Beruflich Dokumente
Kultur Dokumente
16/12/2011
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CONTENTS
1.0
BASIS OF DESIGN
2.0
DESIGN STANDARDS
3.0
SCOPE OF SUPPLY
4.0
5.0
6.0
FIELD INSTRUMENTS
7.0
SPECIAL INSTRUMENTS
7.1. GENERAL CCTV SYSTEM
7.2. MILL ELECTRONIC EAR SYSTEM
7.3. TELEPHONE SYSTEM
7.4. PA SYSTEM
8.0
ENVIRONMENT INSTRUMENTS
8.1. OPACITY MONITOR
8.2. AMBIENT AIR QUANTITY
8.3. ENVIRONMENTAL DISPLAY BOARD
9.0
10.0
ERECTION HARDWARES
10.1. CABLE TRAYS
10.2. TUBE FITTINGS
10.3. CABLE GLANDS
10.4. ACCESSORIES FOR ERECTION
11.0
ENGINEERING ACTIVITIES
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Continuity of power supply facilities for inspection, testing, maintenance, cleaning and general
repairs will be of prime importance in the design.
1.2.
Standardisation of equipment and its components to reduce the necessary stock of spare parts.
1.3.
All electrical equipment shall be designed for operation at the required capacity in ambient air
temperatures (49 C) in a dusty plant environment.
1.4.
The design shall include the necessary provisions for the safety of man, machine and environment.
1.5.
The voltage, frequency and symmetrical short circuit levels for supply and distribution shall be as
follows: 1.5.1. Incoming power (Grid Power) :
3 Ph, 11 KV 10%, 50 Hz 3%
40 KA at 11kV
Non-effectively earthed
1.6.
: 230V, 1 Ph + E + N , 50 Hz
: 415 V, 3ph + E + N, 50 Hz
: 415V, 3 Ph +E + N, 50Hz
1.6.2. MCC
: 4-20mA
1.6.9. All variable speed motors shall be squirrel cage with VVVF drive.
1.7.
Environment Conditions
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Min. 06C
Max. 49 C
Min. 06C
Max. 49 C
1.8.
IP4X
IP55
IP65
IP65
: Hardwire/ Profibus
: Profibus
: Profibus/ Hardwire
: Hardwire
1.8.7.
: Profibus/ Hardwire
IS 1554 (Part 1)
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3.0
IS 1951
IS 3975
IS 5831
IS 8130
IEEE 472
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The Plant DCS Scope shall be comprised complete system with programmable controllers
(PCs); power supplies; Ethernet switches; distributed / remote I/O panels, Supervisory
computers (HMI); computers for process optimization, Management information System,
peripherals;
Online UPS 1 x 30 KVA Centralised Un-interrupted Power Supply systems (UPS) supply
As per details shown in enclosed drawing No.A0-ANICPL-NGP-CFGD-I4-01-Rev-00 & Scope of Supply &
Price Schedule Annexure-IV-B-1
3.2
SOFTWARE:
Licensed OS & Application software bundle for online & offline programming, configuring, diagnosis,
troubleshooting, firmware update of flash PROMs of the department level controllers along with
necessary drivers and interfaces.
Licensed OS & operator station software / HMI software for graphics development, tag configuration
& management, data acquisition, plant viewing, plant operation, plant control, real time & historian
trending, alarm generation and log, Reporting, event log, historian, PID and other process loop manual
& auto tuning, interfacing & access for Field bus devices / drives, interfacing & access for X-ray
analyzer system, bulk solid analyzer, refractory management system & process optimization systems,
OPC interface, ODBC interface, Web interface, Data link for MIS system Etc. with necessary drivers and
interfaces.
Engineering station software consisting of Item 3.1 & 3.2 of above.
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Any other software required for the reliable & successful operation of the system offered. The
Suppliers shall provide original licenses for all software each and every stations.
Computers at process optimisation and MIS level shall have adequate capacity to support the
following software, other than plant control software with high processing speed. Mills optimisation packages
Software & Hardware (at DCS end) required for interfacing of Electrical Energy Monitoring including
with plant control system, OPC interface, ODBC interface, Web interface, Data link for MIS system Etc.
Software for auto tuning of control loops. Windows based software for integrated online
documentation to create / modify control schemes, I/O charts, addressing, tag listing, loop diagrams,
termination schemes, having electric, electronic, logic gates, pneumatic, hydraulic, ISA / IEC symbol
libraries, link to manuals, drawings, help menus etc. either locally hosted or available in the network.
Listing of tags, I/O, objects with selective filter and export to MS Excel.
Software for MIS server including remote client licenses, drivers, interfaces, Web connectivity, security
and Hardware firewall. License for MIS and Engineering software shall be valid for 5 remote (Web
display clients) & 5 Local clients with view of online plant overview and critical parameters.
Software for making auto and routine system backup of programs, database, history, logs etc from
controllers and MMI.
All user configurable, user defined software developments like programmable controller logic,
sequential and other process / plant control programs, group / drive interlock, MMI graphics,
faceplates, trends, alarm, event, MIS interface configuration, reports, log sheets, Field bus instruments
/ drives interface & configuration using their respective software, EMS configuration, reports, Mimic,
optimization package loops, strategies etc are to be carried out at plant site along with purchasers
engineers.
The Supplier shall support and upgrade free of cost all the firmware / software meant for the
controllers, I/O sub system, Engineering station, programming tools, communication interfaces, MMI
stations, expert / optimization systems, MIS, documentation software, other system interfaces, Field
bus components, specific software for field bus instruments / drives and any other firmware of system
/ software that are in the scope of the Supplier and supplied by the Supplier including OS up to 3 years
from the date of commissioning and handing over of all systems to the purchaser by the Supplier for
same version. These upgrades, revision level changes, patches, software additions, fixes that are
released either by the Supplier or by the OEM shall be provided for upgrading the purchasers systems.
All software, user interface, drivers, utilities shall be in English language only .All software original CD
with license certificate to be provided for C & I system software (MMI, drives, MIS, EMS, smart vision
etc)
3.3
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3.5
SPARE PARTS
List of spare parts as required for all the systems, for two years trouble free operation shall be
furnished by the supplier and spare support shall be available for 10 years.
3.6
C & I ENGINEERING
Complete C&I Engineering like I/O List Preparations & assignments , development of graphics , Logic
developments for plant controls , Log /Trend & report generations software and Hardware
engineering for Controller / I/O,MIS ,EMS & other panels.
3.7
3.8
TRAINING PROGRAMME:
Hands-on training of 08 (Eight) Man week duration for plant personals through a comprehensive
training program covering programming/fault diagnosis and maintenance areas of the supplied
hardware & software at Supplier's / OEMs works
These training shall be designed to the specific need and shall be with hands on / simulation
experiments. These trainings are apart from those imparted on site during installation &
commissioning. These training sessions shall be facilitated by persons with design / engineering /
commissioning / servicing experience to the fullest satisfaction of the trainees.
Necessary and sufficient documents, manuals, drawings, catalogues, work sheets, circuit diagrams,
block diagrams, standards, case studies and write-ups are to be provided to improve understanding
and for future reference. The hard copies (6 sets) of the as built programme.
Training shall be on selection, applications, engineering, configuration, installation, commissioning,
tuning, setup, diagnosing, troubleshooting, calibration, software installation, integration of different
software, program development, online / offline programming, graphics development, field bus basics,
usage of field bus tools, network configurations, network calculations, network troubleshooting and
maintenance as applicable.
Training to be provided on widows OS, Ethernet, I/O, field bus network, filed bus fundamentals,
controller and its software, controller programming, editing, various I/O, interface modules, power
supplies, MMI system complete, MIS, EMS system, Optimization packages, field bus devices /
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transmitters supplied, field bus devices software like FDT, DTM, GSD, EDS, DDL etc, UPS, Surveillance
CCTV Systems etc.
DOCUMENTATION
3.9
Furnishing of information, drawings and documents, which fully define the equipment technology,
application software instructions, installation and operation requirements, performance
characteristics, warranties and QAP.
Complete As-built documentation of detailed engineering drawings and software.
All documents viz. drawings, GA, block diagrams, schemes, circuit diagrams, bill of materials, writeups, instrument list, test & calibration reports, loop diagrams, PID, interlocking diagram, field bus,
control layer & MMI layer network diagram, network calculations, I/O charts, specification sheets,
manuals, installation / operating instructions, catalogs, hardware / firmware / software manuals,
testing / setup / configuration /calibration / tuning / commissioning / maintenance instructions or
manuals, tag list, EMS, MIS, Documentation software etc. controller & MMI software listing shall be in
English only
Four sets of all the above said documents shall be supplied in hard copy. Three sets of complete
documentation as mentioned above including as built drawings and documents should be provided as
soft copy. All drawings, GA, circuits, loop diagrams etc. shall be in Auto cad format and other
documents in PDF/ HTML / XML as applicable.
4.0
4.1
4.1.1
Plant operation shall be monitored & controlled in automatic mode by operators from Control Rooms.
There shall be two control rooms for cement grinding unit. The 1st control room is Central Control
Room (CCR) and the other control rooms will be in the packing plant. Entire plant operation will be
from CCR. Apart from independent operation of packing plant, it should also be possible to monitor
and control them from main plant CCR.
The process departments shall be controlled from the control rooms through distributed control
organised in the following hierarchical order:
All the departmental level controllers alongwith I/O Panels pertaining to respective areas will be
distributed throughout the plant and located adjacent to motor control centers and in the field as per
the requirement, for real time acquisition of process parameters and plant safety and fail safe
operation.
Human Machine Interface through operator stations connected to department controllers via
redundant high speed Ethernet network data highway.
The Drawing Nos. A0-ANICPL-CHD-CFGD-I4-01-Rev-00 shows overall structure of control system
envisaged.
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At each control Room, plant operation shall be monitored and controlled from a control desk
comprising colour monitors, normal keyboards, mouse etc. Sequential logic controls, interlocks, alarm
generation, analog signal processing, process loops and analogue monitoring shall be done by
department level Controllers associated with these control desks.
4.1.2 LOGIC DESIGN FOR PLANT CONTROL
STARTING OPERATION
Each sequence shall have a fixed set of soft keys for group selection and start "Command".
Local/Remote selection of a drive shall be achieved from DCS. When selected for local operation the
start push button at local will be operative. In remote operation this push button will be ineffective.
However, any stop push button pertaining to that machine /drive shall be effective in both modes of
operation.
The control room MMI shall have the I/O status for the entire machine / equipment / drive / sub
control system in a group. The operators usually refer to this before any drive / group start or after
any trip or fault. This status shall be called in as a popup display / window within the main page by a
mouse click on that particular object.
Apart from the above each equipment / machine / drive / sub control system shall have a common &
universal colour scheme (border, fill, shade etc.) associated with animations / dynamic representation
(visibility, blinking Etc.) for operators to know the status / position of that particular object like
whether it is running or stopped, in local or remote mode, status is healthy or not (fault), fault
occurred while running or while at idle condition, stop switch and other safety switches activated or
not, selected in group or not, Whether safety, process interlocks are satisfied or not etc.
In addition, every equipment / machine / drive / sub control system shall have a similar popup window
for showing the status of the safety, process and sequential interlocks of that object stating the
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interlocks with clear text. This window shall have a automatic link with the controller program so that
whenever a change is done in the interlock at the controller, the same shall reflect in this window of
respective drive / group.
Any fault / tripping while running or during starting shall be indicated in clear text in the alarm banner
and with a voice alarm wherever required which is recordable. The voice alarm shall be an inbuilt
feature of the system and not a separate add on software.
While initiating a group start, the controller checks all status & pre requisite interlocks. On group
START Command, controller shall scan all the inputs to that group and if any fault is noted shall
annunciate on the screen with its tag number. If no fault is there the hooters (located at important
locations for respective section) shall be energised for predetermined time. After completion of set
time, the starting command shall be given automatically and the equipments shall start according to
the designed sequence as per the Block Interlocking Diagrams. A positive feedback shall be available
for the operator as the entire group is started and running as well as for any failure to do so.
4.1.4 STOPPING OPERATION
For stopping, a drive / machine can be stopped individually after selecting out of group, or the whole
group can be stopped. Each group shall have a set of soft keys for the running group to STOP. When
STOP command is given the drive that starts last while group starting stops immediately. All other
drives of the group shall stop in a reverse sequence of start sequence in a staggered manner.
Each group / sequence shall have an Emergency Stop key to facilitate stopping of all equipment in
the group sequence at once without time delay.
4.1.5 STARTING AND STOPPING OPERATION FROM FIELD
For the individual operation of the drive / machine/ equipment / sub control system for test run/
maintenance, local push button station shall be provided near each drive. All the machine safeties will
be effective in local operation of drives. However the set point like speed reference etc, can be set
from CCR / control room or from the respective panels according to the selection in respective panels.
4.1.6 CONTROL ROOMS
Clinker unloading, Clinker silo, Gypsum, Fly ash handling, Cement grinding and transport to cement
silos shall be controlled from Central Control Room.
Cement extraction, packing, truck loading, shall be controlled from Control Room located at packing
plant but the same screens shall be available for monitoring and control of operations on main plant
DCS System.
For field instruments and drives interface, only bus powered, field buses, Profibus is to be used. Analog
4-20 mA shall be used only if such field bus enabled instrument / device is not available or where
explicitly mentioned.
The department level processors shall be programmed to achieve sequential interlocks for start/stop
of plant and machinery, process and safety interlocks, alarm generation & distribution, monitoring and
supervision of process parameters and PI/PID, fuzzy loop controls for process optimization.
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The processors shall have self-diagnostic features to ensure healthy working at all times including
memory, processor loading, status of communication channels and to give advance warning through
audio-visual means for any fault in the same. Suitable programming devices to facilitate on-line
programme changes; storage of programme for safekeeping and hand held terminal shall be included.
Department level processors shall be controlling the sections independently & stoppage of one
department shall not effect in any way the operation of other unless otherwise they are deliberately
interlocked. However, these processors shall also communicate between themselves to take care of
the safety interlocks/process requirements, which are common between the process related sections.
Any programmable controller in the network can access the data and I/O of any other controller in the
same network.
The computers for supervisory control and optimisation shall have adequate memory for colour
graphics, system software and software packages as per Scope of Supply & Price Schedule.
The department level processors, I/Os, power supplies, interface modules & network communication
devices shall be suitable for operation up to 50 .C temperature and computers for supervisory control
and optimisation shall be suitable for operation up to 35 .C temperature but air conditioned room
with positive air pressure is preffered for automation system. The department level processors shall
also have the power supply unit to supply regulated power for the processor system. The power
supply unit shall have over voltage protection, its own diagnostic features to ensure its healthiness and
provide audio-visual alarm for under/over voltage, over current etc. faults. The power supply outputs
shall have protection against over voltage to connected load.
At the department level control, the tasks accomplished are acceptance of commands from the
operator from any of the operator station and giving feedback. Acceptance of commands from the
optimization packages, bulk solid analyzer, X-ray systems, refractory management system etc.
Interlocking and sequencing measures, carrying out of process control function & transmissions of
system fault annunciations to (MMI) supervisory control level. I/O and programme scanning, alarm
generation etc. The programming shall be so done that the controllers shall take the commands /set
points either from the MMI or from the / Mills optimization packages, bulk solid analyzer cum
blending control system, X- ray analyzer as the case may be. With in the MMI there shall be two
sources of set points, manually set by operator or by the PID/fuzzy loops in the controller. These
selections shall be seamless and bump less with necessary tracking of set point / process variable both
in manual and auto mode. For these selections soft keys are to be provided in the MMI
At (MMI) supervisory level there shall be PC based operator station. Each VDU terminal shall have its
own keyboard & mouse and be mounted on control desk.
In the normal course of event, the plant operation shall be done through any of (MMI) the supervisory
computer. However, in the event of any failure in any terminal, operation shall be carried out through
any of the other terminal without any interruption.
The computers for supervisory control shall be configured to achieve sequential start/stop of the plant
section-wise through department level control, colour graphics of the plant equipment/ flow,
consisting of a number of pages to give dynamic status of equipment/process in different colours; bar
graph indication of analogue parameters, real time & history trending, process & system alarm
logging, voice alarms, Reporting, SMS facility with required hardware of Critical alarms on
Purchasers wireless communication system (cell phones) , Voice alarm event logging, set point
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change, tuning face plate of PID loops at operators discretion etc. The computer shall have adequate
memory capacity of SCSI hard disk, EPROMs, and RAMs with battery back up.
4.2 PLANT DISTRIBUTED CONTROL SYSTEM DCS
4.2.1 FUNCTIONAL ASPECTS
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The I/O modules should be suitable for following type of inputs and outputs:
Digital Input/output Modules
The input sensing voltage range and the current consumption of input should be suitable to avoid
malfunction.
There shall be interposing relays (DI Connection Unit) between field signals and DI modules. The
relay shall be Phoenix make with model no. OPT-60DC/48DC/100 (2966621) and relay base shall be
Phoenix make with model no. PLC-BSC-230UC/1/SEN/SO46 (2980348).
Status indication for each input shall be included. Each input (Hot) connection may be referred to a
common neutral connection. The inputs may be connected from different power supply sources &
this should not effect in anyway on the input channel or I/O Module as a whole. The common
neutral shall be wired to a terminal set.
Inputs signals may be from MCC/ HT Switchboards, LT Switchboards, VFD drives, Thyristor Panels or
any other field devices like Pushbuttons, pressure switch, DP switch, Limit switch, pull cord switch, belt
sway switch, proximity switches used for zero speed detection & material starvation / level detection
on belt conveyors etc. installed in the field.
Digital output shall be relay output and shall be suitable to drive contactors mounted in MCCs, HT
Switchboards, Drives and solenoid valves in the field.
For DO module interposing relays shall be Omron Make (Electro-mechanical relays) in Phoenix relay
boards. The interposing relays for both input and output shall have individual LED for indication,
replaceable glass fuse, varistor(voltage protector) for protection.
