitters shall be possible to calibrate from remote place like central control room using HART terminal. 8. The Temperature Transmitters (TT) shall be Universal type and head mounted which can be compatible to any type of RTD or any type of Thermocouple. Rack mounted type TTs shall be provided where head mounted arrangement is not suitable. This TT shall have facility to connect both the elements of the duplex type RTD or Duplex type Thermocouple. The transmitter shall be intelligent type to select the second element out of the duplex element if the element in use fails without causing any process disturbance. 9. Measurement services used in interlock and protection shall have minimum Two (2) sets of measuring sensors/instruments and transmitters while all critical control loops and tripping/protections shall have minimum Three (3) sets measuring sensors/instruments without any exception. 10. All the instrument installation hardware shall be of Swagelok or Parker make only. Bidder shall obtain specific approval from the owner during detailed engineering if any particular item is not available from these two specified vendors. 11. For motorized actuated valves (MOV) the Open Limit Switch, Close Limit Switch, Open Torque Limit Switch, Close Torque Limit Switch, Fault contacts from field/actuator shall be individually wired and engineered in DCS. 12. Oxygen (O2) and Carbon Monoxide (CO) in flue gas shall be separately measured and used in the combustion control for trimming purposes. 13. The instrument installation diagrams shall be prepared based on the 3 Dimensional (3 D) modeling of the instruments and equipment in the scope of supply of the bidder. 14. The Input and Output signal allocations shall be defined in such a way that the mechanical and process redundancy and availability is reflected in true sense in DCS. 15. The cable supply and the cabling work from the field to DCS is in the bidders scope for the field sensors and equipments in bidders scope of supply. 16. The field signals in the owners scope which are envisaged for DCS engineering will be wired at Marshalling cabinet in the central control room. The marshalling cabinet is in Bidders scope. The cabling between Marshalling cabinet to DCS cabinet is in Bidders scope. Bidder need to coordinate with the owner for the detailed engineering of these signals in DCS.

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EPC Technical Specification

17. Bidder shall provide dedicated Electronic earthing for DCS system and the PLC systems in the bidders scope of supply. 18. Bidder shall provide minimum 6 (Six) Human Machine interfaces (HMI) as operating stations per unit basis. Each HMI station shall be fully equipped with the dedicated server, System and application software. 19. Besides the above Six (6) HMI stations, 2 (Two) numbers Large Video Screens each with dedicated servers shall be provided with system and application software. These large video screens shall be able to display any graphics and mimics from any part of the plant area configured in the DCS system. 20. Bidder shall supply 2 (Two) numbers DCS Engineering cum Plant operation stations per unit basis. 21. For the DCS system the power supply requirement in terms of the Voltage rating and the VA capacity shall be provided by the Bidder to the owner for Non-UPS category of 110V AC and 240VAC and UPS category of 110V AC and 240V AC. Owner will provide one set of double feeder of the required rating at the AC Distribution Board (ACDB) in the scope of Bidder. On the similar line owner shall supply one set of Double feeder of 220VDC to Bidder at the DC Distribution board in Bidders scope. Any distribution within the system supplied by Bidder is in the Bidders scope. Different voltage rating requirements of the bidder supplied system shall be derived by the Bidder. 22. The Steam and Water Analyser System (SWAS) alongwith the Sampling, Sample Handling, Primary Coolers, Secondary Coolers, Chiller units, Wet panel and the Dry/Analyser Panels is in Bidders scope. 23. Vibration monitoring system for Main Steam Turbine Generator, Turbine drive of Boiler Feed Pump, all HT electrical motors and HT motor driven rotating equipments shall be in Bidders scope. Bidder shall supply GE Bentley Nevada make 3300 series field sensors and 3500 series monitors. Bidder shall supply Key Phasor unit for each equipment. 24. Condition monitoring system of GE Bentley Nevada Make SYSTEM1 model shall be in bidders scope. 25. For the HT drives in owners scope, the sensors, monitors and the rack shall be supplied by owner. Owner shall wire the signals to System1 in bidders scope. 26. Each rotating equipment shall be able to Start and Stop from local as well as from remote Central Control Room through DCS system. The Local - Remote selection facility shall be provided either at HMI in central control room or at MCC which shall be decided during detailed engineering. 27. Every rotating equipment must be provided with Emergency Off pushbutton at local which is lockable to Release. 28. Entire power plant needs to be catagorised in to the specified hazardous area classification standards. All the instruments and the systems shall be procured complying to the catagorised hazardous area requirements. 29. Geo-Position Satellite (GPS) based Master Clock system shall be supplied by bidder for the time base synchronisation between different DCS and PLC systems. The GPS master clock system shall provide sufficient slave outputs individually for each system. 30. Sequence of Event Recording and Annunciation system shall be from the DCS family and in bidders scope. The SOE shall have 1 msec resolution. 31. Turbine related control systems such DEH, Turbine Bypass, Gland steam pressure control, TSI, TSE, ATT, ATRS, ETS etc. is in bidders scope. 32. All BTG area field gauges, switches, primary sensors, transmitters, Junction boxes, cables, cabling, final control elements, transmitter enclosure/racks, local control panel, instrument installation hardware, etc are in Bidders scope.

