3.00.

00 CONTROL AND INSTRUMENTATION SYSTEM FOR ASH

HANDLING SYSTEM

3.01.00 GENERAL
The Contractor shall provide complete Control & Instrumentation systems
for control, monitoring and operation of associated drives and auxiliaries in
all regimes of operation in safe and most efficient manner. The Contractor
shall provide all systems, equipment, accessories and associated
equipment, which are included in Contractor’s scope, in a fully operational
condition acceptable to the Employer. The Contractor shall also provide all
material, equipment and services which may not be specifically stated in
the specifications but are required for completeness of the
equipment/systems furnished by the Contractor and for meeting the intent
and requirements of these specifications. The work shall be consistent with
modern power plant practices and shall be in compliance with all applicable
codes, standards, guidelines and safety requirements in force on the date
of award of the contract.
The following clauses describe the brief scope of supplies only. The
detailed technical specifications are stipulated under Part - B, Section-VI of
the specification as well as in various other Parts of the Technical
Specifications.

3.02.00 MEASURING INSTRUMENTS

Following shall be provided as a minimum meeting specification requirements of
Sub Section-MEASURING INSTRUMENTS, Section-VI, Part-B, of Technical
Specification for the ash handling system & equipments of Contractor’s scope.
(a) All the Instruments as indicated in enclosed flow
schemes/diagrams/relevant tender drawings/ BOQ & corresponding
Mechanical sections meeting redundancy and other requirements specified
under technical specifications are to be provided as a minimum.
(b) All Instruments which are Integral to equipment like pumps, motors etc.,
which are not indicated in enclosed P & IDs but required for control,
monitoring and operation of the equipment/plant/ Systems are to be
provided. All the instruments shall be provided by the Contractor to meet
actual system requirements subject to Employer’s approval.

(c) Further, all the instruments which are required to implement the control
philosophy as specified in corresponding Mechanical sections shall be
provided by the Contractor, within the quoted lump sum price.

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 d) For temperature elements being supplied by Contractor, temperature
transmitters shall be provided by the Contractor. These temperature
transmitters shall be DIN rail type mounted in junction boxes, supplied by
the Contractor.

e) Two nos. hand held type calibrators shall be provided for the
adjustment/calibrations of HART compatible transmitters. Also refer clause
3.00.00 of Sub Sec-IIIC-02, Sec-VI, Part-B.

3.03.00 ELECTRICAL POWER SUPPLY SYSTEM

A) Microprocessor based modular 24V DC power supply system shall be

provided by the Contractor for powering of control system including network
devices, 24V DC solenoid and field instruments of Contractor’s scope.
24V DC power supply system for control system shall comprise of 2 sets.
Each set shall consist of 1x100% microprocessor controlled intelligent
modular rectifier banks, controller-one for each rectifier bank, 1x100%
Nickel-Cadmium batteries for one (1) hour duty, 1x100% DC distribution
board. 1x100% microprocessor controlled battery health monitoring system
(BHMS)-common for both the sets. Also refer tender drawing no. 0000-
999-POI-A-019B.
B) Contractor shall provide On line UPS of suitable capacity with remote
monitoring having a battery backup of 30 min for powering of OWS/EWS &
other HMI items. The batteries for UPS System shall be Sealed
Maintenance Free type.
C) The Contractor shall furnish all required hardware/ equipment/ cubicles
for conversion and/or stabilization of the power source provided by the
Employer (refer to the terminal points) to all other voltage levels which may
be necessary for meeting the specific requirements of equipments/
systems furnished by him within the Contractor’s quoted lump sum price.
This will include Power distribution boards/boxes, necessary MCBs/Switch-
fuse units etc. for further sub distribution.
D) Power supply system shall meet the specification requirements as
stipulated under Sub-Section-IIIC-06, Part-B, Section-VI.

3.04.00 PROCESS CONNECTION & PIPING

Process connection and piping including all impulse piping, pneumatic

piping/tubing, valves, valve manifolds, fittings and all other accessories
required for proper installation & completeness of impulse piping system
and air supply system for instruments, pneumatic actuators, etc., as
stipulated under Sub-Section-IIIC-03 (Process connection and piping),
Part-B, Section-VI of Technical Specification.