Each output shall have its own fuse protection plus blown fuse and output status indication. Outputs
shall be isolated from each other.
Each output shall have its own Hot, and Load terminals and shall be capable of driving solenoid
valves, relays and contactors having up to 5 Ampere minimum continuous rating and 10Amperes inrush current @ 250V AC
The same input and output cards shall be used for local and remote I/O racks.
Contact output module shall work in conjunction with PID/PI module to
put for close loop operation.
Receipt of binary signal for logging running time of some special machines through counters.
The frequency response of both digital input & output channels shall be selected so as to interface
pulses of 2 wire 230 V AC proximity switches employed for speed monitoring of screw conveyors,
rotary air locks etc. up to 10Hz, pulses from counters in weighing systems etc up to 2 Hz, having low
`on time in the order of milliseconds and pulsed outputs required for bag filter solenoid valves having
`on time of about 1 seconds. These timings shall be taken care including the I/O and program scanning
time of the controller. For pulsed outputs having very short duration, viz solenoid valves of bag filters
etc, Solid state switching modules having switching at high end (i.e. no hot line / power to solenoid coil
when the output is off) and negligible off state leakage current may be considered.
The DI connection unit relay voltage sensing range shall be above 150V AC, to avoid false sensing
because of induction voltages.
Sufficient and necessary measures are to be considered for reducing the effect of false sensing of
inputs due to induction voltages associated with long multi core cables. Vitreous enamelled, wire
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wound bleeder resistance of suitable rating or any other device are to be used to offset, the off-state
leakage current effect produced by 2-wire AC proximity switches interfaced directly to the input
channels of I/O like ZSS, belt starvation switches.
4.2.2 ANALOG INPUT/OUTPUT MODULES
Input modules shall be dual ended industry standard analog signals of at least 12 bit resolutions.
Signals from transducers will be 4-20mA DC for special cases and specifically mentioned, otherwise all
field instruments are interfaced with bus powered, field bus avoiding 4-20mA loop. 420mA Analog
input cards should be able to process signals within this range +/- 5%. Outside this range, signals
should be marked as bad quality. However they can handle up to 30mA. The supplier is to assume that
all transducers / transmitters will draw 24VDC from the system power supply and size the same
accordingly. The required 24DC Volt DC power supply shall be housed in each I/O cubical, having group
isolation and fuse protection for each channel.
Analog Outputs for special / specific cases shall be galvanically isolated signals each providing at least
16 bit resolution. Output signals shall be 4-20 mA into a load of at least 750 ohms. All analog output
requirements in general shall be catered by the field bus / digital network avoiding 420mA loops.
Input signals such as resistance temperature detectors (RTD) and other zero based signals will be
connected directly to the Suppliers special input modules. Such RTD module shall accept PT 100, 3 / 4
wire RTD with lead wire compensation. The response for sensor break shall be configurable. Their
configuration shall have scaling, filtering, range, linearising, rate of raise validity, alarms, differential
temperature between channels etc.
4-20mA & 0 10 V analogue isolated output for close loop control and reference value. All analog
output requirements in general shall be catered by the bus powered, field bus / digital network
avoiding 420 mA loops.
24V power supply pack for 2-wire field instruments shall be located in I/O panels and its power
distribution with necessary glass fuse protection and discharging diode to be considered. 24V DC
Power supply rating shall not be less than 10Amp for field transmitters.
The error of Analog I/O modules shall be better than 0.1 %
4.2.3 DEPARTMENT LEVEL PROCESSORS
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Group level processor will be supplied in a configuration to ensure continuous and bump less
processing of data while permitting on-line changes to control logic. There shall be an online and
offline programming feature. The programmable controller shall have Remote, run, program, online
program & test modes(Simulation mode).
All processors will be sized for not less than 150% of the I/O requirement both in terms of physical and
memory size handling.
Group level processor (programmable controller) shall have at least 40% memory capacity left free &
unused after the final programming is completed and while handing over the system. Processor clock
speed shall be 133 Mhz minimum.
Any failure of the power supply shall be indicated as system alarm in the engineering station and MMI.
Suitable protections (Surge suppressors etc.) shall be provided to ensure trouble free operation of
Power supplies.
These programmable controllers shall have visual indication for the processor / CPU status, backup
battery status, forced I/O status, activity status of all communication channels and I/O
communication. The system alarm / fault conditions are to be reported in the programming /
configuring software as well as in the MMI.
The programmable controller shall have Flash PROMS for upgrading the firmware through the
programming / configuring software. The processor configuration and user software are to be stored
in a battery backed up memory of sufficient capacity like RAM or non volatile memory for its
continuous utilization. The battery backup for memory shall be for at least one year with out power to
the controller. Also the controller shall have another memory storage means with in itself like
EEPROM / SCSI of sufficient capacity to restore the software backup in case of eventualities. Specific
means are to be made available in the controller for restoring this stand by backup in to the main
memory even without the requirement of the programming station. How ever periodic backup are to
be taken in the programming / engineering station.
The controllers shall be of minimum 32 bit, high performance, RISC, multi task processing including a
capability to process in 16 bits and shall be chosen to have the following loading pattern while handing
over with the entire plant running in its full mode and configuration. The CPU load shall be less than
60% , the memory utilization shall be within 60% , the loading of communication channels like high
speed Ethernet, I/O channels, programming terminal channel if any shall be less than 60% .
For any tag whether it is of I/O, digital, analog, field bus, calculated, derived, MMI, MIS, EMS / load
monitoring system, expert system / optimization package based, tags from X ray / bulk solid analyzer
etc, the tag name or identification shall be unique and same throughout the system where ever it is
referred. There shall not be any tag name conversion or cross-reference required for the entire
system. Any inclusion and deletion of the tags, changes in the tag attributes, values etc. done on the
engineering station or any other MMI / station in the network are to be reflected and updated in all
the MMI / stations in the system and vice versa.
The programmable controller & its software shall be confirming to IEC - 61131 programming standards
having ladder, Structures text, statement list, functional block diagram & sequential function chart.
Intermingling use of these languages with in a single controller as per the requirement of the
application shall be enabled and permitted. The software shall have features for conversion of
program developed in one language to other. All these languages shall work in their native form
without translation from one to another language before execution. However with respect to the
controller and its functioning there shall not be any adverse or favorable effect for one language over
the other. The programming of the controller shall be object and tag based. The controllers / software
shall have pre configured library programs / functional blocks meant for process plants like cement
plant embedded in to them. These library objects can be used as many times as required in the
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system. Also these library objects can be modified as per user requirement and saved as a new object
in the library. Any library program or function block developed in any one of the controller can be
easily exported and used in another controller for monitoring & control purposes.
Licensed OS & Application software bundle for online & offline programming, configuring, diagnosis,
troubleshooting, firmware update of flash PROMs of the department level controllers along with
necessary drivers and interfaces are to be provided. This software shall be multi user windows based
engineering & commissioning tool and shall be of professional edition. Apart from engineering station,
one more MMI shall have all the requirements in terms of hardware and software to be utilized as an
engineering station. Such windows based software along with controller shall have the following
features.
Online and offline programming with drag & drop, cut / copy & paste, search & replace, editing and
both manual and auto backup utility
Object based programming using active-X faceplates, COM, DCOM. Pre configured Library / reusable
program modules containing process plant related functions. This shall support OPC.
Graphical Configuration of the controller, its memory, its DB, its functions, its status and modes,
Graphical Configuration of communication channels, I/O interface modules, analog and digital I/O
modules, Special interface modules, Field bus modules etc.
Creation and modification of tags. Searching with listing filters for tags, words, specific instruction,
block, forced I/O, used and unused tags etc
Diagnosing and troubleshooting of the controller, communication channels, I/O and other interfaces.
Firmware update in the Flash PROMs of the controller / I/O modules
Forcing of I/Os, Forced I/O shall be easily accessible with different colour at client stations. There
shall also be provision for withdrawing a dedicated list of forced i/os controller wise. Mirror image of
I/O shall be available separately to confirm removal of bypass at the operator station itself. Force
activation tracking facility with access password and key data entry to get forcing activation shall be
provided.
Programming of logics, sequential controls, startup / safety / process interlock functions and timed
operations.
All of IEC 61131-3 programming standards.
Program & data base backup and restore facility. Up load / down load of program and DB Between
controller and Engineering station and between the RAM and backup memory with in the controller.
A browsing tool to navigate and locate different controllers, objects, programs, files, devices, I/O,
nodes & tags
Integrated online documentation tools for creating of I/O charts, data base, documents for FBD, Tag
list with attributes
Analog input / output processing with dead band, scale, range, trigger, threshold, filter - first/ second
order & butter worth filters, sample rate, multiplication factor, hysteresis, rate of change, hi, (hihi) /
low (low low) / deviation alarms, clamp, square root, square, ramp, spike suppression, overflow,
linearising etc.
Functions / instructions like, relay instructions, immediate input, output latch /unlatch, one shot raise
/lower, type conversions, logic gates, flip-flops, multiplexers, decoders, on/off delay timers, retentive
timers, bi directional counters, high speed counters, clock, clear, High/Low selection, comparison,
absolute value, limit monitoring functions, Rate limiter, lookup tables, generation of curve, arithmetic
functions, logarithmic, trigonometric calculation, math, Averaging, max / min, SD, square root, sort,
integrators, totalizer, Ratio, PID, Enhanced PID, Predictive control, multi variable control, Fuzzy,
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totaliser, file operations like search / compare, copy, move, fill etc., if, for, else, next, break, jump,
return, end, label, FIFO, message, string, ASCII instructions, block data transfer, Bit shift, bit mask, bit
unpack, rate of change detection, edge detection etc.
Auto tuning software for the control loops like PID / fuzzy etc.
The PID blocks shall have different set of controller parameters (Kp, Ti etc) to adopt for process
dynamic condition and any set of parameter can be selected by the operator with necessary authority
Subroutine objects for various applications like group, AC/ DC drives, DOL, RDOL motors, auto
calibration for damper, Solid flow meters, ZSS, bag filter timers, running hours and any other repeated
controls with input & output pins.
Modes for drives, loops Auto / Manual, Local / Remote
The following additional software are to be loaded and are to be used in the engineering station and
another MMI that is capable of working as an engineering station.
1) All the necessary software, drivers and interfaces required for the filed bus instruments like FDT,
DTM etc, GSD, EDS, DDL files, device / transmitter specific software so as to read / write the data,
diagnose, configure, calibrate, restore factory setting, tune and access those field instruments
through the network. If HART instruments are used then the respective software are also to be
made available.
2) Necessary software, interfaces, drivers required for the AC / DC drive systems for applications like
drive monitoring, configuration, parameterization, trending, troubleshooting, upload /down load
of parameters etc through the network.
3) The softwares those are required for the configuration, programming, diagnosing, up/down
loading and troubleshooting of programmable controllers for the sub control systems in the plant,
supplied by different vendors along with necessary drivers and interfaces. This shall enable the
engineering station as well as the MMI to read / write data in to those controllers at site through
the network. No separate PC or configurator shall be used for configuring the above mentioned
devices & all the mentioned software shall be available inbuilt in the system itself. All of the above
software shall also be available in the Laptop also along with other software. The Processor
software shall be capable of communicating and setting of communication parameters for all
Profibus related software systems like Transmitters, VFDs, SCS PLCs, RS 485 Communication.
4.2.4
This shall consist of large capacity computers comprising colour monitor with keyboards, printers,
programming aids etc. The MMI programming and configuration shall be enabled in all the MMI
stations with password privileges. Any creation, change or modification done in any one MMI shall be
reflected and updated in all MMI stations in the network. There shall be an automatically generated
cross- reference list in what display each tag is used. The database shall be global and available in all
MMI stations. The MMI stations shall have simultaneous multiple controllers support, so that all
controllers are accessed from any of the MMI station for control & monitoring. The OS shall be on
latest windows platform. There shall be tool tips for all GUI. MMI system shall be object based and
shall support / apply standards like ActiveX controls, COM / DCOM, OPC version 2.0 or later, ODBC,
advanced DDE, Web enabled - Microsoft Internet explorer, Microsoft visual basic, SQL & MS office
suits like Excel, Word and Access. All PCs are suitable for Workstation Grade.
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Colour graphic terminals / MMI stations shall have 22 inches, anti glare, flat screen, sleek, LCD Colour
monitor (TFT) with keyboard. The pictorial information shall be displayed on the colour monitor in a
variety of colours.
Keyboard shall be normal windows 104 QWERTY keyboard and the mouse shall be Optical with scroll
button. They are used to perform the following functions, which are indicative only. The system shall
be so designed to keep the operator at ease for monitoring and controlling the plant effectively:
a. Group/path/standby equipment selection, group selection / start / stop / EM stop, Individual
drive selection in-group / out of group / start / stop, opening & closing of popup/pull down
displays for equipment / interlock status / trends and navigating between pages with soft keys
(hyper link) and mouse click. Intuitive navigation using short cuts, direct input etc.
b. Introduce new set values for close loop control and provide set value for open loop control
with mouse click and entering values with key board.
c. Select, acknowledge and reset system and process alarms with mouse click
d. Activate or de-activate, Auto / manual selection of control loops and opting of expert /
optimization system control in / out for a particular loop using soft keys
e. Select variables for single or multi-trend real time & log displays.
f. Call up various graphic or alphanumeric displays using soft keys. The MMI shall support picture
in picture
g. Change maximum and minimum alarm and trip values of process variables, Forcing of I/O.
h. Display build time under all conditions is to be less than 3 seconds. Display update time under
all conditions is to be less than 1 second.
i. Adjustments of the process parameters with software protection having different levels of
privileges. Suitable interlocking/safety features to be provided such that changes are carried
out by an Authorised Agency only.
j. The colour monitor shall display the following in various combinations:
Process and plant conditions in flow sheet form with line and three-dimensional figures.
This shall consist of static and dynamic objects with animation like visibility, colour fill,
blinking, colour change etc.
Measurement value with engineering units, data, texts
Real time & historical Trend log display with scroll keys.
One mimic page for each group
Zoom facility for any section of the mimic page
Current and historical, acknowledged / unacknowledged system and process alarms
Current and historical events and operator actions.
Log sheet and reports
Integrated views of third party software packages
System Configuration
SCS Configuration
DP/PA Configuration
Drawing document attachment
Fault Navigation
Asset Management
Short notes on logic
Plant overview
All pictures shall have a uniform frame consisting of:
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Heading
Dialogue lines
Picture
This picture shall indicate the latest in-coming fault / alarm message from each plant section. The
alarm shall be displayed in different colours as per priority. Such priority levels are to be configured by
the user. The system alarm message shall have different colour from that of process alarms and shall
have the top priority. A flashing star shall be provided near the alarm message, which shall remain in
flashing condition as long as the alarm is not accepted.
The text of alarm message however, shall remain steady. Once the alarm is accepted, the star shall
become steady.
An alarm banner shall be incorporated in all main as well as zoom pages. This displays the latest alarm
with date & time stamp. The time stamping accuracy shall be less than 50 ms. System alarms &
machine safety alarms shall appear in all alarm banners irrespective of the process graphics page kept
open. For process alarms, the alarms that can be shown in the banner for that particular graphic page
are user selectable controller, group, section or department wise. Any popup window shall not
cover the alarm banner. The alarm text shall be user configurable. In case of process variables the
alarm banner shall display the value at the time of alarm with engineering units and the alarm set
point. This set point shall have hysteresis, alarm delay, alarm repeat time with set value in absolute
terms or in percentage terms to avoid multiple alarms. The alarm display shall also have the tag name
and priority number along with text. Every alarm shall have a provision for voice message, which will
be played during alarm (like wave file). This voice message can be user recordable and attached to
each alarm as required. This voice message shall also be acknowledged as the alarm text is
acknowledged.
The process & machine safety alarms shall be grouped process section wise or group wise and with in
that group they are sub-grouped as function wise (department Process, production, mechanical,
electrical, instrumentation, utility etc.) Both current alarms and historical alarms shall be called to
display either main group wise or sub group wise. These alarm display shall have filters with pull down
menus having check boxes & text fields / buttons for selecting or deselecting of all alarms / group /
sub group / specific equipment or machine, tag, process / system alarms, period with date and time,
priority, acknowledged / unacknowledged alarms, current / history alarms, alarms having operators
note Etc. The alarm list can be exported to MS excel. The alarm history can be archived using
removable media. The alarm list or a particular alarm shall have provision to send the same to EANICPL
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mail/SMS recipients over the intranet or Internet as the case may be. The decision shall lie with the
operator.
Every alarm shall have one text field / file associated with it having space for up to 10 lines / 150
words or equivalent number of characters for operators to enter notes. The hard disk memory space
shall be occupied / utilized only if the operator uses that option for any alarm. This operator notes are
also shall be available in the alarm history. The present date & time and the operator identity are to be
attached to such notes when they are created / modified.
4.2.7 EVENTS:
There shall be an event recording system in the MMI. There shall be an event banner in each main as
well as zoom pages. This displays the latest event with, tag name / equipment name, date & time
stamp. Events are displayed in a colour distinct from alarm messages. Event here means all operator
control actions like log in, security level changes, start / stop / EM stop of group / drives, set point
changes for loops / devices like weigh feeders / solid flow meters / VFD - speed / damper opening /
actuators etc, selection of equipment in /out of group, auto / manual selection of loops, selection of
expert / optimization control for any loop, blocking of process variable, bypassing of ZSS & other
signals and any status, acknowledging of alarms, online DB modifications, system restart messages,
activity that are not treated as alarms and at the same time required to be recorded etc.
For reporting the events, they shall have standard set of (library which is user created / modified)
texts as defined during detailed engineering like started, stopped, selected in group, bypassed, set
point changed from previous to current, auto selected, manual selected, increased, decreased, open
command, close command etc. Since the MMI is object based, those events that may be applicable
and required for that object can be associated with it while configuring that object.