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EPC Technical Specification

33. Closed Circuit Television (CCTV) system for the BTG area shall be provided by the Bidder. 34. Plant Optimisation system shall be supplied by Bidder. 35. The sequence start up modes shall be of Automatic Mode, Semi-Automatic Mode and Operator Guide Mode 2.04.0 Bidder shall supply, engineer and commission the system keeping focus n following important aspects of Operation friendliness, Maintenance friendliness, Constructability and investment protection: 2.05.0 Application of sound maintainability principles and techniques shall be strictly adhered to. As a minimum following shall be considered: 1. Standardization of parts, instruments, hardware, actuators, primary sensors etc., which are used throughout entire plant. 2. Minimum use of special tools, Modular replacement, Grouping of functions, Separate adjustability, Malfunction identification, Easy removal, replacement and repair, Easy assembly and disassembly and Tamperproof design to include proper identification to prevent improper mounting and installation. 3.00.00 3.01.00 CONTROL & INSTRUMENTATION SYSTEM PHILOSOPHY The Instrumentation and Control System shall mainly realize the following functions in order to assist the operator to perform safe start up/shutdown and normal/emergency operation of the plant. 1. Closed loop modulating control of parameters for optimized operation of turbine & auxiliaries, boiler & auxiliaries and Generator. Open loop control for automatic sequential operation, interlock and protection of various drives. Continuous supervision of system parameters and equipment operating conditions

2. 3. 3.02.00

The I&C System shall be configured to perform the following basic functions: 1. Automatic sequencing of the start-up and shutdown of major equipment and auxiliaries including group/plant level start-up to minimize operators intervention under normal operating condition. 2. Regulation function for various valves and dampers to achieve guaranteed performance and to achieve the most fuel-efficient operation. 3. Protection of plant equipment and monitoring of equipment life. 4. Acquisition, display and archiving of plant data and generation of reports. Centralized control has been envisaged from one Central Control Room. The entire unit operation and monitoring under all regimes of operation i.e., start up, loading, normal operation, shutdown etc. shall be possible through operators consoles located at Unit Control Desk (UCD) in the central control room. It is mandatory preferred to have same platform for all control and monitoring system within the power block The central control room (CCR) shall house operators stations, printers, auxiliary console for emergency push buttons, minimum number of hardwired control station and hardwired window annunciation for safe shut down, engineering
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3.03.00

