SUB–SECTION – B-09

CONTROL PANELS FOR CHP & AHP

TELANGANA SUPER THERMAL POWER PROJECT TECHNICAL SPECIFICATION

PHASE-I (2X800 MW) SECTION-VI, PART-B
STEAM GENERATOR ISLAND PACKAGE BID DOC.NO.: CS-9591-101-2
 TECHNICAL REQUIREMENTS
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CONTROL PANELS

1.00.00 CODES AND STANDARDS

Programmable Logic Controller IEC: 1131

2.00.00 CONTROL TYPE

PLC based

3.00.00 PANEL CONFIGURATION

3.01.00 HCSD Control System (For Ash Handling System)

HCSD control system comprising of OWS mounted on table type control

desk(located in AHP Control room) to house PC/keyboards/printer/mouse, PLC
processor panel, I/O racks & associated equipments shall be provided for the HCSD
system being supplied by the Contractor. Separate, vertical, free standing PLC
processor panels with Perspex/glass door for visual access to LEDs shall be
provided for HCSD system.

3.02.00 Local control panels for Coal handling plant (under BTG scope):

Local control panels for traveling trippers, sump pumps, hydraulic scoop coupling
and dust suppression system. shall be free standing, floor/wall mounting type.

3.03.00 Local control panels for Ash handling plant:

Bottom ash local control panel for each unit and Silo control panel along with mimic
for control of various drives in bottom ash area & silo area respectively. Necessary
miniature push buttons, control/selector switches, lamps, meters, annunciation
windows etc suitable for 24V DC operation shall be provided.

3.06.00 All drives related to Coal Handling shall be controlled through microprocessor based
Distributed Control System (DCS) as specified in C&I module.

3.07.00 All drives related to Ash Handling System except for the controls of HCSD system
shall be controlled through microprocessor based Distributed Control System (DCS)
as specified in C&I module.

4.00.00 CONTROL SYSTEM

1). The control system for HCSD system shall be PLC based.

Each PLC system shall be provided with 2 x100% processors in hot standby
mode. Standby processor shall be energised and continuously monitored for
healthiness. In case a failure of working processor, the standby processor
shall take over the operation automatically by bumpless transfer and
necessary failure alarm shall be provided. Both the work stations of a PLC
system shall be suitable for operation and also for programming hence

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software shall be provided accordingly. The processor along with their

accessories shall be housed in a free standing vertical type PLC panel
separate from control desk. The operation and supervisory system shall
consist of PC (latest model), TFT monitors with key boards which shall be
mounted as an integral part of the control desk.

2). The processor along with OWS, printer etc. and control panels shall be
interlinked through independent dual data highway and dual I/O
communication links.

3). The push button and selector switches mounted on control desk shall send
necessary signals through PLC.

4). The PLC shall provide supervisory information for alarm, various types of
displays, status information, trending, historical storage of data etc. and also
perform self monitoring and diagnostic functions.

5.00.00 CONTROL PHILOSOPHY

1). Normal / local mode of operation shall be selected from the key board.

(a) In normal mode of operation, which shall be the default mode, all
drives shall be operated from control desk through keyboard.
Whenever required for maintenance, maintenance mode for equipment
will be selected through keyboard. Operation interlocks, except trip
interlocks shall be locked using a unique password. After
maintenance, the drives shall be started through keyboard, with all
process interlocks, by re-entering the password. Normal mode of
operation can be selected then. Irrespective of any PLC mode of
operation, the running equipment can be stopped from keyboard or
from desk/panel or from emergency stop push button.

6.00.00 TRAINING

Further to the relevant clause regarding training specified elsewhere, Contractor's

experienced personnel/engineers shall also provide training courses on offered PLC
system to Employer's engineers in the following areas:

(a.) Operator training

(b.) Hardware Maintenance training

(c.) Software training

(d.) Any other specialized training as required for system operation and
maintenance.