The events shall be grouped process section wise or group wise. The event display shall have filters
with pull down menus having check boxes & text fields for selecting or deselecting of all events /
group / sub group / specific equipment or machine, period with date and time Etc. The event list can
be exported to MS excel. The event history can be archived using removable media.
OPERATOR INSTRUCTIONS:
Every object especially drives / machines and equipments shall have a facility to hold instructions,
operator hint (like note pad) which are specific to that, either temporary or permanent. This field can
hold equipment data, operating limits, cautions, taken for maintenance etc. These instruction field /
file associated with the equipment shall have a space for up to 10 lines / 150 words or equivalent
number of characters for operators to enter. This can be considered as an attribute to that object and
can be invoked by right mouse click or with a soft key. The hard disk memory space shall be occupied /
utilized only if the operator uses that option for any equipment. The present date & time and the
operator identity are to be attached to such notes when they are created / modified. A privilege class
is to be created for such entry. A search feature to be provided for listing the tag / object for which a
operator hint is created / modified over a time period.
4.2.8
4.2.9 HISTORICAL:
The picture shall indicate all events & alarms occurred in the last 24 hours in chronological order. The
alarm history shall also be available section wise, Equipment wise.
Historical alarms should be displayed according to the filter settings as mentioned above while
opening them. The same can also be printed in A4 sheet. The alarm history shall be limited only by the
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hard disk space and not otherwise. The period of holding such alarm history is user configurable. The
purging of the history shall be FIFO once the period set is reached. The alarm history shall have all the
alarm attributes associated with the alarms as mentioned above. There shall be a provision for backing
up of this history as soft copy if required and the same can be loaded in to the MMI for viewing and
printing.
Historical events should be displayed according to the filter settings as mentioned above while
opening them. The same can also be printed in A4 sheet. The event history shall be limited only by the
hard disk space and not otherwise. The period of holding such event history is user configurable. The
purging of the history shall be FIFO once the period set is reached. The event history shall have all the
event attributes associated with the events as mentioned above. There shall be a provision for backing
up of this history as soft copy if required and the same can be loaded in to the MMI for viewing and
printing.
4.2.10 ACTUAL FAULTS:
The picture shall indicate fault of various plant sections still prevailing. The operator shall have to press
"Actual Faults" key. All faults prevailed in various plant sections shall be displayed and current alarm
message shall also be displayed.
4.2.11 LOG PICTURES:
There shall be different types of logs pictures played on the running hours specific energy
consumption etc. for shifts, daily and monthly basis.
The process calculations and performance calculations like running hours, specific heat / energy
consumptions etc, can be done in the controller and the same can be provided as a derived tag for
display as well as log sheet purpose.
These log sheets shall be user configurable and modifiable both in terms of structure, pattern and
data. The operator can view the log sheets shift wise, day wise and month wise. The operators can
create their own log sheets with the process variables & structure as required by them. The sampling
rate, time of capturing the data, range of data, format of data and any other tag attributes required
can be selected by the operator using a log sheet creation / editing utility which lists all tags in a tree
like structure with check boxes and selections.
4.2.12 START-UP CONDITION PICTURE:
Before starting a particular section of the plant, operator shall be able to learn from dialogue whether
all start up conditions have been fulfilled i.e. whether all local switches are in remote position if
applicable as in the case of VF drives, all drives of desired section are healthy etc. If any defective start
up conditions are found, the central processor PC shall inform the operator of the defective condition
via the display.
4.2.13 START-UP PROCEDURE PICTURE:
Before starting a particular section of the plant, the operator shall be able to learn from dialogue the
start -up procedure of desired section. A pull down window or a popup window shall be made
available for the same.
Semi-graphical picture
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This picture shall display the desired plant section in mimic form in colour. Status of the various
drives shall be indicated by changing the fill / edge line colour of the symbol / visibility / blinking or
combinations as follows:
This scheme is given, as indicative, detailed and final scheme shall be complied during detailed
engineering. Also refer to section 3.1.1
- Motor ON
- Motor Normal & OFF
:
:
Green fill
White fill
:
:
Some of the other conditions are Equipment / motor started from local, fault while running in local,
fault or statues unhealthy at idle condition, in group or out of group, start-up / safety / process
interlocks satisfied or not, tripped due to fault like overload / due to process interlock / safety
interlock, machine in simulation mode i.e. MCC module in test position, motor under pre trip alarm
etc.
ANALOGUE PROCESS VARIABLES:
Actual values, set points of temperature. Pressure, speed, flow etc. shall be displayed in Bar Graphics
form in addition to numerical display as required. Process variable at alarm condition shall be
indicated in different colour with blinking on the graphics. Bad process variable points are to be
indicated in different form. If required the diagnostic values like sensor temperature etc. apart from
the primary process variable from field bus or smart devices are to be displayed on the graphics.
4.2.15
4.2.16
TREND:
This picture shall display in the form pictures of curve measured or calculated values for process
variables, analog, digital / binary values over a particular period. These trend displays that are
permanent can be grouped and selected from a menu and also by using soft keys assigned and placed
near the relevant equipment on the graphic display page.
All the tags, points either I/O based or derived or from any other system like blending control system /
expert system /refractory management system / EMS etc. can be selected for trending. All such tags at
the discretion of the operator can be invoked for either real time or historical trending. An easy tool
shall be available for configuring such trend displays with pull down windows / menu driven / wizard.
These trends can be temporary or permanent one if saved.
The trend page shall have minimum of six variables per trend display with different colours as selected
by the user. The tag, description, heading for trend, range of displayed variable, auto scale, the
engineering unit, sample frequency required for plotting, period, background colour, pen colour, grid
size etc are configurable by the user. The trend can use the objects like up / down arrow, right / left
arrow, double arrow etc for scrolling, pause, link buttons etc from the object library of MMI.
The trend display shall have a common time scale at the X-axis showing the date and time, different
scales for each variable selected on the Y-axis with engineering unit. Also the Y-axis shall be shown as
common for all variables in terms of percentage. The tag name, description, range, engineering unit,
alarm priority for that tag, etc are to be displayed in the same colour as that of the variable in the
trend as legend. Here the description shall be either the tag description or a user defined one.
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Navigation keys are to be provided for the trends at the time scale axis like, forward / fast forward,
reverse / fast reverse, pause, historical display or current display etc. The period of trend display can
be selected from 1 minute to one month in a single display. On right clicking or by any other means, a
window shall appear to select the period of the trend with calendar, start date, end date, start time,
end time, duration of the trend, format (24 hours) etc. The trend can be seen seamlessly between
current as well as historical data. Both data presented together on a same trend. That is while
scrolling from the historical data up to present time; the trend display shall continue to update real
time values on the screen. There shall be time offset function to trace a signal in real time and
compare it with values from other day. There shall be area zoom within the trend. The trends shall
have facility to pick, calculate, mark and display the peak (max) low (min), mean and average values
for a selected duration.
A ruler function in which, the actual value of the trended variable at that time shall be shown on the
legend while moving the curser of the mouse over the trend curve. A dynamic display showing the
date and time (dd.mm.yyyy - hh.mm.ss) shall be available on the trend page and shall show the time
pertaining to the curser position. A suitable means shall be made to fix points / markers on the trend
curve with automatic value display if desired by the user for specific reasons like take print out or for
presentations. The trend curves shall show points of alarm with specific markers according to alarm
setting of that tag. There shall be a filter option to either select or deselect this option. The trended
variables can be shown either as merged or banded with or without grid lines as per selected option. A
suitable means shall be provided to show / hide (de clutter) individual traces as required with in a
trend display. The trend display shall use maximum area of the monitor screen for clarity. Trends shall
have provisions for operators to include annotations / smart clipboard. The trend values shown over a
defined period can be copied and pasted in to Ms word / excel. Also trends shall be saved as a soft
copy like captured display and also shall be printable.
The trend display shall be built as and when it is called for display, by taking the data from the
historian and current values and then can be seen seamlessly till the display is closed. The historian for
the trends shall be limited only by the size of the memory / hard disk and not otherwise. By default all
the analog tags / points are included for the historian. User can choose any point out of history at any
time and also can included those points if required in future including binary points. The sampling rate
of tags /points shall be user settable for individual tags as per the requirement.
X / Y plots shall be available to trend two values against each other to determine the relationship
between them
However control function blocks like PID controller shall have their own default trends showing PV,
MV, set point and deviation / error for tuning and to learn the behaviour of the controller for different
settings.
4.2.17 GENERAL VIEW:
This picture shall display the following current values of each control loop:
- Actual values
- Set point
- Manipulated value.
Every PID, fuzzy control functional blocks shall have a user-friendly faceplate for tuning and setup by
operators. Such faceplates can be displayed by a mouse click. A privilege class shall be included for
changing the values or tuning the loops. These faceplates shall have data values like PV, MV. Set point,
deviation /error, alarm points and text, auto / manual selection, local / remote set point selection,
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override, trend, All PID tuning values and their multiplication factors, auto tuning, bar graph display
etc.
Application software instruction manuals shall be complete, correct, indexed, and current for the
system supplied. English language manuals will be provided to the End User. If interpretation or
clarification of instructions is required by the End User or Engineer, such assistance shall be readily
available at the End User or Engineer. This includes, but is not limited to, on line help menus,
telephone support, bulletin board or other on-line information, and access to technical specialists.
The software must include at least the following pre-programmed algorithms / function blocks:
-
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Square root,
Characterizer (function generator)
lead / Lag
Averaging, max / min, SD calculation
Integration (accumulator), tantalizer
Exponential filters
Ramp control, ramp function generators
Arithmetic, logarithmic, trigonometric, calculations (floating point & integer)
High/Low selection and limiter
Time delays, queue for digital and analogue signals, clock
AND/OR/XOR/ NOT gates, RS flip flop
Logic (toggle) switch and analogue transfer switch
Rate limiter
PID (proportional, integral, derivative), derivative shall be selectively applied on the error
process variable signal. Face plate for manual tuning and calling in the auto tuning with
password
Fuzzy control blocks
Digital control blocks and /or elements
Bit manipulations like shift, bit mask, unpack
Rate of change / raise detection / edge detection
Input block to accept inverted compound ranges for process variables, set points and
trending function
Motor control DOL, RDOL, damper actuator (on shot & incremental), diverter gate, AC VFD,
DC drive, solenoid valve single / double coil,
Sequence control
Mode selection like Auto/ Manual, Local / Remote
Analog input / output processing with dead band, scale, range, trigger, threshold, filter first/
second order & butter worth filters, sample rate, multiplication factor, hysteresis, rate of
change, hi, (hihi) / lo (lolo) / deviation alarms, clamp, square root square, overflow, spike
suppression, linearsing etc.
Comparators
Counters, speed calculators, multiplexers, decoders, demultiplexers, Running Hours,
Totalizer, Equipment Faceplate
Absolute value generators
Storing elements
Auto calibration routine for damper actuators
Auto calibration routine for solid flow meters / weigh feeders
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Weigh feeder control for total set point with DP control and ratio control to individual
feeders
Zero speed detection function with pulse input from field proximity switches with adjustable
pulse rate / timing and with bypass / block facility
Faceplate for timed operation of solenoid valves employed for bag filters etc. with operator
adjustable on, off and interval timings.
The group timing settings like interval time between drives shall be available in a separate
faceplate and are user adjustable with login rights.
Sequence of operation of silo extraction gates with operator selections
Airflow volume calculations with DP transmitters with temperature compensations.
Performance calculations like total power consumptions, operator efficiency, machine
efficiency, machine productivity, false air, running hour, idle running hour, etc.
Extensive user access rights and different level hierarchy & privileges with security features and
encrypted passwords are to be provided. The screen layout, opening of pull down menus,
information on the menus, access rights etc are governed by the password protection. Some of them
are Instrument Engineer to have access over all programming, editing, full privileges of operators /
process engineers, I/O/ network/ controller/ tag / alarm/ event/ historian/ control loops
configuration, interlocks, graphics development, Full access to field bus devices and drives,
documentation etc. Operator view graphics to all or selective plant, to operate, drive / group start,
stop, equipment selection, equipment in / out of group, give set points, mode change local/remote,
auto /manual, alarm acknowledge / reset, alarm, event list, select & view trends, select point / tag to
trends, alarm notes, equipment operator instructions, log sheets viewing, printing etc. Process
engineer All privileges of operator, tuning of PID, creation/ editing of calculation blocks,
performance equations, log sheet creation, configuration, modification, tag / point blocking,
bypassing of interlocks like ZSS, setting timings for bag filters, alarm voice message, alarm process
alarm priority, alarm / trip level etc,
There shall be a possibility / provision in the MMI system to integrate Live video information via
Ethernet. It shall be possible to use JPEG, JPG, GIF, and BMP images as background or as objects in
the graphics. There shall be one tag per object. The tag Database shall be global. The aspects of the
objects shall be available at aright mouse click including the tag name, attributes, status etc. The tags
Database shall be exported to MS excel by the user with filtering option. The number characters for
tag name shall be minimum 32.
The development of graphics, trends and process display shall be done in any of the MMI stations.
The tags shall be selected through browsing. A power full search tool shall be provided for searching
tags, objects and cross-reference where these are used. The cross-reference generation shall be
automatic within the network. A set of pre configured process related, electrical, pneumatic,
hydraulic, static, dynamic, 2D, 3D objects with attributes shall be available as library for use in the
process display. User can modify any of the library display and can save it to the library. User defined
display / object can also be included in the library.
The total system shall be with global timing including clients, server, controllers, etc.
4.2.18 PRINTER
With the help of collected data, the data logger at the HMI generates the following reports as and
when required and prints command given by the operator:
- Alarm & event history reports
- Operating hours reports
- Production / packing reports
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4.2.19
The computers for engineering station and operator stations (MMI), EMS, MIS server, optimization
packages shall be of HP/DELL Make only.
The engineering station and one of the computers of the MMI shall be provided with CD writer to take
back up. Apart from one Zip drive shall be provided for taking back up.
The engineering station shall be loaded with the necessary software required for MMI graphics
development, configuration and editing and software required for using it as an MMI station. All
software backup are to be taken in different media other than floppy disk.
4.2.20
A laptop computer of latest configuration with necessary licensed software including OS loaded as
Portable Programming Unit for the programmable controller and other field instruments / devices /
drives. This shall act as a portable engineering station. This portable computer shall be loaded with the
necessary software. This laptop computer shall have DVD writer / DVD combo drive, external optical
mouse, USB 2.0 ports, serial and parallel ports, multimedia ports, 10/100 mbps Ethernet port,
necessary hardware, ports, cables and drivers. Any add on device required to take back up like server
to be provided by supplier.
4.2.21 SALIENT FEATURES OF CONTROL SYSTEM
I/O Panel
I/Os in Panels or integrated to MCC shall be connected to department level processor through
redundant serial link(Profibus). Such redundant cables are to be routed in two different routes. Usage
of Armoured data cables shall be considered instead of unarmoured cables in conduits. However the
effect of noise, EMI etc, in an industrial environment is to be taken in to consideration. Armoured OFC
is suggested for this purpose.
High-density I/O modules with modularity of 16 channels shall be provided.
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The output channel shall be suitable for 5 Amp. Current capacity (Potential Free).
All I/O modules including spare I/O modules shall be complete with all accessories like wiring arms /
terminals, mounting base etc. It shall be in ready to use condition.
The I/O and their interfaces shall have provisions to be configured either as remote I/O or as
distributed I/O. The minimum speed of the I/O data communication shall be 10 Mbps. The protocol
envisaged for this purpose is profibus which is widely used, industry standard and open protocol. The
same shall be clearly mentioned in the offer.
There shall be a provision for control system interrogation from anywhere in the network especially
connecting the portable programming terminal (laptop configured as an engineering station) at the I/O
network level for accessing and programming, editing, diagnosing, monitoring the respective
programmable controller through the network. Such interface can be provided one per departmental
level controller at the point of maximum I/O concentration like I/O in MCC. Any way the I/O data
communication will have higher priority than this terminal communication.
TRANSIENT, STATIC & EMI/RFI PROTECTIONS:
The complete technical data for all types of proposed I/O modules including EMI / EMC aspects,
Electrical environment & disturbance immunity compliance, insulation resistance, protection against
impulse voltage, HV electrical noise / surge, burst disturbance, electrostatic discharge, radiated
electromagnetic field disturbance, Radio interference, RF interference according to the applicable
standards (like IEC 60255, EN 55022, EN 50082).
The system shall be internally protected against system errors and hardware damages resulting from
Electrical Transient on power wiring
Electrical Transient on signal wiring
Connecting and disconnecting devices or removing or inserting modules in DCS
The DCS system shall be capable of accepting various signals for its direct use while preventing noise
errors due to Electromagnetic Interferences (EMI) or Radio Frequency Interferences (RFI) including
nearby Radio stations, hand held two way radios, electrical storms , Solenoid valves, relays ,
contactors carrying heavy currents. RFI/EMI noise immunity shall be as per SAMA standard PMC 33.1.
The surge withstands capability for input & output modules shall be as per IEEE 472.
Departmental Level Processor
Memory capacity
I/O Handling Capacity
Remote I/O
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0.1ms/1k
word
including
I/O
as
well as program scan.
Serial port
:
At least one serial port per controller.
Smart / intelligent, digital process transmitters shall be interfaced with respective department level
processors on Profibus. Protocol details shall be furnished to supplier. Necessary hardware and
software shall be included. Those protocols and field bus that supported by the controller offered are
to be indicated in the offer. While calculating the I/O requirement those additional diagnostic and
status parameters / data like sensor temperature etc. from such intelligent transmitters are to be
taken in to account. The system shall be so designed and engineered such that these field bus enabled
transmitters are accessed for two-way read / write communication from the MMI level. The necessary
software, drivers and interfaces required for the filed bus instruments like FDT, DTM etc, GSD, EDS,
DDL files, device / transmitter specific software for calibration, configuration, diagnosis, maintenance,
function block changes are included in the scope. 20% spare components like linking device / segment
coupler, repeater, Power supply, field bus JB, Ts, terminators etc and field bus cables are included in
the scope As for as possible field bus devices / transmitters are going to be used. For any application if
such devices / transmitters are not available, then they will be with 4 20 mA DC analog signal with
HART communication. Hence the I/O and the programmable controllers shall be HART pass through.