Volume II, Part E, Section I Scope and Control Design Criteria for BTG Package

Adani Power Dahej Limited 4x660 MW Thermal Power Project

EPC Technical Specification

station together with operator console (if any) for turbine generator, generator control and protection panel, fire detection and protection panel, etc. All electronic system cabinets, interposing relay cabinets, UPS cabinets and power distribution boards, electrical interface panel if any, etc. will be located in the Control Equipment Room (CER) adjacent to the CCR. 3.04.00 Power Cycle Plant automation will be achieved mainly using an integrated, functionally distributed, microprocessor based Distributed Control System (DCS), with redundant measurement and control functions to operate in conjunction with the Burner Management System (BMS) of the Steam Generator (SG) and the Electro Hydraulic Governor (EHG), Automatic Voltage Regulator (AVR) of the Turbine Generator (TG), Sequence of Event Recorder (SER) etc. The plant start-up, shutdown and all regimes of operation shall be automated with provision for plant cold, warm and hot start conditions. No operator intervention is envisaged during normal operation and foreseeable emergencies. Generally, prior to a parameter reaching trip level, alarm will be generated to warn the operator about the emergency. If separate independent microprocessor based systems are provided for STG integral controls like Electro Hydraulic Governor Control, Automatic Voltage Regulator (AVR), Turbine Supervisory Instrument (TSI), etc. The DCS will interact with the following major in-plant subsystems through gateway stations/remote terminal units (RTUs)/hardwired interfaces: a) b) c) d) e) TG Protection & Integral Control Electro-hydraulic Governor Automatic Voltage Regulator Turbine Supervisory Instruments (TSI) Any other STG non-integral control shall be implemented in DCS.

3.05.00

The STG non-integral controls shall be implemented in Plant DCS. The primary objective of the interface will be centralized monitoring and presentation of data. 3.06.00 Important parameters from the independent offsite packages as listed below shall be monitored in plant DCS also: a) Demineralising Water Treatment Plant. (Through Gateway) b) Coal Handling Plant. (Through Gateway) c) Ash Handling Plant. (Through Gateway) d) Compressed Air Plant (Through Gateway) e) Fuel Oil Handling Package (Through Gateway) f) Fire Protection Package (Through Gateway) g) DG Package (Through Gateway) CCW and ACW system will be implemented in DCS. Dedicated controller may be placed in Cooling Water Pump House. Condensate Polishing Unit, Hz Generation Plant etc., as a part of BTG package, shall be microprocessor based and soft wired signals to DCS for monitoring through gateway.

3.07.00

Volume II, Part E, Section I Scope and Control Design Criteria for BTG Package

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EPC Technical Specification

3.08.00

Supply and installation (including laying and termination) of control cables/ special cables/ instrumentation cables wherever both end equipments are in BTG package vendors scope. KKS tag numbering philosophy shall be followed through out the plant. REDUNDANCY CRITERIA Any single failure of instruments or control equipment shall not affect the performance of the unit in any way.

3.09.00 4.00.00

4.01.00

For hardware configuration following guide lines shall be followed. a) For very critical application like protection of Boiler and Turbine, Triple Modular Redundant (TMR) / Dual Redundant / Quad hardware (I/O units, processors) and triplicate sensors shall be TUV certified safety system SIL-3. As per IEC 61508. For critical closed loop control system 2 out of 3 redundant sensor/transmitter shall be used. For balance protection, control loops, sequential logic and related measurement dual hot redundant hardware including field instruments shall be used. For balance measurement non-redundant hardware may be used. The DCS should have redundancy in following levels - Main processor, I/O modules, Network interface module, communication cable and power supply. Sensor for protection and sensor for control/monitoring should be separate.

b) c) d) e) f) 4.02.00

The signal distribution from sensors which are shared due to process restrictions between control loops, logics, monitoring purposes and between back-up instruments on the panel shall be as follows: a) b) Redundant components and equipment within given systems shall be distributed among processors and I/O cards to the extent practical. Critical inputs shall be supplied with redundant sensors/transmitters with each input connected to different input cards. Where redundant inputs exist, the DCS shall be configured to automatically reject erroneous data. Where required, one-of-two, two-of-two, two-of-three, or median select schemes shall be utilized to ensure the integrity of critical inputs. Wherever there is a process redundancy (Left/Right or Running/Standby) or transmitter/switched redundancy available, such inputs shall be routed through independent input cards. No two control loops/interlock loop shall share the inputs (either binary or analog) vide input cards if process signals are independently available. Protective inputs for two drives shall not be allotted to the same input card. The use of redundant outputs driving the same final element or equipment shall generally be avoided in favor of failsafe design and redundancy of the plant equipment. In case inputs/outputs are required from one logic to another, they can be soft wired provided, they are on same processor. For those
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c) d)

e) f)