7.00.00 PLC EQUIPMENT AND SYSTEM REQUIREMENTS

7.01.00 Each PLC system shall consist of redundant processors, PCs with TFT (latest

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version with latest application software) & keyboard, I/O modules, UPS / power
supply with battery backup, printer etc. Each PC based operating and programming
workstation shall be fully equipped for operation and control of the various systems.
The configuration of PLC shall be as per enclosed drawing. Details of various
components shall be as given below :

a) Processor Two (2) numbers. one as hot standby

b) Memory Non volatile EPROM, Lithium or Ni-Cd battery for 360

hours backup, 20% spare capacity for future use.

c) Selection Normal/Test/Program/Off facility shall be provided. In

test mode all outputs shall be blocked.

d) Monitor & Keyboard Twenty inches (20 inches) TFT flat monitor with
resolution of 1280 x 1024 pixels non interfaced,
refresh rate min. 75Hz, with flat membrane type
keyboard/ mouse. The numbers of OWS shall be as
per PLC configuration diagram.

e) Processors & I/O Modular design. Possible to change any module

racks without disconnection of any wire. Keying in of
individual wire connectors shall be provided to ensure
that only the correct card is plugged on the I/O
module. Wiring between I/O cards & terminal blocks
shall be through prefab cables. Twenty (20%) percent
spare capacity in input output and CPU memory
modules shall be provided in each rack over and
above system requirement. One additional Ethernet
port shall be made available in each PLC system so
that wireless communication modem can be
connected by the Employer in future. All Output cards
shall be sourcing type and Input cards shall be sinking
type.

f) Isolation between 1.5 KV with opto couplers.

Input, Output and
controller

g) Indication Individual signal status of each Input / Output, power

supply status.

h) Fail safe mode On power supply failure / both PLCs failure /

communication failure etc. the output shall be
automatically switched over to fail safe mode. In CPU,
memory should exist where the sequence was
aborted. Further, in case of such failures, operating
drives / equipment shall be tripped or kept running as
per a pre-determined programmable requirement

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finalised during detail engineering.

i) Fusing philosophy Individual fuses with blown fuse indicator for each
output. Individual fuses for each input/ group of inputs,
keeping in view of system availability.

j) Switching capacity Output modules shall be rated to switch on/off

coupling relays of 2.5 VA at 24V DC and solenoid
valves at 110 V AC. Coupling relays are provided in
HT/LT Switchgears.

k) CRT/CPU and Input Hundred percent redundant Communication links

output routed in separate GI conduits.
communication links

l) Printer Color laser printer shall be suitable for A4 size paper,

4 pages per minite, 600 dpi (black) and heavy duty(>_
30000 pages per month)

Number of printers shall be as shown in the tender

drawing ‘PLC Configuration’.

m) Power supply i) Two (2) nos 415V AC feeders shall be provided for
each control panel / desk and remotely located I/O
panels.

ii) Power supply to HCSD control system i.e., PLCs,

I/Os, printer, OWS, and control desk shall be fed
through 2x100% UPS with battery back-up rated for
30 minutes at full load. The UPS shall be smart type
line interactive complete with software & hardware for
remote management along with features of surge
suppression & AVR facility. The UPS and batteries
shall be rated for 20% spare capacity. Redundant DC
power packs shall be provided for DC loads.

iii) All the batteries shall be heavy duty Ni-Cd type.

n) Command Manual command shall prevail over auto command.

hierarchy Protection command shall have priority over all other
commands.

o) Databus Hundred percent redundant. Necessary interface

hardware and software for dual fibre connectivity and
interconnection with DDCMIS for two way transfer of
signals through OPC compliant Ethernet link following
TCP/IP standards.

p) Time To be synchronised with DDCMIS

Synchronisation

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system.

q) Date No disturbance due to change of date/year.

Insensitivity

r) System reaction Less than 100 msec. from input signal to output signal
time including logic processing.

s) Display Max 1 sec for control related displays. 2 to 3 sec for

response other displays.

t) Feedback/field By 24V DC. Status feedback from MCC/field shall be

interrogation in the form of one changeover contact. Discrepancy
shall be alarmed. All analog signals shall be routed
through analog cards.

u) Programming Flow chart/Block logic ladder diagram. Tag based

format addressing format shall be used for programming.
The same shall be submitted for Employer's review
before programming of the system.

v) Long time 168 hours latest data on hard disc. Data to be stored:
storage &
retrieval

i) Alarm list.

ii) Five analog points at scan rate.

iii) Fifteen analog points at one secs rate.

iv) Balance analog points at 5 minutes rate.

v) Binary points on status change.

vi) Log reports.

w) Software All application software with locks and passwords for

PLC functioning like input/output scanning,
acquisitions, condition processing, control and
communication, operator interface of monitors, display
trends, curves, bar charts, historical storage/ retrieval
and alarm functions. Complete set of documents for
modifications / editing / additions/ deletions of features
in software. Comprehensive list of all application/
system software.