Maximum of 15 PA Devices per DP/PA coupler segment and maximum 3 segments and DP/PA
communication through OFC up to the Spur Junction Boxes are envisaged for field devices.
All MCC Feeders and AC drive (LV & MV) shall be connected on bus level (Profibus) in each department
level processor. Necessary hardware, protocol and special cable shall be provided. All SCS panel shall
be provided with the standard interface with plant control system. Details of the interface shall be
provided by the Purchaser. Separate Bus and its communication board for MCC, Drives, SCS and field
devices shall be considered.
Those open network protocols and profibus, those are required for such drives interfacing and
supported by the controller offered ,are to be included. This bus level communication to the controller
shall be direct without gateway. While calculating the I/O requirement those additional electrical
variables, diagnostic, alarm, status data (like winding temperature, motor thermal utilization, heat sink
temperature, last fault occurred etc.) from the drive and the parameterization data that are required
by the drive (like over load setting, speed range, ramp setting, critical speed setting, current limit etc.)
are to be taken in to account. As a safety measure, only the start / stop / EM stop commands/Analog
Setpoint/ are to be interfaced through I/Os also apart from the profibus network.
The system shall be designed and engineered in such a manner that this two way digital open
communication interface shall support and enable reading of process & control data like drive current,
speed, KW, winding temperature etc, status, alarms, faults and diagnostic messages from the drive
and writing of drive parameter, set points etc to the drive from the MMI.
All sub control system shall be connected on bus level(Profibus) in each department level processor
unless & otherwise specified. Necessary hardware, protocol and special cable shall be included.
The programmable controller, the I/O and communication modules shall have the intelligence to act
as independent nodes on the network and need not have to have a controller to perform bridging &
routing, also multiple processors, I/O and communication modules can be mixed and used.
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Minimum speed of communication for the profibus should greater than 1.5 MBPS.
Data Highway
Open system Interconnection type data highway shall be provided (e.g. Ethernet)
Communication speed shall be Min. 100 MB/ sec.
Topology: Bus topology with (two) redundant network having 48 (min) port Manageable Ethernet
switches. 25% spare ports shall be available in Ethernet switches. The failure of any network card in
the MMI station or failure of any one Ethernet switch / anyone Ethernet bus shall not affect the
operation of the plant in any manner.
Redundant OFC Shall be used for monitoring packing plant operations.
Computers for Supervisory Control (MMI), Optimization, Engineering station and
Process
Engineers Room
The machines shall be of rugged and industrial grade version only.
PC placed in process engineers room shall have Internet connectivity with necessary software and
hardware.
The computers at supervisory (MMI) level shall have the following capacity:
No. of tags Unlimited
Multiple window
Limited only by OS capability
No. of trend display pages
Not Specific
Multi trend display
Not Specific
Event list length
20000 events (practically no limit and user
configurable for a specified duration. Only the memory or hard disk space is the limit)
Alarm list length
1000 process alarms and 100 system alarm
(practically no limit and user configurable for a specified duration. Only the memory or hard disk
space is the limit)
Screen change (in secs)
< 1 secs
Display updating (in secs)
< 1 secs
CPU loading
Shall be less than 60% at all times expect
during system startup
Memory loading / utilisation
Shall be less than 60% at all times expect
during system startup and graphics page change
HMI SPARE TAGS
40% spares tags license shall be available
after plant commissioning.
4.3 ENERGY MANAGEMENT SYSTEM
Electrical energy management system shall include supervision of the main electrical feeder and
control of loads with the target to minimize energy cost. The supply of the EMS shall be as per the
Scope of supply & Price schedule.
Relevant data as power factor, peak demand shall be taken into account.
Load control shall be based on production/maintenance planning and shall include priority programs
for selective alarming. Key parameter shall be integrated into the normal operator station display.
Minimum specification required for EMS shall be as per mentioned in Scope of Supply & Price
Schedule.
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For the MIS system, a separate server having stable, reliable and comprehensive data archiving
capacity to act as a data warehouse & algorithms with client server architecture shall be used. The
server shall be connected to the redundant high speed Ethernet highway. The server shall Read / write
data as required from / to the respective controllers / the MMI stations / the X-ray system / Bulk solid
analyzer system / the EMS system / the refractory management system and any other system
available in the plant intra net that may have the data required by the MIS server like lab data.
The server shall have OPC 2.0 (or latest), programmable controller and other system interface
capability. It shall have its own advanced data archiving algorithms to minimize the size of the memory
used for archiving and at the same time maintaining the integrity of the data values. The server shall
have capability to read / write the data in the same format as available in the controller / MMI or
other system & does not require any conversion of data. It shall support 16 & 32 bit float, integer,
BCD, ASCII, binary, I/O image, string data. However for writing of data in to the controller / MMI the
`write attribute of the respective tag shall be enabled by the user. The server shall have auto archiving
mechanisms with backup. The information about other systems that are not in the scope but are
required for the server interface should be possible.
MIS Server suitable for entire plant shall be provided. It shall have the following features for the data
archiving. Data handling having tag name (this tag names shall be same as that used in the control
system), tag description, engineering unit, sample rate, scan classes, data type, range, zero, span,
filtering, dead band, square root, linearising, alarms, multiplication factors, compression and
expansion algorithms, buffers, snap shots, queue, data error reporting etc. The sampling and archiving
of data shall be designed and engineered to take samples automatically from the required system in a
fashion that wont unduly load the high speed bus, the controllers / MMI and also the CPU / memory
utilization of the MIS server. The server shall also have facility to enter manual data in to the database.
The servers hard disc shall hold at least 5 years of plant-archived data.
The server shall have its own maintenance & system management tools to configure the tags,
interface configuration, archive, server management, health check to check the functioning of the
drivers, interfaces, buffer status, archiving activity, read snap shot & archived data, manual archiving,
archive backup routines, archive deletion / inclusion, archive force shifting etc. the server shall have
API, ODBC, OLEDB, OPC interface and data link for RDBMS like Oracle and shall have Excel add-ins for
import / export of data.
Apart from archiving, the server shall have plant view graphics, trends, reports; log sheets as
mentioned below and clients having access privilege in the plant wide intranet can view these. The
same shall be available through World Wide Web. The server shall have powerful SQC, SPC &
calculation ability with performance equation calculation for report generation like production report,
electrical energy report, total & specific heat / power consumptions, operator efficiency, machine
efficiency, machine productivity, heat balance, false air, running hour, idle running hour, plant
stoppage report etc. These report configuration, development and generation shall be user friendly.
This server shall be an interface to the external systems through the plant intranet like user
department computers, ERP system like purchase, stores, maintenance, costing, finance, sales and
interface to the EDP data server. The server shall have necessary hardware, software, interfaces,
drives, security features & firewalls for web connectivity. Through this connectivity the plant
information & status can be made available for viewing at places across the country.
The Management Information software shall be developed for Production Sequence log, Field Statistic
log and Production reports as per the details furnished below. These reports shall be user defined,
user configurable & user modifiable. There shall not be any limit on the number of reports:
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The production sequence log shall contain all operational messages, operational faults and EVENT
alarms in chronological order. EVENT alarms shall only be stored at their appearance. Operational
messages shall include important events only (e.g. start/stop of group on/off of a loop, etc.). A
minimum of 2000 messages shall be stored and printed out on request. Each message shall include
message number, plant reference code, designation of event, date and time.
EVENT messages shall be easily selectable to be displayed or printed. At least two search criterias (e.g.
plant identification code and period of time) shall be available for easy retrieval of stored messages.
4.4.2 FAULT STATISTIC LOG
Statistics shall be kept on all "FAILURE" and "WARNING-ALARMS and DIAGNOSTIC information of the
particular equipment.
The alarms for the particular plant departments and within the plant departments according to control
groups shall be logged. The following shall be printed-out for each of the alarm:
Plant identification code, clear text, counter reading. The statistic logs shall be printed-out on request,
without resetting of the counters.
4.4.3 PRODUCTION REPORTS
The system shall automatically generate a shift report after each shift, a daily report at the end of the
last shift and a monthly report at the end of each month. Print-out shall be on request, except the
daily report, which shall be printed-out automatically.
The reports shall contain all basic production and consumption figure sorted per department e.g.
integrated values of all products, storage capacities at the beginning and at the end of the report,
maximum-mean-and minimum production and process values, running hours, total and specific
consumption.
The production reports shall indicate a computer stop during the reporting period (if any). Printingout of any content available on the displays shall be possible.
It shall easily be possible to modify titles and the content of the report. It shall also be possible to
manually enter additional information to the finished report.
The operator shall also be able to request the following reports:
4.4.4 ACTUAL REPORT:
Report from the beginning of the current shift to the actual time.
4.4.5 SHIFT REPORT:
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Report from the last reset of relative values to the actual time.
The system shall also provide remote work place approach to interface with stores, purchase, finance,
maintenance for production related activities.
4.5
SCOPE OF WORK
Supply, installation and implementation of Optimization system in the following areas at our ANICPL
works, with supply of all software with original licenses, Hardwares, implementation and
commissioning
4.5.1
Cement Mill Roll Press with finish mode / Roller press with Ball mill circuit (optional) Main M/C
Supplier Details Shall be Furnished Later
Pre-configuration of the system will be taken up at your premises with proven strategy for a plant of
similar design and process. These approach concepts in conjunction with our methodology as
prescribed in our discussions shall be used as the basis for commissioning.
The equipment test should be conducted in fully integrated system. Initial performance tests will be
carried out using benchmark strategies. Both tests should be conducted prior to shipment.
S.NO
DESCRIPTION
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1 x SPC Module
1 x Personal Assistant
1 x DCS Connectivity
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4.5.3 DOCUMENTATION
The following documents shall be provided for reference of purchaser prior to dispatch of equipment:
4.5.4 HARDWARE C&I
Detailed descriptions, catalogs, O & M manuals, drawings and diagrams of all hardware supplied,
containing:
- Functional descriptions of systems, system manual (Complete DCS System)
- Functional descriptions of keyboard, MMI, I/O, power supplies, panels, etc.
- Procedure to operate and handle control equipment, controller, I/O, Data cabling, EMC
guidelines.
- Procedure to test, calibrate and trouble shoot.
- Maintenance descriptions
- Adjustment of ranges, parameters etc.
- Field bus, I/O bus, data highway system cable specifications, network calculations & procedures
for interface
- G.A, internal layout of the control desks, special furniture, and GA & wiring scheme of I/O panel,
processor panel, Field mounted I/O panel, power distribution board and junction boxes with
complete bill of material.
- System configuration diagram showing field bus instruments / drives, I/O, controllers, EMS, X-ray
system, bulk solid analyzer system, refractory management system & MMI stations showing
approximate distance, type of media used and other major components in the network.
- Service support policy with respect to hardware and software supplied.
4.5.5 SOFTWARE
Detailed functional description of all standard software packages including OS as well as the usersoftware for:
- Supervisory level system (MMI) including graphics / tag / trends configuration &
development, event, alarm generation, OPC interface, Active X controls, Library, control loop
tuning, backup utility etc.
- Department level system controller, I/O and communication channels, programming,
configuration, diagnosis, troubleshooting, instruction sets, and description
- Any other system containing Software packages like MIS, EMS system, optimization package etc.
- Field bus devices (Profibus) / drives
The Instruction shall include
- Information to carry out changes and adjustments, setting parameters, ranges,etc.
- Functional plans providing easy understanding of package.
- Functional descriptions of special systems, e.g. PID Loops, fuzzy controllers
- Procedures of documentation and storage.
4.5.6 PROCESS CONTROL DESCRIPTIONS
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1. Number of nodes connected on profibus shall be as per Annexure-B enclosed in Scope of Supply
& Price Schedule
2. Profibus connector shall be with LED indication and suitable to connect diagnostic tool shall be
considered
3. Dualised servers in the system have been considered with parallel hot redundancy.
4. Processors shall be suitable for continuous running in 50 deg C room temperature.
5. Following shall be considered for profibus network
a)
b)
c)
d)
e)
f)
g)
I/O cubicle
MCC.
Transmitter.
Drive.
SCS.
MV Panels
Meters
Maximum DP nodes shall be limited to 30 Nos. and with repeater 60 nos. for MCC, 40 DP
node for SCSs & VFDs and execution of data within 500 msec to be ensured.PA nodes shall be
limited to15 Nos per segment with max 3 segments.
6. Minimum 1.5 Mbps speed shall be maintained between the following
a)
b)
c)
d)
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13. Minimum five engineers and four Forman shall be deputed for engineering and site
supervision.
14. The disk capacity for data storage shall be for the period of atleast 3 months.
15. Release version of software of MMC level and group level processor shall be latest one.
16. Changes in supervisory software shall be effected through Engineering station & shall be
updated automatically to all operating stations. The operator shall remain active while such
changes are carried out.
17. Default status of outputs shall attain in the event of failure of any of the group PCs.
18. The system shall have multi window features simultaneously active.
19. Freely configurable trend graphs ready for instant use shall be made available during post
commissioning period besides pre assigned trends.
20. The system shall display the overview of the system hardware in block diagram and any
hardware fault shall be displayed by change in colour. A comprehensive diagnostic shall be
included to monitor hardware status on all the operator stations.
21. DP/PA coupler shall be supplied with end terminator.
22. For all I/O panel and processor panels, Thickness for load bearing member shall be 2 mm and
for non load bearing member shall be 1.6 mm.
23. Special tools, tackles, erection hardware etc. required for successful installation and
commissioning of the complete system shall be included in the scope of supply whether
specifically mentioned in this document or not.
24. The operator station shall be workstation grade PC with latest Configuration not ordinary
server/commercial grade.
25. For MIS & EMS separate Server/PC at the OS level should be provided with necessary software
and hardware for interface with Main Plant DCS. License for MIS and engineering software
shall be valid for 5 remote (Web display clients) & 5 local clients.
26. Surge suppressor will be provided on input as well as output side of each communication bus
of MTL/Phoenix make.
27. All operating system software (Windows (latest compatible with the offered system))
platforms shall be in single platform except server at OS / Engineering level.
28. Fire-wall with anti-virus software with license CD shall be provided for all OS/Server grade
applications.
29. MIS/EMS package Manager shall be suitable for energy management system.
30. All field digital signals shall be routed through a glass fuse of 2 amp rating.
31. The quantity / inventory or spare hardware, which would be maintained at site by the supplier
for instant replacement during the warranty period shall maintain by his own spares for
commissioning at site other than procured by the customer.
32. There shall be free upgradation of softwares with License and required hardware if new
SCADA and controller programming software in case the supplied software goes obsolete
within 3 years of commissioning and shall confirm to extend Product & Service support for 10
years from commissioning.
33. Heater with thermostat for all panels for 3 deg C shall be considered.
34. 1 no. Profibus board for EMS at all station shall be considered.
35. CPP data interface to view its MIS & Plant view software and hardware.
36. Future plant expansion data exchange for view & control with existing server & clients.
37. Auto schedule system back up facility.
38. Free training for 8 engineers at suppliers works for DCS.
39. Voice alarm facility shall be considered.
40. Forced IO list schedule updates & report to MIS.
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41. Signal forcing registration in system with time stamp & user name.
42. System configuration, SCS networking, DP/PA networking, Drawings / documents attachment
to object, fault navigation, asset management short notes on logic, plant overview pages to be
define & dynamically updated wherever possible.
43. Alarm event suppression for pin point information.
44. Plant efficiency calculation sheet shall be furnished after plant commissioning.
45. General purpose CCTV system shall interface to the LAN.
46. MIS/EMS shall be understood deeply with third party interface and protection against
unauthorised access & virus.
47. 20% spare networking hardware shall be considered.
48. Fibre & Networking cable shall be colour coded & meter marking.
49. AMC comprehensive for 1 year for UPS, Telephones etc.
50. Critical system finalisation with Technical recommendations from ANICPL.
51. EO commissioning starts within 3 months and final commissioning with in 6 months after plant
commissioning.
52. Commissioning spare kit shall be available with commissioning engineers.
53. Service agreement for 3 visits/3days per year for 1 year and two emergency visit.
54. CCR printers shall be IP printers & others shall be USB printers.
55. No settlement in between Project execution for anything required for system completion and
for best engineering practise to complete the system. Any settlement will be settled after plant
start up. Execution shall not suffer on account of it.
56. Dash board shall be provided in MIS for non reporting parameters.
57. Model predict control shall be part of EO.
58. Alarm/event suppression for pin point information
59. Totaliser updation time shall be configurable 10msec to 10 sec.
60. Battery back up capacity for controller shall be 360 Hrs.
Supervisory control level (MMI) shall be so configured that the operation, faults and alarms of Packing
Plant can also be monitored in operator station in CCR apart from control through packing plant
control room.
The computer platform for Engineering station, optimisation systems and process engineers system
shall be identical to plant supervisory control system.
Total numbers of close loop controls are estimated around 35. These closed loops are combination of
pulse / analog output.
The following redundancy schemes are to be followed for the control system. At I/O level redundancy
of power supply has been envisaged. For the network cabling, MMI level High speed Ethernet shall
have a hot redundant architecture. That is two data media are laid in two different roots. The I/Os in
different shipping sections of MCC are to be interconnected with similar two numbers of data media.
For the profibus bus cabling to the field transmitters / devices profibus cable are to be laid up to the
segment coupler / linking device. Each stub / branch need not to have redundancy.
Armoured type cables should be considered for OFC, UTP, STP, Coaxial, screened cables and all other
data cables which are going to outside the room. However, there shall not be any compromise on
performance, functionality, EMI / EMC aspects, Electrical environment & disturbance immunity
compliance, protection against impulse voltage, HV electrical noise / surge, burst disturbance,
electrostatic discharge, RF interference and availability.