Volume II, Part E, Section I Scope and Control Design Criteria for BTG Package

Adani Power Dahej Limited 4x660 MW Thermal Power Project

EPC Technical Specification

g)

h)

i) j) k) l) 5.00.00 5.01.00

inputs/outputs resident on other processors, the same shall be hardwired. The operator stations shall be identical in capability and independently linked to the system. Although these stations shall be normally dedicated to a specific function, any station can replace the function of any other station at any time. All power source and power conditioning equipment in the system shall be redundant. While allocating control tasks for Interlock Protection, following criteria are also to be satisfied . These redundant power supplies shall have diode auctioning or auto switchover facility. Left and right air-flue gas paths do not share redundant processors. Left and right water paths do not share redundant processors. Those auxiliaries which are common to both paths (BFP-C) will be resident in the processors other than those used for left/right paths so that both paths will not be lost due to the failure of a processor. The Air and Water paths do not share processors.

SPECIAL TECNICAL REQUIREMENT MODULATING CONTROL LOOPS 1. Co-ordinated Master Control: Co-ordinated master control system shall control the operation of boiler and turbine as an integrated system consistent with the generation requirements but constrained by the unit capability. The system shall enable the operator to select either of the three modes coordinated mode, boiler follow mode, turbine follow mode. 2. Combustion (Air and Fuel flow) Control 3. Furnace Draft Control 4. Steam Temperature Control 5. Deaerator Pressure Control 6. Deaerator Level Control 7. Blow Down Tank Level Control 8. Steam Turbine Control 9. Condenser Hotwell Level Control 10. Turbine Bypass Control

5.02.00

Other modulating control loops shall include at least following:Mill level control, Mill air flow control, Mill outlet temp. control, Fuel oil flow/pressure control, Secondary air damper control, Primary air pressure control, Air heater cold end temp. control, Reheat steam temp control, Feed water pump re-circulation control, Condensate pump re-circulation control, HP/LP heater level control, PRDS control (Aux. Steam), Turbine inlet steam pressure control, Lube oil temp. control, Gland steam pressure & temp. control, Make-up water flow / tank level control.

5.03.00

PLANT INTERLOCK AND PROTECTION The interlock and protection system for the plant and equipment shall ensure :

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EPC Technical Specification

a) b)

Safe start-up or shutdown of major auxiliaries by automatic operation of the associated facilities including steam turbine and steam generator. Smooth, continuous, safe and efficient operation of the plant, equipment and auxiliaries, by automatic interlock starting of backup facilities in case of failure of the running facility.

The Unit Protection System shall sense abnormal or hazardous operating conditions and shall automatically initiate shutdown, isolation, or runback of major equipment as required to protect personnel and equipment. The Unit Protection System shall be implemented at two levels. Individual equipment shall be protected by logic contained within its distributed processors. Equipment to be considered in the development of interlock and runback logic shall include the following :Condensate pumps, Feed water pumps, Circulating water pumps, Pulverizers, Steam turbine (load rejections), ID Fan, FD Fan, PA Fan Unit trip logic shall also be provided to allow the simultaneous tripping of the steam generator and steam turbine within a unit. The interlock and runback logic shall be implemented in the unit protection processors The steam generator control & logic shall be implemented. Separate cubicles for BMS, complete with redundant processors, memory, power supply, input/output cards and communication bus shall be provided. Redundant system shall be hot on-line and changeover to standby shall be immediate without any interruption to the process. Diagnostic at operators station shall be provided in case of transfer / failure of unit. Provision of de-interlocking / forcing of inputs shall be provided to bypass selective interlocks for maintenance. Inputs an d Outputs shall be arranged group wise. 5.04.01 Boiler Protection Boiler protection system shall be provided to achieve the following functional requirements. ---Boiler Protection actions including Master Fuel Trip (MFT). Purging. Sequence control, interlock and protection during unit start up, shutdown and under emergency conditions.