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x) Accessories Industrial grade furniture shall be provided along with

Control desk/OWS/printer.

y) Software The Contractor shall provide software license for all

license software being used in PLC based control system
including HMI. The software licenses shall be
provided for the project and shall not be
hardware/machine specific. All licenses shall be valid
for the continuous service life of the plant.

z) Software As a customer support the Contractor shall

upgrades periodically inform the designated officer of the
Employer about the software upgrades / new releases
that would be taking place after the system is
commissioned so that if required, same can be
procured and implemented at site.

7.02.00 Annunciation System

i) Facia Translucent glass/plastic window with engraving.

ii) Operation Through PLC.

On occurrence Audible horn and flashing of facia lamp.

a) of trouble

b) Acknowledge Audible horn and flashing of facia lamp shall stop.

button pressed Facia lamp will become steady.

c) Reset button If fault is removed then facia lamp will go off.

pressed

d) Test button All lamps will glow.

pressed

iii) Monitoring Power supply to annunciator shall be monitored.

8.00.00 DESK/PANEL CONSTRUCTION

a) Type Fabricated from cold rolled sheet steel

Frame thickness 2.0 mm

Enclosure thickness 1.6 mm

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Gland plate thickness 3.0 mm

b) Switches AC22 category

c) Fuses HRC cartridge with visual operation indicator.

d) Name Plates & Each panel shall be identified by a name plate. Panel
Labels internal equipment shall be identified by paint marking.
Nameplates shall be non rusting metal or 3-ply
lamicoid, with engraved lettering and shall be subjected
to Employer’s approval.

e) Grounding 25 x 3 mm copper ground bus to be provided for each

panel

f) Space heater 240V AC, single phase, thermostatically controlled

space heaters to be provided.

g) Terminal block 650V grade. clip-on type.

h) Type Elmex - CATD type for CTs. Elmex - CSLT for other
application.

i) Spare 20 percent.

j) Wiring 650V grade. PVC insulated stranded copper wire.

k) Panel Lighting Each free standing panel shall be provided with a door
switch operated fluorescent lamp and a 240V AC plug
point.

l) Painting Treatment as per IS: 6005. Two coats of lead oxide

primer followed by powder painting with final paint
shade of RAL 9002.

m) Degree of For panels located in

enclosure
protection i) Air conditioned areas : IP-32

ii)Other indoor areas : IP-52

iii)Outdoor areas : IP-55

iv)Dusty areas like : IP-65

bottom ash area, silo area etc.

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9.00.00 TYPE TESTS

(a) All equipment to be supplied shall be of type tested quality. The Contractor shall
submit for Employer’s approval the reports of all the type tests as listed in this
specification and carried out within last ten years from the date of bid opening.
These reports should be for the tests conducted on the equipment similar to those
proposed to be supplied under this contract and the test(s) should have been either
conducted at an independent laboratory or should have been witnessed by a client.

(b) However if the Contractor is not able to submit report of the type test(s)
conducted within last ten years from the date of bid opening, or in case the type test
report(s) are not found to be meeting the specification requirements, the Contractor
shall conduct all such tests under this contract, at no additional cost to the Employer
either at third party lab or in presence of clients/Employers representative and
submit the reports for approval

(c) All acceptance and routine tests as per the specification and relevant standards
shall be carried out. Charges for these shall be deemed to be included in the
equipment price.

(d) The type test reports once approved for any projects shall be treated as
reference. For subsequent projects if NTPC, an endorsement sheet will be furnished
by the manufacturer confirming similarity and "No Design Change." Minor changes if
any shall be highlighted on the endorsement sheet.

9.01.00 Programmable logic controller

9.01.01 Following test reports shall be submitted for the equipment:

a). Dry heat withstand test

b). Variation of temperature immunity test

c). Variation immunity test

d). Temperature cycle test

e). Noise immunity test

f). Dielectric test.

9.01.02 Following tests shall be conducted under this contract as routine tests:

a). Tests on internal and external wiring.

b). Incoming power supply voltage and frequency variation test.

c). Test for verification of functional characteristics of I/Os.

d). Task transition test (for each task, the Contractor will list out the user
accessible conditions which shall be used in the simulation of the task).

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e). Functional testing of software and hardware in accordance with the approved
block logic diagram with simulation of the system with switches, relays and
solenoid valves etc. or equivalent loads.

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