Optical Fiber Cables shall have a rugged construction, excellent mechanical protection and superior
protection in adverse environments . The armoring shall be of aluminum or steel. It shall have
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protection from crushing, cutting and rodents. It shall be suitable for Industrial environments, Inter
and Intra Building Installations. It shall have hybrid compositions in loose tube or tight buffer
constructions. It shall have gel filled buffer tubes to prevent water migration and fiber sub-units shall
be colour coded for easy identification. It shall have length markings in meters for easy determination
of cable length.
4.5.8 SURGE & LIGHTNING PROTECTION DEVICES
Surge & Lightning protection devices at the input power supply line of UPS, PLC Cabinets, VFD panels
etc:
The device used in this application shall be of stage II/ Class c type. The surge current handling capacity
of device shall 20KA of 8/20 uS waveform and for the rated voltage. The device shall be pluggable and
shall have the necessary diagnostic functions like overload Indication and remote outputs. It shall
confirm to the latest IEC 61643-12.
Surge & Lightning protection devices for Profibus and Serial interface:
The device (for the required 2-wire or 4-wire Interface) shall have the surge handling capacity of 10KA
(Core-Core) and 20 KA (between Core- Ground). The device shall be pluggable and on-site testable. It
shall confirm to the latest IEC 61643-21.
Surge & Lightning protection devices for Ethernet:
The device for Ethernet networks (Along with RJ45 connectors) shall be able to protect all signal paths.
The discharge surge current handling capacity of device shall be 350 A/ 2.5KA (Between Core-Core/
Core-Ground) of 8/20 uS waveform. The protection adapter shall fulfill the performance requirement
and transmission quality in acc with class D (cat. 5e). The device shall confirm the test standards in acc
with IEC-61643-21.
Surge protection devices shall be considered for neutral also.
4.5.9 CONTROL DESK
Control desks have been envisaged for Main plant CCR, Packing plant control room & Associated DCS
Engineering room.
Central Control Desk and Local Desk
i) The basic frame work of control desk shall be made from 50x50x6mm MS angle or 30x30x3.2mm
Aluminum angle with extruded Aluminum members bolted construction. CRCA sheets of 2mm
thickness shall be used on all sides and at the bottom of desk and door shall be made from 1.5
mm thick CRCA sheets with suitable stiffeners. Supports for mounting, terminals, PC related
instruments, speaker, power supply units, Power Distribution Boards, etc. shall be provided.
Removable type undrilled cable gland plate shall be provided at the bottom. The aluminum sheet
shall be anodized.
ii) Control desk shall be sand blasted and shall undergo phosphatising treatment after
fabrication of desk. This will be followed by two coats of zinc chromate primer and thereafter
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two coats of air drying nitrocellulose base synthetic enamel paint. The paint shade shall be
decided later in consultation with customer.
iii)Control desk shall be dust and vermin proof, totally enclosed, free standing type. Neoprene
gaskets shall be provided wherever necessary for complete dust proofing. The class of
protection shall be IP42.
iv) Industrial type compact fluorescent tube lights with proper diffuser shall be provided for
illumination of the interior of the control desk and shall have DP MCB for switching. Minimum
two nos of cooling fans shall be provided on the door of control desk for the exhaust of heat
dissipated by computer.
v) Earth bus bar shall be of 35x8 mm copper running through the desk and two numbers terminals
shall be provided for panel body earthing. All the sheet metal body parts, doors and metal
covers of equipments inside the control desk shall be earthed.
vi) Colour Monitors, Key boards, mouse, printers, Public Address System Master Unit, Walkie Talkie
Station, P&T telephone, intercom telephone, CCTV switching unit, Process Log Books etc. Shall
be mounted / placed on Control Desk in appropriate cutouts / suitable arrangements.
vii) Central Control Desk with colour monitors & keyboards shall be configured in U-shape and
sectionalized as per the process departments.
viii) Internal wiring of the control desk shall be done by 2.5 sq.mm PVC insulated stranded copper
conductor.
ix) PVC cable channels shall be provided for panels / desk power, data internal wiring. Data cables
are to be routed away from that of power wirings as per guidelines. Suitable openings are to
be provided between sections of the control desk for inter panel wiring.
x) PVC sleeve number ferrules shall be provided at both the ends of complete internal wiring to
identify their terminal details.
xi) 230 VAC UPS supply shall be provided of adequate capacity at one point of the control desk.
For power distribution tapping within the control desk suitable size copper bus with pre drilled
holes with bolt & nuts are to be used. Proper acrylic shrouding is to be provided for this bus.
Each section of control desk shall be provided with Necessary Incoming MCB, outlet MCB and
sockets for feeding power to PA system, wireless sets, and monitors, PCs, speaker and printers.
Each section of control desk shall also comprise MCB of suitable rating for isolation of power.
Similar arrangement shall also be made for 230 VAC Non-UPS supply to be provided by
purchaser at one point. Service sockets and lighting of control desk shall be done with Non-UPS
supply. Clear markings are to be done to identify UPS supply from Non-UPS supply. These MCB
and power sockets are to be placed having easy access.
xii) The control desk and the associated furniture shall be ergonomically designed as per standard
industrial practices for comfortable working to the operators. At the same time due care to be
taken for the aesthetic look of the same. The control desk shall have hinged doors both on
front and backside. Suitable intake & outlet louvers are to be provided for natural air-cooling.
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There shall be ample space in side for keeping the PCs, speakers, power supplies etc.
xiii) As per the configuration diagram enclosed the Main control desk at CCR shall house the PCs &
monitors for MMI stations, optimization package, One for refractory management system, one
for Quality control lab data, one for MIS, One for EMS, one wireless station, two or three
telephones, one or two PA stations, one PA master console and one CCTV switching unit.
The control desk for packing plant shall be identical and suitable to accommodate the touch
screen type monitor with additional protection from dust entry.
4.5.10 PROCESSOR AND I/O PANEL
For all I/O panel and processor panels, Thickness for load bearing member shall be 2 mm and for non
load bearing member shall be 1.6 mm.
with IP42 protection having solid base frame. They shall be internally wired up to 2.5 mm Sq. size
screwed terminal strips. Internal wiring of panels shall be done by 1 /1.5 mm sq. 1.1 KV grade, 90
Deg.C, PVC insulated stranded tinned copper conductors having tinned copper braided shield.
Analogue and digital signal shall be strictly separated. It is intended to have CPU and I/O in the
separate panel. The programmable controllers shall have separate panels and located in the
Distributed locations control room. The processor panels shall have sufficient space for keeping the
Ethernet switches, field bus interface cards, I/O interface cards, power supplies and the associated
cables. Suitable means of natural & forced ventilation ( with min. 2 nos. of cooling fans) are to be
provided for the panels to evacuate the heat generated in the I/O modules, power supplies, controller
etc.
Power wirings are to be laid away from I/O and data cables. For I/O panels that may have high density
of I/O, shall be of front & back opening front side the I/O, power supplies are mounted /accessed and
necessary terminals if any are to be mounted at the rear side for working convenience. For
programmable controller panels front opening is sufficient.
The I/O panels & controllers shall be installed in each plant area near to the respective motor control
stations / integrated to the MCC and shall be suitable for operation at site ambient temperature. I/O
panels that are required to be mounted at field away from MCC rooms etc shall have IP65 protection.
Controllers & IO panels shall be with RTD for monitoring of Room temperature.
Industrial type fluorescent tube lights with diffuser shall be provided for illumination of the interior of
the panels with DP MCB protection. Suitable rated DP MCB are to be provided for the incoming as well
as for distribution of power in side such panels. A copper earth bus of 25x6 mm with pre-drilled holes
is to be provided at the bottom of the panels. All the metal parts, doors are to be connected to this
earth bus. Special care has to be taken considering the EMC guidelines. All the necessary &
appropriate measures like providing of surge suppressor, filter, Ferrite beads, shielding etc. are to be
done for reducing the effect of EMI in the system and its components in an industrial atmosphere
All cable entries are from bottom. Removable, undrilled sheet steel gland plate to be provided at the
bottom of panels. No terminal block or any other components for that matter are to be placed up to
350 mm from the bottom for glanding and dressing of cables.
Sufficient and necessary measures are to be considered for reducing the effect of false sensing of
inputs due to induction voltages associated with 230V AC for interfacing and long multi core cables.
Suitable earth terminals are to be provided for tying unused cores. Vitreous enameled, wire wound
bleeder resistance of suitable rating or any other device are to be used to offset the off-state leakage
current effect produced by 2- wire AC proximity switches interfaced directly to the input channels of
I/O like ZSS, belt starvation switches.
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These panels shall be sand blasted and shall undergo phosphatising treatment after fabrication of
panel. Two coats of zinc chromate primer and thereafter two coats of air drying nitrocellulose base
synthetic enamel paint shall follow this. The paint shade of processor panels and I/O Panels shall RAL
7035 of DIN.
SPECIFICATION OF CHAIRS
Chairs are envisaged for sitting of operational person in front of VDU in Control rooms.
4.5.11
Chairs shall be executive type and very comfortable to sit. It shall be revolving type. It shall be rugged
in construction. The design of chairs shall be as per ISO 9241, Part-5 standards. The chair shall be
designed considering below minimum specs
leg strength of 75 pounds (34 kg) applied one inch (25 mm) from the bottom of the leg
seat strength of 225 pounds (102 kg) dropped from six inches (150 mm) above the seat
seat cycle strength of 100,000 repetitions of 125 pounds (57 kg) dropped from 2 inches (50
mm) above the seat
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considered for synchronization, sharing the load at the output, taking the entire load in the event of
failure of any one UPS, charging of the battery by any one of the UPS either the master or the one that
is live and without fault or both the UPS sharing the battery load. Each UPS shall have provision for
two incomers. The system shall be able to keep a single unit isolated either partially or fully in the
event of disturbances like a simple fuse failure to failure of the entire inverter (any type of one single
failure) without affecting the load. Once the faulty UPS is restored the same shall be put in line and
start sharing the load along with the other one without affecting the load. Paralleling either at DC level
for battery charging or at the AC output bus, the control shall be decentralized to maintain true
redundancy otherwise if independent control is used redundancy shall be considered there also.
Bypass arrangement shall be considered, in case of both UPS fails. Suitable Servo Control Voltage
Stabilizer (SCVS) with isolation transformer shall be provided.
UPS system of each station shall be designed in such fashion that in normal condition both the UPS will
work and each share 50 % of total connected Load and supplying to a common output bus. In the
event of failure of one of the UPS, entire load will be taken care by another UPS automatically without
any time delay i.e. bump less transfer so that none of the plant control system components /
equipments like controllers, PCs, I/O, communication modules, field instruments, X- ray analyzer, bulk
solid analyzer, EMS, MIS, optimization systems are get affected. The Plant Control & Instrumentation
Load shall connect to a common circuit of both the UPSs comprising static switches through main UPS
distribution board. In the event of failure of input AC voltage, power supply shall be made available
from battery.
Common Amarraja/HBL make 1.2 V NiCad battery bank with 02 / 01/ 0.5 Hr backup in hot redundancy
mode with normal operation load sharing having transparent Styrene acrylonitrile container & micro
porous ceramic vent plugs suitable for 60 minutes back up at 100% loading. The battery charging
facility shall be built-in the UPS unit.
UPS shall have individual Input & Output source selection panel. All the UPS shall be considered with
different incoming power supply considered for reliable / redundant operation. For better
maintenance / isolation the UPS output isolator shall be provided in source selection panel itself. In
the event of failure of any one supply second shall immediately take over. Changeover switch shall be
considered for input selection. Changeover switch rating shall be one step higher than the incomer
rating of the UPS panel. All the UPS ratings shall be at 40 Deg.C ambient. All the UPS systems shall be
of modular design and shall be of same platform or model / series except for the change in the ratings.
UPS batteries shall be initially charging through UPS.
Application:
To provide UPS to critical loads in cement plant control & instrumentation systems including nonlinear loads like computers, monitors, SMPS, Programmable controllers, I/O sub systems,
communication modules, X- ray analyzer, Bulk solid analyzer (BSA), MIS server, EMS, field instruments
etc.
Rectifier Type
Digitally controlled 3 phase full wave fully controlled, 12 pulses, Thyristor Bridge or IGBT active
rectifier with necessary isolation transformer, commutating line reactors, harmonic filters, incoming
isolators, fuses etc.There shall be a switching mechanism for adopting between two incoming supplies.
Input
Output
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Accuracy
Overload capacity
: > 0.95
: < 10 %
: yes
Inverter Type
Digitally controlled, sine wave, Pulse width modulated IGBT bridge with necessary output filters and
isolation transformer having voltage and frequency independent control operation.
Input
: As per design requirement
Output
: 230VAC as per requirement as mentioned
earlier, single phase (+5 % Adjustable)
Voltage regulationStatic
Recovery time + 1 % in 20 ms
Output voltage distortion
Frequency regulation
Frequency Syn. Window
Output
Protection :
Overload at 0.8 PF
Inverter efficiency
Crest factor
Non-linear load compatibility
Capacity to clear branch
circuit fuses
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: Static: + 0.5%
: + 1 Hz
: True sine wave
Short circuit and overload including
Instantaneous overload and earth fault
Electronic sensing and operation
: 125%
overload
for
10
minutes,150%overload for 2 minutes,
200% overload for 10 secs.
: > 92 %
: 3:1
: up to 100%
: Yes
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Duty
: Continuous
Overall efficiency
: > 92 %
Losses at No Load
: Supplier to Furnish
Total harmonic content at output
: <5%
Noise level :
< 80 dB at 1 meter
%Load Sharing difference between
: to be furnished by Supplier
Parallel UPS
EMC / EMI compliance
: to be furnished by Supplier
MTBF
: to be furnished by Supplier
Transfer time from Bypass to UPS in Sync
: < 5 msec
Transfer time from UPS to Bypass in Sync
: < 5 msec
Transfer time from UPS to Bypass in UnSync
: < 20 msec
Communication interface
: profibus communication with main dcs
Software tool
Windows based software tool with necessary interface and cable for UPS monitoring & diagnosis
including remote monitoring and interrogation, monitoring of alarms, faults, metering indications,
data logging, status of UPS and battery, setup, tuning, commissioning & maintenance of UPS.
Alarm and Interlocking
Following potential free normally open and fail safe contacts 2A @ 250 V AC, shall be provided for
alarm / annunciation on central control desk:
Following indication shall be provided on the front panel. For these indications a comprehensive, fully
digital, alphanumeric LCD display with membrane key pad & audio alarm buzzer shall be provided for
metering, status / fault / alarm display, mimic, diagnosis, controls, issuing commands like On/ off,
setting up, tuning troubleshooting, testing and commissioning of the UPS. This display shall indicate
the status, alarm, fault etc. in clear text indicating the exact fault / alarm:
Indication
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Boost charging
Normal charging (trickle)
Main supply connected to rectifier
Load connected to UPS I
Load connected to UPS II
Load Connected to both UPS
Failure of rectifier unit - UPS I
Failure of rectifier unit - UPS II
Failure of inverter unit - UPS I
Failure of inverter unit - UPS II
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: Bursar
: Natural or Forced cooling, as per design requirements.
Page # 43
Protection
16/12/2011
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AC input breaker
DC output fuse/breaker
Battery fuse/breaker
Automatic charge control according to the rate and duration of battery
discharge
Rectifier current limit
Reverse battery protection
Inverter short circuit and current limit protection
Static switch power circuit failure
Battery low voltage
Inverter output breaker
Inverter output short circuit, earth fault & overload
Converter and inverter temperature
DC link over / under voltage
There shall be an intelligent battery management system with microprocessor controlled;
temperature compensated battery-charging system with trickle and boost charging. There shall be a
display available for indicating the battery backup time at the present load conditions. Also the
charging of battery after an input power failure shall be according to the rate of battery discharge and
the duration of discharge and the condition / type of battery thereby increasing battery efficiency and
life. A programmable automatic battery-testing feature shall be included. The battery charging system
shall be suitable for the initial battery charge / discharge cycles required during commissioning.
For power wiring inside the panels, only electrolytic grade copper bus bars shall be used. For lower
power and for small lengths, high conductivity, multi strand, PVC insulated, 1100 V grade, flexible
cables with hydraulically crimped lugs at the ends may be used. The cross section details of the bus bar
/ cable are to be furnished in the offer. The copper bus bars shall be sleeved. The bus bars shall be
suitably supported to avoid stress on the terminals / connections. Copper cable between UPS and
Battery bank shall be supplied. Between battery stands, copper cables shall be used for
interconnection.
All cable entry shall be from the bottom of the panel and a removable undrilled gland plate shall be
provided. No components / devices are to be mounted above such gland plates for up to 500 mm. This
clearance is required for termination of power cables. All Power modules and components shall be
accessible from front of panel only, in case rear access being a must, it shall be indicated clearly in the
bid.
The cooling arrangement shall be that the cooling air passes through the heat sinks in a separate duct
to prevent re-circulation of cooling air inside the panel & dust deposition. The cooling air duct shall be
brought up to the top of the panel / cubicle and vented. The hot air vent duct opening at the top of
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the panel shall have a flange type arrangement with a bolted (removable) sheet steel plate / roof, in
order to provide a suitable ducting arrangement above the panel to lead the hot air out side the room
later if required. No components / accessories / electronic cards shall be in the path / vicinity of the
hot air vented from the UPS. The cooling fans of the UPS shall be able to disassembled for checking /
replacing from the front of the panel and can be replaced during the UPS is on and serving the load.
In the parallel and redundant UPS, necessary and sufficient provisions are to be made for working or
attending the faults in any UPS that has failed while the other continue supplying to the load. Suitable
isolations, shrouding and other safety aspects are to be provided.