The boiler shall be protected against abnormal conditions such as the following :Both emergency trip buttons pushed, Loss of all fuels, Reheater protection acted, Air flow less than 30 %, Loss of flame, Furnace pressure very high, Furnace pressure very low, Loss of both FD fans, Loss of both ID fans,
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Adani Power Dahej Limited 4x660 MW Thermal Power Project

EPC Technical Specification

Loss of AC at any elevation in service and less than fie ball, Loss of DC voltage supply, Circulating water not adequate 5.04.02 Furnace Safeguard Supervisory System FSSS shall be designed in accordance with boiler manufacturers recommendation and meet NFPA requirements. The FSSS shall include Burner Control System (BCS) and Furnace Safeguard System (FSS) and shall be TUV approved safety system SIL-3, as per IEC 61508. 5.04.03 Soot Blower Control Soot Blower system shall be provided to ensure automatic sequential operation of soot blowers. 5.04.04 Steam Turbine Protection Turbine protection shall be TUV approved safety system SIL-3, as per IEC 61508 based with fault tolerant 2 out of 3 voting logic for input and output of TMR system. Protection and interlock system shall meet all applicable safety requirements, including those stipulated in VDE 0116 sections 8.7, VDE 0160 etc. The hardware modules utilized to implement the turbine protection system shall be TUV approved, meeting the above mentioned VDE standards. The turbine generator shall also be protected against excessive over speed by separately actuated over speed devices / emergency over speed governors. Should the speed controller fail to limit the turbine over speed, the emergency governor shall trip the unit at specified over speed. In addition to the emergency over speed governors, an emergency hand trip device shall be provided to facilitate manual tripping of the unit. In case the vacuum unloading gear fails to check a falling vacuum, a trip device shall be provided to trip the unit at a preset value to protect LP turbine blades and condenser tubes from excessive heating. Bidder shall provide all the required primary sensors and system hardware for the Protection System as per his standard and proven practice. Minimum Primary sensor redundancy in 2 out of 3 shall be provided for following parameters:Lube oil pressure low, Axial shift high, Over speed, Condenser vacuum, Lub oil temperature, Eccentricity, Steam Temperature High, Vibration Very High The above redundancy principle redundancy in the other inputs as follows required for the safety of the turbine shall be based on Bidders experience and proven practice Lube oil temperature high, Condenser vacuum low, Steam inlet pressure low, Loss of Governor fluid pressure, Exhaust hood temperature high, Hot well level high, High vibration

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Adani Power Dahej Limited 4x660 MW Thermal Power Project

EPC Technical Specification

5.04.05 5.04.06 5.04.07 5.04.08 5.04.09 5.05.00

Automatic Turbine Run-up System Automatic Turbine Testing System Turbine Supervisory Instrumentation Turbine Stress Control Turbine Water Induction Prevention Processor Task Allocations: Segregation and distribution of the

regulating controls and open loop/sequence control shall be made looking in to the maximum process and system availability. However, the allocation of the controls in different DCS cabinets and processors is subject approval by the owner during the detailed engineering.
5.06.00 5.07.00 Flame Monitoring System Furnace Temperature Measurement Bidder shall provide furnace temperature measuring probes. These temperature probes shall be used for continuous furnace temperature monitoring and control. All these temperature elements shall be installed with suitable thermowells. Besides these temperature elements, few elements will be electrically operated for insertion and retraction. Bidder shall include actuator, duplex thermocouples, position transmitter and limit switches. Control logic and monitoring shall be implemented in DCS. Bidder shall furnish write up & technical catalogues indicating type of thermocouple, actuating mechanism, position transmitter provided. 5.08.00 Boiler Feed Pumps (BFP ) The Boiler Feed Pump Package shall comprise of all field instruments like gauges, transmitters, flow elements, speed measurements, actuators, control valves etc. for control and monitoring of BFP and its auxiliaries. Instrumentation shall be complete in all respect to achieve complete functional equipment. Steam turbine driven BFP shall be equipped with its electro hydraulic governor, control valves and actuator. Governor shall be integrated with DCS for complete remote control and monitoring of the turbine. 5.09.00 5.10.00 5.11.00 Chemical Feed (Dosing) System Turbine Vibration Monitoring System Field Instruments, Analyzers, Supervisory Instruments shall be selected based on following principle. 1. There shall be Hazardous area classification for the entire plant. All the C&I equipments and instruments shall be procured complying to the applicable area classification. 2. The instrument models shall be selected in such a way that there will be flexibility to use it across the range of the application.

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EPC Technical Specification

3. The make and model of the instrument shall be identical for a particular type of measurement e.g. All temp transmitters shall be of same type and make, process transmitters of particular category shall of same make and same model. 5.12.01 Field Instruments Field instruments shall be suitable for area in which these are located. In general field instruments shall be weatherproof, dust tight and corrosion resistant with protection class IP-66. Field instruments shall be suitably grouped or clustered area-wise and shall be terminated in local junction boxes. 5.12.02 Process Transmitters All the Process Transmitters shall be 2-wire smart type with HART protocol compliance facility for remote calibration. Transmitters shall also have 4-20 mA DC output with driving capacity upto 500 ohms. Transmitters shall be properly grouped and mounted in transmitter enclosure to be placed at suitable locations. All the transmitters shall have inbuilt local indication of the process parameter in engineering units. For flow measurement DP type transmitters shall be used and the square root extraction shall be done at the DCS or PLC processor.

5.12.03

Field Switches and Field instruments Process Gauges, Temperature Sensors (The RTD and thermocouples shall be of duplex type and both elements of each RTD and thermocouple shall be wired upto and engineered at DCS.), Process Switches, Flow Elements, Final Control Element.

5.12.04

Steam and Water Analysis System (SWAS) which includes following `

Make-up DM Water Hotwell condensate CEP discharge Condensate polisher outlet Deaerator outlet Economiser inlet Boiler water Saturated Steam Main Steam Closed Cycle Cooling Water(DMCCW) - Conductivity - Conductivity - Conductivity, pH, Dissolved Oxygen - Conductivity, pH, Silica, Sodium ION - Dissolved Oxygen - Conductivity, Hydrazine - Conductivity, pH, Silica, Phosphate - Conductivity, pH - Conductivity, pH, Sodium ION - Conductivity, pH

5.12.05 5.12.06 5.13.00

Gas Analyzers and Emission Monitoring System: This shall include Oxygen and CO analysers for control purposes. Coal Bunker Level Monitoring System Electrical Control System Complete control, monitoring and status indication of the electrical system shall be provided through dedicated Video display unit in CCR.

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EPC Technical Specification

The status input of all relevant electrical equipment and sub-systems and Electrical parameters will be considered as Inputs to the DCS for Display of complete Electrical status of the system. The Electrical control system shall generally include but not limited to the following : a) Generator excitation system control (& governor control for synchronization), Generator Transformer breaker (Main & Tie) control and synchronization, Generator transformer cooler control, station transformer (2 nos.) cooler control 11KV & 6.6 KV breakers of Unit & Station Switchboards controlclosing (dead bus auto changeover) and tripping of Incomer & Tie breakers. 11KV & 6.6 KV outgoing breakers (except motor feeders) controlclosing and tripping of breakers 415V breakers of Unit Switchboard, Station Switchboards and ESP boards DG Distribution board. Emergency Switchgear closing tripping. 11KV, 6.6KV & 415 V systems fast / slow bus change over (i.e. unit to reserve/reserve to unit with auto/manual synchronization.). Emergency DG control. Unit Auxiliary and Station Auxiliary Transformers OLTC control with tap position indication. Metering for generator, generator transformer, unit and station system, and DC system. Monitoring, status indication and animated single line diagram of complete electrical system including transformers and off site facilities like Ash Handling system, Coal Handling system, Water pre and post treatment system, cooling tower/CW system etc. Alarm annunciation. Online monitoring of generator capability including display capability curve on the monitor. Island operation of TG set. UPS and batteries.