5.2 UPS POWER DISTRIBUTION BOARDS
1. Distribution Boards shall be floor mounted type with lifting hooks as per the requirement.
The Main UPS distribution boards for the two UPS systems and the sub distribution boards
meant for each plant section which are located at field / MCC rooms shall be of floor
mounted type only
2. The board shall be heavy duty, totally enclosed; dust and vermin proof (IP 54) having
suitable synthetic rubber gasket for doors. Electrical Danger stickers shall be provided on
the front door. Aluminum anodized, engraved nameplates are to be affixed on the front
door.
3. The board shall be fabricated out of 2mm thick CRCA sheet steel, chemically de rusted,
degreased, phosphatised, primer coated and painted with enamel finish as per DIN RAL
7035 outside and white inside.
4. Base channel (50 x 100mm) shall be provided for floor mounted type panel at the bottom
and painted with black enamel.
5. Doors shall be provided for front operation and shall have padlocking arrangement.
6. The incoming Molded case Circuit Breaker / SFU handle shall be within the door and
operation of the same shall be by opening the door. Same is the case for the outgoing
MCBs also. There shall be no cutout on the door.
7. The DP MCBs on outgoing feeders shall be numbered for their identification.
8. All the phase and neutral bus bars and interconnections shall be colour coded & PVC
sleeved. Transparent acrylic insulating sheet shall be provided for shrouding the live parts.
These bus bars shall be suitably supported with 660 V grade epoxy insulators. These bus
bars shall have suitable sized tapped holes for tapping power to the outgoing MCBs.
Suitable size, colour coded, 1.1KV grade PVC insulated, flexible, multi strand, tinned copper
conductor are to be used for wiring between the Bus bar and the MCB and also for the
MCB to the terminals. These wires are to be provided with identifications on both side and
are laid / dressed in PVC wire ways.
9. For neutral connections, separate neutral bus shall be provided and suitably mounted on
epoxy insulators.
10. Two separate terminals for earthing shall be provided on the panels. These earth studs are
connected to a 25x6 mm copper bus bar having pre drilled and tapped holes running at the
bottom of the panel
11. The board shall be supplied with all interconnections between SFU's, Bus bars and MCBs.
The number and rating of DP MCBs are as required and are mounted on DIN rails for easy
removal & fixing. Suitable size (minimum of 4 Sq.mm) screw on type terminals are to be
provided for phase & neutral of each outgoing MCB with numbering.
12. Extended hylam separators between Double pole MCBs shall be provided to avoid
flashovers from one affecting the other.
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13. Boards shall be suitable for entry of all cable from bottom with undrilled, removable gland
plates.
14. Suitable cable glands and lugs for incoming and outgoing cables shall be provided.
15. Component mounting angle/channel shall be suitably chosen and depth adjusted as per
requirement, so that shrouding sheet covers come in the same vertical plane.
16. Sufficient space for proper termination of incoming and outgoing cables shall be provided
inside the board to facilitate ease of erection, maintenance and repairs. Up to a height of
350 mm shall be left free at the bottom of the panel.
17. Power distribution board shall be provided with earthing strip with screw arrangement.
18. The rating of the incoming MCCB / SFU and outgoing DPMCB are to be well coordinated, so
that any short circuit / earth fault on load side are to be isolated by them without affecting
the UPS.
19. The GA, wiring scheme, rating, BOM of such UPS distributions are to be got approved from
the client.
Junction Boxes
1. Junction boxes shall be heavy duty, wall mounted type, totally enclosed, dust and vermin
proof, enclosure class IP- 54 with synthetic rubber gasket.
2. Junction Boxes be fabricated out of 2 mm thickness sheet, chemically de rusted,
degreased, phosphatised, primer coated and painted with shade RAL 7035 Siemens Gray.
The JB shall have front door either hinged if size is more then 10 terminals or bolted
otherwise. The wall mounting bracket shall be made such that, a gap of 30 mm is
maintained between the JB back side and the mounting plane / wall. Two numbers of earth
studs are to be provided for all JB. For JB having 50 terminal or more shall have one 25 x 3
mm copper earth bus with 5mm pre tapped holes for earthing of shield / drain wires of the
cables.
3. Terminals shall be of screw on type, PVC, DIN rail mounted, suitable for 2.5/1.5 sq.mm
wires with numbering. These terminals are to be fixed at a depth and angle that is
convenient for termination and working and are to be kept projected from the JB back
wall.
4. Junction box shall be provided with 1A/2A glass fuses to avoid inrush of current to the PLC
Modules in case of short circuits etc.
5. Shorting links shall be provided for fused terminals and neutral terminals in each JB. Apart
from the above a set of five earthing terminal blocks of 4 Sq.mm size are to be provided for
JB having 50 terminals and above to terminate spare cores of cables.
6. Sufficient space for proper termination of incoming and outgoing cables shall be provided
inside the junction boxes to facilitate ease of erection, maintenance and repairs. Undrilled
plates are to be provided at the bottom of the JB for cable glanding.
7. PVC channels shall be provided inside junction boxes of 25 terminals and above for proper
dressing and termination ease.
8. Quantity of fuses and shorting links may change during detailed engineering.
9. The GA, dimensional drawing of the different JB are to be got approved from the client.
The purchaser shall approve one number of junction box of each size before the
manufacture of the required quantity
10. 1 no. power socket and light arrangement for 100TB Junction Boxes shall be considered.
11. JB with 100 or more than 100 terminals shall have Light & Power socket.
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All data, field bus, Ethernet, I/O data and CCTV cables that are necessary, including redundant cables
as mentioned in the scope of supply. All connectors, terminators, junction boxes that may require for
these cables shall be the part of system. The outer sheath of these cables are to be colour coded as
per international standards for easy identification.
OFC is envisaged for cables from Programmable controller to Remote I/O and for extension of the high
speed Ethernet to MMI packing plant and to the EMS station at the electrical load centre.
6.0
FIELD INSTRUMENTATION
6.1
GENERAL
Those field instruments, transmitters for measuring temperature, pressure, Air / water flow, level
either continuous or point type, vibration, position, speed, zero speed monitoring etc. meant for
the cement mill both for process control / monitoring, machinery / human safety and that are not
supplied along with the main machinery of any plant which are necessary for the safe, efficient
operation of the plant are included in the scope. The indicative specification of those instruments /
transmitters is given below.
For all the field bus instruments / transmitters either supplied by the Supplier or from the main
machinery supplier, the necessary junction boxes, linking device / segment coupler, repeater, Power
supply, field bus JB, Ts, terminators etc and field bus cables are included in the scope of the
Supplier. Necessary software, drivers and interfaces required for the filed bus instruments like FDT,
DTM etc, GSD, EDS, DDL files, device / transmitter specific software for calibration, configuration,
diagnosis, maintenance, function block changes are included in the scope.
DESIGN DATA AND TECHNICAL SPECIFICATION FOR FIELD PROCESS INSTRUMENTS
6.2
1.
2.
3.
The suitable compact instruments incorporating latest technology with solid-state modular plug-in
construction.
Necessary companion flanges, clamps, mounting brackets, hardware, JB and other accessories to
make the system complete and operational. Any device not included in the specification but
considered necessary for proper erection, mounting and operation of the equipment shall be
deemed to be within the scope of supply under this specification.
Field mounted instruments should be suitable for satisfactory operation under the environmental
working conditions existing in a cement plant and shall necessarily have dust proof sheet metal
enclosure. Care should also be taken to ensure that rats, lizards and other creeping reptiles cannot
enter the instrument enclosure. Additional enclosure, if required, to give better safety should be
included in the scope of supply. Such enclosures shall have a paint shade of DIN RAL 7035. All field
instruments, segment couplers, power supplies, linking devices etc. which by itself are not
confirming to IP65 enclosure, are to be suitably housed in such enclosures without affecting the
performance, function, working, maintenance and access of the instrument / transmitter
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Page # 47
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
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To reduce inventory, as far as possible, standard equipment in standard sizes and ratings should be
offered. The purchaser reserves the right to select the equipment of a particular manufacturer /
type / model and the Supplier shall supply equipment of that particular make/ type / model if so
required.
All openings for ventilation and forced draft etc. shall be suitably protected with screens. When
screens are provided on top of the equipment, means shall be provided to protect them from
falling objects.
The equipment should be designed so as to ensure safety of operating and maintenance personnel.
Aspect of ease of maintenance, testing, calibration and repair should be given due consideration
while designing the equipment.
All equipment offered should be sturdy and continuous duty type. The instruments must retain
their guaranteed accuracy/sensitivity/repeatability/ total probable error under the conditions
existing in cement plant i.e. heat, dust and vibration.
The equipment should be tropicalised and given protective dips to prevent any damage due to
fungus, mildew etc.
The power supply available at the plant site is 415V +10%, 3phase, 50 Hz + 5% and 230 V AC+ 10% .
For other control voltages, adequately rated step down transformers/power supply units shall be
provided by the Supplier.
Standard analogue signal for all measuring circuits shall be 4-20 mA DC(Other than profibus) and
shall be isolated. Pressure & Temperature Transmitters, which are in C&I suppliers scope, shall be
Profibus based.
The output signal (4-20mA DC) for all measuring devices / transmitters shall be galvanically group
isolsation shall be provided isolated from the input signal and from the AC power supply,
ground/earth bus.
The admissible burden (external load) connected to the 4-20 mA DC output of a measuring device
shall be approx. 0-600 Ohms.
Appropriate 4 wire / 2 wire transmitters with galvanically isolated 4-20 mA DC signal for remote
measuring indication will be provided in sub-control systems (e.g. DC drive, AC drive, MCC,
Vibration transmitter, actuator with remote position indication, AC current and power
measurement etc) which are being supplied by other manufacturers.
All control loops shall include fail-safe provisions and shall be stable for all process conditions.
Cyclic stability in general will not be acceptable.
All the tapping points on main machinery shall be provided by the Supplier and at other locations,
such as hoppers, ducts, pipes, inlet/outlet chambers etc., these shall be arranged and made by the
selected Supplier as per drawing / as directed at site.
All steel work shall undergo a process of degreasing, pickling, cold rinsing, phosphating and
passivating. It shall be given two coats of high corrosion resistant primer and finished by
application of synthetic enamel paint of shade 631 of IS:5. The final finished thickness of the paint
film shall not be less than 100 micron.
230V AC to Field Instruments shall be fed from Instrument Power Distribution Boards to be
supplied by the selected Supplier. However, 24V DC to transmitters shall be arranged from power
supply units assembled in I/O panels that are supplied by the Supplier. UPS supply shall be provided
only for powering the electronic circuitry / cards and for I/O interface control voltage of 230 VAC
from MCC control transformer are to be used.
Suitable earthing terminals/ points / studs are to be provided for all instruments as per the
requirements.
To the maximum possible extent only Profibus instruments / transmitters shall be used.
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20.
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While designing and engineering a filed bus system, any segment shall be loaded only up to 60 % of
capacity / number of nodes keeping remaining nodes for future expansion. This spare node shall be
evenly distributed in the plant sections / locations. Spare / free junction boxes / slots are to be
provided for this purpose at site.
In case of non-availability of field bus instrument / transmitter for measuring a particular process /
safety related variable, the same shall be clearly stated in the offer with reason. Such instruments
shall be then with 4 20 mA analog output.
For discrete interface of point contact type instruments like limit switches, proximity switches,
level instruments, pressure switches, flow switches etc. with I/O shall be suitable for 230 V AC VAC
+ 10 % 50 HZ + 6% and all relay outputs shall be rated for 5 A at 250 VAC. All sub control systems if
any shall be in 230 V AC level only.
For all the supplied instruments, transmitters, gas analyzers, RTD, Thermocouple, the test and
calibration report / certificate from the manufacture shall be provided.
All relevant catalogues, complete specification sheets, selection guides, write up, field bus profiles,
tools, and function blocks available; communication protocol etc for the offered instruments /
transmitters shall be furnished in the offer.
The range of the instruments shall be provided during detailed Engg.
The final specifications / configuration / type / model / size / rating / range / dimensions / make for
any of the instrument, sensor, thermocouple/RTD, pressure / temperature transmitter, level
transmitter, Vibration transmitter, proximity switches, zero speed switches, timers, pressure
switches, solenoid valves, PLC, level sensor, safety system etc. are to be approved by DCPA before
procurement and supply.
21.
22.
23.
24.
25.
26.
6.2.2
6.2.3
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thickness. Mounting Adjustable C. S flange of 108 mm dia, 4no 16mm dia hole at 79 mm PCD.
Length below head as per process / plant requirement. Calibration DIN 43760.
b) Bearing RTD: All the RTDs to be with head but with no junction connection at the RTD Head &
with 10 mtrs. Of extentendable Teflon cable with GI Conduit for direct connection at local junction
box.
PT 100, 3 wire, duplex RTD complete with die cast AL. screwed cap, dust & weather proof - IP 65
head with chain, nickel plated, spring loaded brass terminals and ceramic block. Cable entry
ET. Insulation Ceramic beads filled with MgO powder and epoxy sealed. Leads 3 wire, silver &
PTFE insulation. Inset sheath SS316, 8mm OD, Mounting with adjustable SS 316 ferrule fitting.
Length below head as per requirement. Calibration DIN 43760.
Size and type of RTD will be informed during detail engineering. It shall be supplied with necessary
fittings/matching flange and without cable.
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a)
Limit of error
b)
c)
Type
d)
Type of element
: Pt 100, 25 SWG
e)
Insulation
: Mineral
insulated,
elements
embedded in highly compacted
magnesium oxide insulation within
a seamless metallic tube.
f)
Protective
overall dia
g)
sheath
of actual
and :
Mounting
h)
Head
i)
Accessories
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02 LEVEL TRANSMITTERS
For applications without weighing systems and requires continuous level monitoring, like clinker /
gypsum/ slag hoppers and silos / bins of fly ash, cement, slag etc suitable continuous level
monitoring transmitter / instruments are to be employed. The selection of such systems shall be
guided by the type of the material, size of the material, stickiness of the material, moisture content
in the material, possible maximum & minimum temperature, condensation, total & effective height,
minimum / blocking distance, hopper / silo / bin size & shape, location of the instrument verses the
inlet & outlet chutes, interfering structures, scattered echoes, attenuation factors with measuring
range, power supply requirements, field bus interface etc. For such applications suitable type /
model, without moving parts, guided wave radar or non-contact ultrasonic (time of flight)
measurement solutions with interference echo / multiple reflection suppression logics, signal
pattern recognition by fuzzy logic, user friendly, having easy commissioning and setup features . The
exact type, detailed catalog and specification sheet for the proposed measuring solution to be
furnished application wise in the offer.
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Description
ULTRASONIC TYPE
TRANSMITTER
1.1
Measuring Principle
1.2
Model
1.3
1.4
Probe mounting
Flange type
1.5
Ambient temperature
Enclosure
1.6
Relays
1.7
Measuring range
15 meters
1.8
Resolution
1.9
Sensor Material
Polycarbonate
1.10
Electronic unit
1.11
Display type
1.12
Keypads
1.13
Data protection
1.14
Interface
4-20 mA output
1.15
Calibration
1.16
Memory
1.17
IP Protection
1.18
Included
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Design
Remarks
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Sl No
Description
Design
RADAR
TYPE
TRANSMITTER
Measuring Principle
1.2
Model
1.3
Material
1.4
Probe mounting
Flange type
1.5
Probe
Temperature
1.6
1.7
Frequency
24 to 25 GHz
1.8
Measuring range
RADAR - 60 meters
1.9
Response Time
1.10
Resolution
1.11
Display type
1.12
Data protection
1.13
Interface
4-20 mA output
1.14
Calibration
1.15
1.1
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Remarks
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b)
Electronic Controller :
(i)
Power supply
(ii)
Alarm contact
(iii)
Mountingof
Controller
(iv)
Local indication
Sensor Probe
(i)
Exposed material
SS 304
(ii)
Insulation
(iii)
Material Temp.
Vitreous
Probe Housing
Cast Aluminium
Probe length shall be 1 meter for
small hoppers & 1.5 meters for Silo
and big hoppers.
The switch shall provide immunity for false actuation in the event of
coating and clinging in silo/hopper and also on probe.
a)
Application
b)
Power supply
c)
Output
d)
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Housing
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16/12/2011
e)
Calibrating range
0 to 50 K ohms
f)
Operating temp.
g)
Available
A- Max.2
for
operation
single
Rev - 0
point
Cable entry
1/2"
i)
Special features
field
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a)
Type
b)
Accuracy
c)
Repeatability
d)
e)
Output
Profibus-PA
f)
Mounting
Pedestal/pipe
g)
Page # 55
h)
Bolts
i)
Paint
Epoxy base
j)
Process connection
1/2" BSP
k)
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l)
Primary element material shall provide good creep fatigue resistance and
low hysteresis.
m)
n)
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Type
b)
- Accuracy
- Linearity
Better than 1%
c)
Repeatability
d)
e)
Output
Profibus-PA
f)
Mounting
g)
h)
Bolts
i)
Paint
Epoxy base.
j)
Process connection
: 1/2BSP
k)
Special features
l)
- 3-valve manifold.
- Impulse pipeline 30 metres, 12mm on each leg with straight connectors
for extending standard lengths, end tube fittings etc.
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Enclosure
b)
Power supply
: 220 V +10%, 50 Hz + 5%
c)
Input
d)
Output
e)
Overload capacity
6. R/mA Converter
a)
Type
: R/mA
b)
Supply Voltage
c)
Input
: 1K/5K
d)
Output
e)
Load
: 750 Ohms
f)
Accuracy
: + 5% of span
g)
Housing
: Cast Aluminium
a)
Type
b)
Range
c)
Power supply
: 220V AC
d)
Mounting
: Field mounted
e)
Protection
: IP55
f)
Tone
7. Field Hooter
8. Pressure switch
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a)
Type
: Diaphragm/Bellows
b)
Repeatability
: 0.5%
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c)
ON/OFF Differential
: Adjustable
d)
Switching
e)
Mounting
: Field
f)
Working pressure
g)
9.