b) c) d) e) f) g) h) i)

j) k) l) m)

Commands will be issued from Operators console for operation and monitoring of all sections of the all feeders (except motor feeders) as minimum. 5.14.00 Information System Information shall be provided to the operator in several formats as follows and the bidder shall include them in his scope of work:X(t) plots, Bar charts, All graphic formats and dynamic information to be prepared from the flow diagrams, All log formats and report formats, All start-up guidance formats, System Summaries, Single Point Trend, Group Trend, Sequential Points Print Out, Alarm Summary, Review of Alarm Limits, Dead bends Scan/Calculation Rates, Off Scan Summary, Constants Summary, Scan Period Summary, Point Quality Summary, Trend Log Summary, Trend Recording Assignment, Bar Graph
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EPC Technical Specification

Assignment Summary, Group Review Summary, Reports & Logs, Shift, Daily, Other Reports, Turbine Run up Log, Boiler Start-up Log, Turbine and Generator Diagnostic Log, Turbine Recall Log, Turbine Shutdown Analysis Log, Pre & Post Trip Analysis Log, Sequence of Events Log, Maintenance Data Log, Special Logs, Performance Log, Operator Command Summary Log, Long Term Historical storage and Retrieval, Process Graphic Displays Faceplate Displays, Bar Chart Displays, Trend Displays, Permissive Displays & Step Indicator, Operator Guidance Messages, Printed Reports and Logs 5.15.00 5.16.00 6.00.00 6.01.00 Performance Calculations and Plant Optimization Online Computer Aided Microprocessor based Machinery Maintenance Management Systems (OCAMMMS) UTILITIES Electric Power Supply The power supply shall be designed to meet the electric power requirements of various C&I systems including DCS. The power supply to the entire instrumentation & Control System shall be 230 VAC 50 Hz from UPS at one point. Necessary distribution to make the system complete and reliable shall be done. The requirement of 24V DC power supply shall be through a separate battery charger plus battery can be considered. 6.02.00 Air Supply Air Supply system shall be designed for dry instrument quality air (Dew point of ve 40 Deg C) at 7.0 Kg/sq.cm (min) terminated with an isolating valve and distribution network to cater to various instruments. The instrument air supply system for various pneumatic C&I devices shall be complete in all respects with necessary filter regulators, valves, piping/tubing etc. Each pneumatic instrument shall have an individual air shut-off valve. The pressure regulating valves shall be equipped with internal filters, pressure gauges and built-in filter. All pneumatic actuators for control valves/dampers etc. shall be designed to operate at minimum of 4.0 Kg/sq.cm supply air pressure. 7.00.00 7.01.00 PERFORMANCE GUARANTEE REQUIREMENTS 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 performance 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: a) Drop 50 percent of maximum load capability from approximately full load at a rate of 10 percent per minute.
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Volume II, Part E, Section I Scope and Control Design Criteria for BTG Package

Adani Power Dahej Limited 4x660 MW Thermal Power Project

EPC Technical Specification

b) c)

Drop load from full rated output to the lowest runback limit, at a rate corresponding to the fastest run back rate. Pick-up 50 percent of the maximum load capability from approximately 50 percent load at a rate of 10 percent per minute.

During transient conditions causing deviation of process variables, the control system furnished under the specification shall not permit deviations which exceed those confirmed and guaranteed by the manufacturers of the controlled process equipment for load changes as indicated above. A tentative list of parameters to be monitored for this test are given in the Table-1, given below. The control loops shall perform to return the controlled variable to the set-point in a stable manner without cycling in the shortest possible time and without any loop interactions or cycling of generation when generation matches unit load demand. 7.02.00 The bidder shall also guarantee that the control system provided by him will be responsive and stable and will maintain the deviation of controlled variables from set point within the limits specified so that the equipment being controlled will operate as specified over the range required. The controls shall operate automatically, with no assistance from the operator. The controller shall successfully demonstrate the performance of closed loop control systems before acceptance and taking over of this system by the Owner. All runback conditions listed below shall be proved by the bidder without any oil support : a) FD/ID/PA fan trip b) BFP/CEP trip c) Mill, feeder trip d) Turbine trip/;Turbine load rejection e) Any other condition decided during detailed engineering stage. PERFORMANCE REQUIREMENTS FOR DCS a) b) c) d) e) f) g) h) i) 8.00.00 Analogue closed loop execution time (except fast loop) Digitial logic execution time Screen update time Display response time Controllers switchover time SOE resolution Controller loading Memory loading System bus loading 250 ms max. 100 ms max. 1-2 sec. max. 1-2 sec. 20 ms max. 1 ms 60% max. 70% max 60% max.

7.03.00

Metering Bases of Chart Units The following system of units shall be followed throughout the specification unless otherwise mentioned : a) b) Pressure Differential Pressure : : KG/Sq.cm or Bar mm of water Kg/Sq.cm. column or

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Adani Power Dahej Limited 4x660 MW Thermal Power Project

EPC Technical Specification

c) d) e) f) g) h) i) j) k) l) m) n) 9.00.00 9.00.01

Draught Vacuum Temperature Flow (steam, condensate, feed water) Flow (furnace oil) Flow (Air/Gas) Flow Base Density Level Conductivity Gas Analyser Sox/NOx

: : : : : : : : : : : :

mm of water column mm of water/Hg column Degree Celsius Tonnes/Hr. Kg/hr. N Cu.m/hr. 760 mm of Hg at 16 Deg. C gms/cc mm Micro-mho/cm. Percentage by Volume. PPM

STEAM GENERATOR (SG) PACKAGE The Supplier shall be responsible for providing all materials, instruments and services specified or otherwise required to fulfill the intent of ensuring smooth operability, maintainability and reliability of Instrumentation & Control System of this package. Bearing of I.D., S.A., P.A. Fans and any other equipment driven by H.T. motors shall be provided with RTDs / Thermocouple for continuous monitoring of temperature, alarm and trip signal from DCS. All such temperature elements shall be duplex type. Control valves and damper actuators. Field junction boxes, marshalling cabinets, local panels for fuel system, chemical feed system and auxiliary panels, fireman aisle panel at burner floors, etc. All gauges, switches, electronic transmitter, temperature element etc. related to control, monitoring and equipment safety. Double root valve shall be provided for any application above 40 kg/cm2 pressure. TURBINE GENERATOR (TG) PACKAGE The Supplier shall be responsible for providing all materials, instruments and services specified or otherwise required to fulfill the intent of ensuring smooth operability, maintainability and reliability of Instrumentation & Control System of this package. Turbine supervisory and monitoring system and associated field sensors. Turbine protection System. General Auxiliary Control System. EHG Control System, ON load valve testing and ON load trip testing (ATT).
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9.00.02

9.00.03 9.0004

9.00.05 9.00.06 10.00.00 10.00.01

10.00.02 10.00.03 10.00.04 10.00.05

Volume II, Part E, Section I Scope and Control Design Criteria for BTG Package

Adani Power Dahej Limited 4x660 MW Thermal Power Project

EPC Technical Specification

10.00.06 10.00.07 10.00.08 10.00.09

Redundant hardware (TMR) for turbine and generator protection and control; and non-redundant hardware for monitoring of EHG and AVR. Redundant Gateway and necessary software and interface for monitoring of EHG, AVR and excitation systems through DCS. All integral field instruments viz. sensors, flow elements, etc. along with all accessories. All gauges, switches, electronic transmitter, temperature element, Control valves and damper actuators etc. related to control, monitoring and equipment safety. All source point nipples, isolation valves, root valves, stubs etc,. Local control panels and gauge boards for TG auxiliaries as required for equipment / system operation.

10.00.10 10.00.11

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