Accessories
ANICPL
a)
Application
b)
Type
c)
Range
d)
Protection
: IP55 /IP65
e)
Power Supply
f)
Output
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g)
In-built features
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on
delay
Accessories
with
Type
Power Supply
: 220V AC + 10%, 50 Hz + 5%
: 1 to 1000 Hz
Measured Variable
Measuring Range
: 0 20 mm/s Adjustable
Output Signal
Accuracy
Enclosure Protection
: IP 65
Items to be provided
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Enclosure Class
: IP 65
Output
Cable entry
Paint Shade
Enclosure Class
: IP 65
Output
13
Cable entry
Paint Shade
CONTROL DEVICES:
a.
GENERAL REQUIREMENTS
Sensing elements, field devices and instrument items and transmitters which are required
and included as part of the mechanical equipment by the tenderer, have to be clearly
defined. This definition shall include specifications of equipment, quantity, and make.
Instruments required for the machinery safety along with transmitters shall be included as
part of main package.
b.
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e)
f)
Electronic
Analogue
prote
Mountin
k) Connections
- All others
A documentation giving details of all special electrical devices included in the Tendered'
scope of supply (wiring
diagrams, maintenance
manual,
special operating
instructions, etc.) shall be provided.
All types of elements will be subject for approval by the Purchaser/Consultant.
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Limit switches (2 NO + 2 NC) for diverter gates, actuator controlled valves, shut off valves
etc. are part of the tenderers scope of supply.
5 LEVEL DETECTORS/INDICATORS
Types of level detectors vary for individual applications. The tenderer shall
provide
specification, mounting device and typical drawing of preferred level detectors only.
Level detectors for Bucket Elevator Boot, silos, hoppers, process bag filter hoppers, shall
form a part of tenderers scope of supply. Ultrasonic/ RADAR level sensors is preferred for
continuous level monitoring for hoppers and silos.
6 PRESSURE, FLOW AND
PROTECTION
TEMPERATURE
SWITCHES/SENSORS
FOR
MACHINE
Shall be supplied and installed by the tenderer to suit the individual application. Locally
mounted, continuous monitoring devices with an isolated output 4 - 20 mA, 2-wire
technique, external load upto 600 Ohm is required. For applications which require one
set point only, switches with liquid filled (mercury type) or pressure operated contact
systems can be applied. All transmitters shall be provided with locally mounted indicator.
Switches to be adjustable over full range and calibration scale visible with the case closed,
shall be ensured.
The type of switch or sensor shall be subject to approval by the Purchaser.
Flow element wherever required (Venturi, Orifice, piezzo rings ) shall be included in the
scope.
7 TEMPERATURE DETECTORS
Temperature detectors (RTD, Pt 100 3 wire type including junction box) wherever specified
or necessary for protection and monitoring like large process fan bearings, gearboxes etc.
shall be tenderers scope of supply.
8 VIBRATION DETECTORS
Big fans, gear boxes, Mill and any other critical equipment shall be provided with vibration
sensors for X-Y-Z Co-ordinates. The scope of supply of the tenderer include the sensor and
the locally mounted transmitter (with output signal 4-20 mA galvanically isolated).
9 LOAD CELLS
The tenderer shall supply the load cells of hermetically sealed design with field mounted
electronic unit with local indication and circuitry giving 4-20 mA isolated output for remote
display. The load cells shall also be supplied with brackets and expansion assemblies for
other vessel. Copper straps shall be supplied along with to bridge-over each load cell to
protect them from stray welding current.
Special cable required between the load cell junction box and field mounted electronic unit
shall be included by the Tenderer in addition to special cables required between load cells
and junction boxes (Approx. 25 Meters). The load cell system shall be subject to approval
by the Purchaser.
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10 PROCESS INSTRUMENTATION
Unless otherwise specified, the Tenderer shall provide mounting arrangements (brackets,
holes, flanges, etc.) for process control and monitoring sensors specified for temperature,
pressure, flow, position, etc. Location, size and type of arrangements to be subject
to Purchaser approval.
11 VALVES/DAMPERS/GATES AND ACTUATORS
On/off valves shall be included in the supply. Best quality equipment shall be provided.
Valves shall be standardised and be subject to approval of the Purchaser.
End limit and torque limit switches for valves shall be supplied by the tenderer with 2 NO +
2 NC Contacts.
12 CONTROL VALVES AND ACTUATORS
Solutions with variable speed drives (for pumps, critical large fans, etc.) are preferred to
solutions with constant speed drive and control actuators. Where this is not possible,
control valves and actuators and corresponding mechanical linkages shall be included by
the Tenderer. Actuators and valves shall be standardised as much as possible. Motors
shall be preferable of the 3-phase squirrel-cage type. The feedback element shall be
4 - 20 mA, galvanically isolated. Where required the feedback element shall be directly
connected to the shaft. Actuator internal limit and torque switches shall generally be
included. The pot shall be 1 K ohm & transmitter shall be mounted in the actuator. The
position transmitter shall be 2 wire type and shall be suitable for 24 VDC from the plant
control system.
Actuator travel time and flow characteristic shall be adjusted to the specific application.
7.0
SPECIAL INSTRUMENTS
Application
Collective Surveillance system for monitoring machine operations Expandable Up to 32 nos. camera
For main plant. chutes, hoppers, field activities, gates within the plant sections etc. field of
observations generally being non illuminated.
System envisaged
Multi camera with Two monitors having sequential & manual selecting switcher. Real time and
freeze frame, quad and full screen. Shall accept colour & B/W mixed signal. However if required for
specific areas dedicated monitors shall be employed. Simultaneous background video recording for
any four selected cameras.
No. of camera locations
05 Nos. The system shall be open for expansion.
Camera
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Colour, compact solid state design (CCD) suitable for out door field mounting(24 hours. Viewing)
with necessary protective covers and shades and operating up to 46 Deg. C ambient. Camera shall
be suitable for viewing upto 500mtr . It shall be high resolution day and night vision colour camera.
Signal processing shall be digital ( DSP)
Europe standards of operation including more than 580 TV lines horizontal resolution, approx.
470,000 picture elements or more, pure colour filter, auto back light that adjusts the picture to
prevent the objects from appearing dark due to a strong back light & white compensation, S/N
ratio better than 50 dB, auto gain control , electronic shutter control, etc. These fine tune features
shall be easily set using the On screen menus. The lenses shall be motorised zoom lenses, 1/3 inch
format.
Synchronisation can be done Int/ Ext. switchable. .
Low illumination sensitivity ~ 0.5lux .
CS mounts for lens with remote pan, zoom and tilt controls, with auto/ manual
iris, variable shutter speed. Auto iris lens type shall be auto sensing DC /video
drive.
Standard mount for camera shall be the part of system camera enclosure with
Sun Shield, Thermostatically controlled heater & blower with filter.
230V ,50 Hz, AC operation
All the cameras shall be equipped with surge protection devices.
Monitor
from cam
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Control panel for remote operation with camera/ location switching unit, pan zoom &
tilt controls for camera, auto focus, power On/Off control for camera.
All interconnecting armoured coaxial cables/OFC and power cables along with
necessary power supply and connectors.
Camera, lens and monitor ceiling / wall mounts.
Signal boosters / repeaters if required in case camera distance from monitor is so high.
For very large distances / inaccessible areas where routing of cables are difficult
wireless option having suitable wattage with all accessories like antenna, multi channel
Transmitter/Receiver shall be considered and included in scope .
All the CCTV camera signals shall (both audio & video) have a provision for interfacing with the plant
intranet in Ethernet with necessary hardware, software and interfaces for viewing the video
information at user PC screens and at the MMI.
7.2.1
Electronic Ear
Application
Type
: Folaphone sensor
Power Supply
: 220V AC + 10%, 50 Hz + 5%
: 1-5 KHz
: 1-500 mV
: 1 mV or more
Output Signal
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: 500 ohms
Enclosure Protection
: IP 65
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Test Mode
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Telephone exchange is required for the communication inside the plant premises & colony premises.
The system shall be the latest design with all the facilities mentioned below. The system shall have 300
Line ports with extendable up to 500 lines. IP PBX IP card to connect two systems in LAN or Wan or to
use Internet to make calls (VOIP) or use IP phones or Wi-Fi phones. Distributed client server
architecture with the latest concept in computing based on SLIC.Every extension with individual tone
detectors i.e. TRULY 100% NON-Blocking .DTMF Caller ID inbuilt with incoming call printouts, caller
name display, ID based routing etc
8-channel Auto attendant for distribution of calls. Full fledged no answer, Busy, wrong no., holiday,
after office hours messages etc. simultaneous 8 calls can be answered.
All the features shall be through the motherboard and fully programmable. Apart from the above, the
normal features include Call Screening, Boss Secy., Call privacy, Call Forward, Call transfer, call follow
Me, Call Pick up, Speed dialling, Elaborate I/C CALL ringing assignment (Separate day & night),
Individual line AND extension Class, Programming from any extension with password, Night answer, &
toll restriction are available as standard features.
The system should be housed in aluminium cabinet and utilizes polycarbonate stickers for display
along with Modular Structure ,Ready for future expansion & Flexible configurations , Universal Slots Any card can go in any slot.. The design and shape shall be ergonomic and the operations shall be
simple. The system software shall be suitable for upgraded continuously .
The minimum hardware/software shall be as underThe system should provide telephony functions on any underlying data infrastructure.
The system should be scalable to support: any voice/data convergence traffic increases
The system call server must be based on SW easily up datable and manageable
The system must have an availability of 99,999%
The systems should be able to use SIP end points as extensions for the users and SIP trunks to be
interconnected with other IP PBX and to access value added applications like collaboration or Unified
Messaging.
The system should offer the choice between distributed or centralized communication servers and
media gateways without jeopardizing the WAN VOIP links, features level and applications availability.
The system should integrate with TDM equipment and enable any mix between IP or TDM and Wired
or Wireless phones.
The system should be scalable, distributable and modular.
The system should manage CAC (Call Admission Control) mechanisms to optimize the usage of the
bandwidth in the WAN for multi-site configurations.
The system must manage a large range of telephonic services, integrated contact center applications,
collaboration and Unified Messaging applications.
The system must be able to interoperate with other telephone systems and endpoints using the below
standards: QSIG GF , QSIG BC , DPNSS , DSS1 , H323 , SIP.
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The IP PBX system should provide standard APIs compliant with Internet standards like XML, SOAP &
WSDL for CTI, call control and management functions.
The IP PBX system should also provide legacy APIs such as CSTA, TAPI, CSTA.
The IP PBX system should provide call routing points for connecting Contact Center applications.
System Hardware and Software
The IP PBX hardware must have high flexibility in term of capacity, system upgrade and support IP &
TDM without external interfaces
The Call Server should able to support minimum 1500 users in a stand alone configuration
The Call Server should able to handle traffic minimum 300K BHCA
The system must support the following external telephony interface signaling:
E1 CCS PRI (VN3-4-6-7 /ETSI) DASS2
E1 CAS (R2, Q421, MFC Ericsson, Q23, Decadic)
T1 CCS generic
T0 ISDN BRI (VN3-4-6-7 / ETSI)
E&M
Analog Loop Start and Ground Start (with FSK and DTMF CLIP)
The switching must be able to handle Power over Ethernet devices
PRI card shall be considered for 30 P&T Lines interface .
PoE devices must be managed for : Economic efficiency according to device needs and Security to
avoid overload of the system or the device
For bandwidth intensive users, the supplier should be able to supply a switch device to distribute PoE
to supplementary Ethernet devices
The device must be an economic, plug and play device that offers: auto negotiated 10/100/1000 BT
transfer ,port-based and 802.1Q VLAN support ,802,3af remote power
The proposed system should be based on an open software architecture, Linux being the preferred
one.
The architecture based on soft-switches should permit the geographical relocation of the
communication servers through a standard IP network. Media Gateways should be carrying the
interface cards, which should generate their own feeds from a common source
The system's software can be hosted in appliance servers or in blade servers architectures
The system must manage, control and support a range of IP telephone stations for both voice and
telephony applications as well as IP application stations for voice, telephony, and Web services
support.
The proposed system must support native IP communications in direct or "peer-to-peer" with only the
telephone signaling transiting back toward the controlling communications server.
The voice and signaling frames should be marked [tagged] in order to be recognized. The standards of
marking supported will be: Level 2: IEEE 802.1p/Q and Level 3: TOS / Diff Serv
The system should support for voice encoding the following standards: G.711,G.723.1 and G.729A
The proposed communications system must support H.323, SIP, XML technology
The proposed system should integrate an H.323 gatekeeper server, without external equipment, that
offers the following services:
Automatic registration of the H.323 terminal and assignment of a call number by the RAS protocol
Resolution of the address, the terminal H.323 can be identified by its call number or by its IP address
that can be assigned dynamically by a DHCP server.
Establishment of communications in direct mode
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The proposed system should include the gateways required to allow the buyer to acquire H.323 or SIP
devices to interoperate with the traditional telephony devices (digital stations, IP, analog, private or
public lines).
The proposed system should permit the integration of SIP terminals with other terminals. The SIP
modules are : SIP Proxy, Registrar and Gateway
The hardware of the proposed system must be compliant with the European directive: Restriction of
Hazardous Substances in electrical and electronic equipment (RoHS)
The proposed telecommunication system should allow the use of high level XML APIs based on Web
technology standards (XML/SOAP) to ease creation of telephony and call control features for
integrating telephony services into web applications.
SYSTEM MANAGEMENT
The IP PBX system should provide a suit of applications and tools to permanently evaluate and report
the operational health of the system. It should provide the following functions:
Software licensing check
Automatic recognition of plugged sets
User moving
Monitoring of all the events on the system
Capture of performance and level of use of the resources
Register and log all calls and give accounting information
Monitor and register all users, attendants, trunks activity to generate traffic and level of use analysis
The IP PBX system must include the possibility to have remote maintenance access via dial-up having
access to the system for configuring, diagnosis and monitoring. This access must be protected with
security mechanism to prevent unauthorized intrusions.
The system must include a dedicated management server/platform that will be based on the latest
technologies, such as JAVA/JEE. This server should support a minimum of five (5) clients having
different access rights to the applications.
The management platform must provide a single graphical client (Graphical User Interface GUI) as well
as a web based interface.
The Management platform must provide web access allowing the administrator to manage the system
to use any PC with an internet browser
The management platform must use a client-server architecture allowing different administration
clients to be connected to the system
The management platform must perform at least the following tasks:
Configuration and programming of services, users, categories and all system parameters and features.
This module must provide centralized management in local or remote environments of a single system
or a network. The network manager will be able to quickly and easily edit, create or delete any
network object, by the use of import/export functions and multiple operations.
Faults and Alarms management of all the incidents and fail reports generated by the system itself
informing date, hour, severity level and action recommended to take. This module must be able to
centralize the alarms and events of the system, and:
Give colours according the severity level of the alarm
Notify an alarm depending to the severity level sending an e-mail or activating an script performing an
specific action
Register and generate statistics for the alarms and events in the network in a daily scheme
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Accounting of all calls generated by the users including cost, date, hour. Must provide different
options to group the billing of the calls (cost centre, extension number, trunk, user, city/area
associated to dialled numbers). The accounting module must be able to:
-Adapt to the financial organization of the company along the cost centres and the organization levels
-Manage carriers' fees to apply specific costs. Must be able to manage multi-carrier schemes
-Define thresholds for phone usage and Tracking/monitoring this activity, providing a graphical view of
the accounting thresholds per user, cost canter or group
-Generate reports and graphics classified by:
User , Cost Center , Organization Level, Duration , PIN ,Number Dialled ( Destination) , carrier used
Performance and traffic Analysis of the operation of the system. This must include at least the
following information:
-Measurement of response time
-Measurement of the VoIP traffic
-Statistics on the quality of VoIP calls
-Statistics on the line-occupancy ratio for incoming calls
-Reports and graphics on attendant, trunks and users traffic
-Occupancy rates of the different internal and external links
-Average time spent waiting for an attendant
Directory, module to manage the telephone directory. This must be LDAP compatible to be
synchronized with other directory applications, must also allow web access and provide information
on all desktops allowing click to call features to the users.
The management platform must allow the administrator to generate reports and graphics of the
activity per period of time in terms of traffic, accounting and alarms and giving the possibility to
generate statistics of all this analysis. Those reports must be predefined but the option to personalize
the reports must be also available. These reports should be exportable in HTML, pdf, excel and
LDAP(.ldif) formats
All IP PBX management applications ( Fault & alarms, Configuration, Accounting and performance)
should belong to a single platform and a single image for data storage, minimizing operation expenses.
The management platform must include an troubleshooting & diagnosis tool accessible by WEB to be
used by non expert administrators
The management platform should be able to be integrated with enterprise global network
management platforms (like CA Unicenter TNG, HP Openview, or IBM Tivoli) using standard protocol
SNMP.
Telephony Services:
The offered system must support the following services without
external/additional server to support them:
Text mini-message between advanced sets
Reception of absence mini-message from the called user
Calling Line Identification Restriction (CLIR) for local / internal calls
Communication timeout on outgoing call
Barring for internal and external calls
Call Waiting on :
busy set
busy hunting group
busy voice mail
Intrusion on busy set
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General
The Public Address System is for communication between main station and various group operating
stations. The equipment shall be of industrial duty suitable for trouble free operation under very dust,
high vibration and high ambient temperature (48 deg.C ) conditions.
The offered system shall be telephone based PA system & shall be interfaced with plant EPBAX
Weatherproof Field Station shall be designed for voice communication in the hostile environment
where reliability, efficiency and safety are of prime importance.
The system shall be suitable for use in harsh and hostile environment characterized by:
- Indoor & outdoor usage
- Presence of dust & water ingress
- Corrosive atmosphere
- Extreme & varying temperature
- Loud ambient noise due to industrial processes
- Pilferage
- Mishandling, rough usage & safety
PA System provides transmission of routine voice messages over loudspeakers, to all or selected areas
of the plant, in a reliable, safe and efficient manner.
On integration of the two, the PABX user gets access to the PA System where by they can announce
over the loudspeakers from their telephones. The telephone user can announce in individual zone OR
in multiple zones OR in all zones.
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7.5
ENVIRONMENT INSTRUMENTS
7.6
OPACITY MONITOR
7.6.1
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b)Set - Up
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c) Accessories
01 Fail Safe Shutter mounted on both sides between the flange and sender/Receiver unit or
reflector.
If the air purging unit fails, the flange opening to the exhaust stack closes.
02 Weather hoods fibre glass reinforced plastic that protects the monitor and air purging
blower from exposure to the weather.
03 Air purging unit
d) Technical Data
Supply Voltage
: 220 V AC + 10%, 50 Hz + 3 %
Source Lamp
: Incandescent approximately 10 W
Average life approximately 20000 hrs.
Measured variable
Relay outputs
Enclosure type
: IP 64
Ambient temp.
: 46 deg. C
Opacity monitor shall have data acquisition system with facility to access data from remote.
All opacity monitors shall be on network for centralised data acquisition system.
7.7
TECHNICAL
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The device to be compact, completely integrated multigas measurement device, including sampling
system, built in temperature control unit, zero air system and data acquisition. The metal housing is
isolated and weather protected.
Capable of measuring: O3, CO, SO2, H2S, NOx, VOC (BTEX), PM10/2.5, Meteorological data, Indoor air
quality.
Integral Zero air supply for internal sensors calibration.
Built in Computer (data storage 5 years +).
Remote diagnostic
Intrusion alert SMS.
Email message in case of any problem.
LAN, WLAN, Internet connectivity (GSM / GPRS).
Enclosure:
The device contains modules for up to seven measurement parameters: CO, NO/NO2/NO X , O 3 , SO 2 , H 2 S,
VOC and PM10 or PM2.5. The unit is upgradable with any module.
The device has a build in air-condition for operation for ambient temperature. The flow of cooled air
within the system has to be defined by mechanical installations.
The analytical modules for the gases are mounted on drawers for easy maintenance and repair. A separate
door edgeways for separate maintenance access is standard. This door is used for access at inlet filter
exchange, operation via direct computer connection and calibration.
General:
The internal modules use reference methodology for CO, NO X , and SO 2.
The sensors modules are made by an established manufacturer to ensure trouble free operation. Heated
parts of the modules are insulated for low power consumption.
The Zero air supply is controlled for each analyzer module separately. There is space on each module for
optional available span gas supplies.
A choice of different meteorological sensors may be connected to the base unit.
Module features and specifications
SO2
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Measuring Range
dynamic, up to 10 ppm
Zero Noise
0.5 ppb
< 1 ppb
Reponse Time :
< 90 seconds
Precision:
Linearity:
500 ml/min
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NOX/NO/NO2
Measuring principle: Chemiluminescence.
a) Special reaction cell sample injection for drift minimization
b) Auto zero valve for zero drift minimization
c) Sample hold loop to avoid NO2-artefacts
d) Single chamber design for cost and maintenance reduction
TECHNICAL SPECIFICATIOS FOR NO/NO2/NOx:
Measuring Range
dynamic, up to 20 ppm
Zero Noise
0.4 ppb
Response Time :
< 60 seconds
Precision:
Linearity:
1000 ml/min
TECHNICAL SPECIFICATION
a) Measuring principle: Continuous and simultaneous particulate collection couples with beta ray
attenuation.
b) heated probe and humidity measurement to avoid artefacts due to humidity
c) Aerodynamic particle separation with size selective sampling head for measurements
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Measuring Range
dynamic, up to 10mg/m3
Zero Noise
Cycle time
Accuracy
2% of F.S.
0.6 liters/min.
Principle
Range
Accuracy
Threshold
Operating temperature
Ultrasonic
0 - 60 m/sec.
+/- 3% of full scale
0.3 m / Sec.
0- 50 C.
Principle
Range
Accuracy
Operating temperature
Ultrasonic
0-360
+/- 3
0- 50 C.
Principle
Range
Accuracy
Radiation Shield
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1.
2.
3.
4.
5.
6.
Principle
Range
Accuracy
Sensitivity
Operating temperature
Radiation Shield
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Collecting Area
Range
Resolution
Accuracy
Operating temperature
60 cm
0..200 mm / hr
0.01 mm
5%
0- 50 C.
Metrological Mast:
One Meteorological Mast of telescopic type and of specified height to be placed on an existing system
(Enclosure) so that height of the Meteorological Sensors from the ground level (GL) is 10 meters. The mast
is required for mounting metrological sensors. Necessary hangers and holders along with electrical
grounding set shall be provided for installation of the sensors. Material of construction of mast & sensors
must be resistance to atmospheric corrosion.
Data Management System:
The system contains a built in Data Processing System. This is based on LINUX for high reliability.
It features full Internet connectivity either via air through GPRS/UMTS/EDGE/WLAN (depending on
configuration and availability) or fixed line connection using ADSL/SDSL/DSL or cable modem.
Any other Inter- or Intranet using TCP/IP-protocol can be used, too.
The Datalogger has an internal storage capacity for five years of continuous operation (three averages, one
minute being the shortest).
It has built in temperature sensors to protect the hard disc from booting at too low temperatures.
Watchdog functionality ensures safe and reliable operation.
Connection capability of additional external gas, particulate and /or meteorological sensors are provided.
Data from these sensors are integrated in the internal data base.
For this purpose the following software protocols are supported: AK, Bayern/Hessen (Gesytec), Thermo
Instrument, T-API, Gill wind sonic, Mierij, Vaisala)
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Brand ,size
Working
voltage
Wave
length
Brightness
500mcd650mcd
1.9v-2.1v
Red
Epistar 9mil
620nm630nm
Green
Epistar12mil
520nm525nm
2000mcd2200mcd
3.0v-3.4v
Blue
Epistar12mil
465nm470nm
450mcd550mcd
3.0v-3.4v
MODULE
1
2
3
4
Module size
Pixel in one Module
Scan method
Pixel structure
160mm x160mm
16dots x 16dots
1/4 scan
1R1G1B
SCREEN
1
Pixel density
10000dots/m2
2
3
4
5
6
Brightness Luminance
Visible Distance
Hor. Viewing angle
Vert. viewing angle
Refresh Rate
6000 cd/m2
>10m
H:110
V:55
400 Hz
Certificates
750W/
CE,ROHS,ISO90012008
Temperature Range
Storage
35-85
Working
20~45
10
11
Software
Operating Humidity
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led editor
10~99%
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Storage Humidity
Smoothness
10~99%
0.3mm
14
Life Time
100,000 hrs(11
years)
15
Working Voltage
16
Video format
17
18
Control Method
4096 degree
Synchronous with
computer
19
maintenance
Back maintain
20
Data transmits
Cat 5 network
cable, maximum
100meters
21
22
PC system
12
13
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DESCRIPTION
MAKE
DC Voltage
RANGE
AC Voltage
RANGE
DC Current
RANGE
AC Current
RANGE
Resistance
RANGE
8
9
10
Capacitance
RANGE
Frequency
RANGE
Diode
Continuity
Mode
11
Additional Features
12
Max.
13
14
voltage
between
any
terminal
and
earth ground
Surge protection
Standard Delivery
SPECIFICATION
As per vendor List
600.0milli Volt
10microVolt
Accuracy:0.7
(true
1000v
8kv
Carrying case(c25),Test leads,Certificate etc.
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Measure volts, mA, RTDs, thermocouples, frequency, and ohms to test sensors and transmitters
Source/simulate volts, mA, thermocouples, RTDs, frequency, and ohms to calibrate transmitters
Perform fast linearity tests with auto step and auto ramp features
Power transmitters during test using loop supply with simultaneous mA measurement
Backlight for work in poor light
Circuitry Protection against wrong polarity during measurements
Long battery life
Function ( Measure
or Source)
Voltage
Range
0 to100mV
0
to
10V
( source)
0
to
30V
( Measure)
Resolution
0.01mV
0.01V
0.01V
DC mA
0 to 24
0.001mA
mV(
TC
Terminals)
-10mV to 75mV
0.01mV
Resistance
15 Ohm to 3000
Ohm
0.01 Ohm
Frequency
1 to 1000 Hz
1 to 10KHz
1.0 Hz
0.1 KHz
24V DC
N.A.
0 to 1200 Deg C
0.1 Deg C
0 to 400 Deg C
0.1 Deg C
Loop Supply
Thermocoup
le measuring
RTD
measuring
Accuracy
0.02%
Reading
LSD
Remarks
of
Max.
2
1mA
Load,
0.02%
of
Max.
Load
Reading + 2
,1000 Ohm
LSD
0.025 of Range
+1 LSD
0.5 Ohm
+/- 0.05%
+/- 0.25%
10%
0.7 Deg C or
better
0.3 Deg C or
better
Standard Accessories : Basic Instruments, Battery with AC (Mains) adapter, Test Leads, Instruction
Manuals, Calibration certificate
ANICPL
Page # 87
16/12/2011
Rev - 0
SPECIFICATION
1.2.
01) AC Current
1.3.
03) DC Voltage
04) Resistance
2 KOhms
50/60 Hz
02) AC Voltage
06) Warranty
ANICPL
1.4.
1.5.
1.6.
1 year
Page # 88
16/12/2011
Rev - 0
2 Channels
25 Automatic Measurements
FFT Standard
10
Frequency
11
Positive Width
12
Negative Width
13
Rise-time
14
Fall-time
15
16
17
Positive Overshoot
18
Negative Overshoot
19
V Pwm ac
20
21
Mean
22
Cycle Mean
23
RMS
24
Cycle RMS
25
Vpwm ac+ dc
26
27
28
29
30
31
ANICPL
Page # 89
16/12/2011
Rev - 0
DESCRIPTION
Make
Output (Dual)
Current Capacity
3
4
5
Display
Power Supply
Features
Standard Delivery
SPECIFICATION
APLAB
0-36V DC
5Amps
Voltage resolution- 1mv at 0 to 3.999v
Voltage resolution- 10mv at 4 to 36v
Current resolution- 1mA
LCD display with backlit
230V AC, 50Hz.
Adjustable voltage and constant voltage output
Adjustable current and constant current output
Protection for over or lower voltage & lower current
Basic Instrument, Main Power cable, Test leads,
Instruction manual
1
2
3
4
5
ANICPL
DESCRIPTION
Make
Input
Power
Supply
Output voltage
Output Current
Type
Standard Delivery
SPECIFICATION
As per vendor List
230V AC, 50Hz single phase
0 to 260V AC
8A
Portable
Basic Instrument, Main Power cable, Test leads,
Instruction manual
Page # 90
16/12/2011
Rev - 0
DESCRIPTION
Make
Range
2
3
4
5
Accuracy
Resolution
Display
mA input
Selectable
inputs
SPECIFICATION
As per vendor List
-0.8(vacuum) to 2 kg
-0.8(vacuum) to 20 kg
pressure
Features
Standard Accessories
, +/- 0.1%FS+1Digit
Minimum 5 digits
2 line, 16 characters LCD
0-25Ma
Kg/cmSq, Bar, Psi, mBar, mmHg, inHg,
ftHg, cmH2O, mH2O, etc.
Provided
with
pressure/vacuum
changeover switch, fine adjustment
vernier & release valve.
Microprocessor
based,
Battery
operated.
Basic Instruments, Battery with AC
(Mains) adapter, Test Leads, Instruction
Manuals, Calibration certificate
DESCRIPTION
SPECIFICATION
Make
Rpm range
ft/min
0.2 to 6560
m/min
0.5 to 1999.9
Basic accuracy
Max
rpm
resolution
5
6
ANICPL
Standard Delivery
0.1rpm
Basic Instrument, Batteries
Reflective
tape,
Carrying
Conformance
Certificate
bag,
manual,
Page # 91
16/12/2011
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LT MEGGER
S.N
1
2
3
4
5
6
7
8
9
DESCRIPTION
SPECIFICATION
Make
Insulation
voltage
Insulation
voltage
(basic
accuracy)
Ac
voltage
(accuracy)
Low resistance
O/P short circuit
current
Ohmmeter
accuracy
Overload
protection
Continuity
Beeper
Standard Delivery
250V/500V/1000V/2000v
2
/
20/
200M
ohm,<1000M
(3%rdg+5d),>1000M ohm (5%rdg+5d)
ohm
600 V, (0.8%rdg+3d)
200 ohm, 1%rdg
1.5mA, 0.3 to 0.5mA
20/200 ohm (auto), (1%rdg+2d)
2200V<1min
<100ohm
Basic Instrument, Test Leads, Instruction manual,
Carry bag
DESCRIPTION
Make
Type
01) AC Current
02) DC Current
03) AC Voltage
04) DC Voltage
05) Resistance
06) Frequency
07) Inrush Current
08) Battery Life
09) Sleep function
10) Standard Accessories
ANICPL
SPECIFICATION
As per vendor List
3 & digit
1000 Amps
Accuracy: 2%
1000 Amps
Accuracy: 2%
600 Volts
Accuracy: 1%
600 Volts
Accuracy: 1%
6000 ohms
Accuracy: 1.5%
400 Hz
Accuracy: .5%
100 milli second (useful to capture motor starting
current) etc or initial starting current
150 Hrs
Auto Shut off
To be supplied with the instruments
Page # 92
16/12/2011
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ANICPL
DESCRIPTION
Make
Channel/Function
Temperature
Range
Probe
Temperature
Type
of
Thermocouples
Display
Read Out
SPECIFICATION
As per vendor List
1 Channel
Hold Button
Supply
Supplied
Accessories
Hold Key
Batteries
One Bead Probe Thermocouple, 3AA Batteries
(1000 Hrs Life), instruction Manual etc.
Page # 93
9.0
9.1
16/12/2011
Rev - 0
9.1.1
STANDARDS
TECHNICAL SPECIFICATIONS:
ANICPL
Page # 94
16/12/2011
Rev - 0
All manufacturing process including punching, cutting, bending and welding of perforated cable trays
shall be completed and burrs shall be removed before the application of galvanization process is
applied. Zinc conforming to at least Grade Zn-98 as specified in IS-209-1966 shall be used for the
purpose of galvanizing.
The joints of two trays shall be butt construction and shall be made with the help of coupler plates by
nuts and bolts. The coupler plate and nuts and bolts shall also be properly hot dip galvanized, where
the bends of the trays are required at site the same shall be supplied by the supplier as per
requirement. The spacing of rungs (centre to centre) shall be as per technical data sheet.
While adopting the modules at site if cutting of any length is required the same shall be cut at site and
joined by nuts and bolts with the help of coupler plates.
Tests to be carried out:
Following tests to be performed and necessary test certificates shall be provided.
Raw material Test
Physical and Chemical analysis Test
Galvanization Test
Destructive test for Galvanization for Mass and Uniformity
Accessories:
Coupler plates
Fixtures
Bolts, Nuts and Washers
(Quantity as required / necessary shall be supplied)
Special Notes:
i) Trays shall be free of any Burrs / Sharp Edges .No Recycled / Wastage Material shall be used
for Fabrication of Cable trays
ii) Vendor to submit Material specification details for approval
SPECIFICATIONS OF INSTRUMENT TUBE FITTINGS
9.2
The specification covers the requirement for the design ,material , inspection & testing of Instrument
Tube Fittings which includes the following types Stainless Steel Compression Fitting ( For SS Tubes)
Brass Compression Fittings( For Copper Tube)
Following standards ( latest editions at the time of supply) shall be followed:
ANSI /ASME American National Standards Institute / American Society of Mechanical Engineers
B 1.20.1
B16.11
BS-4368
IS-319
Page # 95
16/12/2011
Rev - 0
Cable Glands shall be double compression type. This glands shall be suitable for using worst climatic
conditions, weather proof IP 66 as per IS13947. Gland consist of check nut, gland body, neoprene
inner ring, armour clamping cone, armour clamping ring, amour clamping nut, neoprene outer ring,
skid washer, outer seal nut. All metal parts shall be made of brass accurately machined for ease of
assembly.
The Sizes of Cable glands shall decided during detailed engineering which will be as per the Control
Cable sizes procured by Purchaser.
10.0
ENGINEERING ACTIVITIES
The engineering activities which shall be carried out by the supplier shall be as follows:
ANICPL
Page # 96
Sn.
Activity
P&I diagram
2
3
4
5
6
ANICPL
16/12/2011
Rev - 0
Remarks
Page # 97
10
11
12
13
14
15
ANICPL
16/12/2011
Rev - 0
Page # 98
16/12/2011
Rev - 0
16
17
18
19
ANICPL
Page # 99
20
Software development
for controller, MMI, MIS
Shall be done at site by
the selected Supplier
involving the purchasers
engineers
21
16/12/2011
Rev - 0
Note: No engineering and documentation services can be off loaded by Supplier after award of
contract without seeking approval from Purchaser.
10.1
01
02
03
etc.
04
System and component fault finding.
05
Minor repairing of the defective equipment/components at site.
06 Erection and commissioning procedures.
07 Preventive maintenance of the equipment supplied.
10.1.2 ON JOB TRAINING AT PLANT SITE
1. Plant personnel will be associated actively with software development erection and
commissioning.
ANICPL
Page # 100
16/12/2011
Rev - 0
2. All the pre-commissioning and commissioning tests and the set values will be made available to the
plant personnel.
3. All the commissioning problems will be discussed and explained to the plant personnel.
10.1.3 TRAINING SCHEDULE
The training at the Manufacturer's Works/design office / OEMs works shall be arranged for four
engineers in two batches.
The training schedule shall be worked out in consultation with the purchaser's representative that the
personnel are mobilised for training at the appropriate stage of manufacturing and design.
ANICPL
Page # 101