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 The instruments which are not located inside building shall be grouped (two
or more) and mounted inside instrument racks. In case grouping is not
possible and these are to be installed individually, canopy with suitable
arrangement shall be provided. The grouping and design of racks/ canopy
shall be approved by Employer during detail engineering.
For all Junction Boxes, Solenoid boxes and Local control panels which are
not installed inside building, suitable canopy shall be provided and design
of canopy shall be approved by Employer during detailed engineering.

3.05.00 INSTRUMENTATION CABLES, CONTROL & POWER SUPPLY CABLES &

ACESSORIES

a) All instrumentation cables (twisted & shielded, PVC insulated &

sheathed with FRLS), control cables (including cables required for
powering of solenoids), power supply distribution cables, grounding cables,
Power cable for input feeder to 24V DC power supply system & UPS
system, data highway/ fibre optic cables including prefabricated cables and
any other cables (as applicable) for direct interconnection of two
equipment/devices in Contractor’s scope as well as instrumentation cables
for connection of signals from/to systems like MCC/SWGR, to PLC in
Contractor’s scope shall be supplied, laid and terminate by the Contractor
on as required basis.
b) All Instrumentation Cables shall meet the specification requirements as
stipulated under sub-section-Instrumentation Cables, Part-B, Section-VI.
d) In case of thermocouples, the thermocouples extension cables between
T/C and temperature transmitters shall also be provided by the bidder.
e) All power supply distribution cables required for directly connecting two
equipment/ systems/devices in Contractor’s scope shall be provided by
Contractor. All these cables shall be FRLS and as per IS:1554 Part-I latest
edition.
g) All the above cables shall be provided along with necessary laying &
termination accessories, hardware etc. All sub trays along with supporting,
connecting hardware, etc., required for laying of instrumentation cables,
control cables, power distribution cables and other cables up to main cable
trays shall be provided by the Contractor. Please refer Electrical sub
section for main cable trays.
h) All required Local Junction boxes, including those required to mount DIN
rail type temp transmitters and power distribution boxes are to be provided
by the Contractor on as required basis.
3.06.00 CONTROL SYSTEM

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3.06.01 Contractor shall provide PLC based control system as described in subsequent
clauses for control, operation & monitoring of Ash handling system & Electrical
breakers provided under this package.

3.06.02 Control System Spare Capacity:

i) I/O Modules: Minimum ten (10) percent spare channels over and above
engineered I/Os shall be provided for each type of I/Os. Further, these spare
channels and other unused channels of I/O modules shall be fully wired up to the
marshalling TBs.

ii) Wired-in "usable" space in I/O racks/ mounting plates/ base arrangement in
system cabinets along with I/O power supply shall be provided for 10% additional
I/Os modules over and above total quantity of engineered I/O modules.

iii) Each processor / controller shall have thirty (30) percent spare functional
capacity to implement additional function blocks, over and above implemented
logic/ loops.
iv) Twenty (20) percent spare relays of each type and rating mounted and wired in
cabinets TB shall be provided for interposing relays mounted in cabinets. All
contacts of relays shall be terminated in terminal blocks of cabinets.
3.06.03 Tentative locations and quantity of new PLC system, HMI:-

Item/ details Ash handling system in Contractor’s scope

PLC I/O cabinets including On as required basis

remote I/O cabinets

Primary operation location Contractor’s scope New Control room

PLC Processors On as required basis

24V DC battery chargers On as required basis

and batteries

Location & Quantity of 2 no. Operator work stations (OWS), 1 no. Engineering work station
HMIPIS (EWS), 1 no. A4 size laser printer.

Control desk and computer One no. control desk of length 2 meter in Contractor’s scope new
furniture control room.
Computer furniture, server rack & table – as required.
Computer chairs – 3 nos.

3.06.04 Offered PLC based control system shall meet the minimum requirements
specified below and specified in Part-B, Section-VI of Technical
Specification.

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 i) Dual processor (hot redundant) PLC based control system.
ii) Remote I/O panels as required for interconnection of signals to PLC shall be
provided on as required basis.
iii) All necessary hardware and software (Licensed) as required to achieve
complete functioning of the system as specified above shall be provided by the
Contractor on as required basis.
iv) System cabinets housing PLC electronic modules and power pack supplies, etc
for the system described above shall be provided by the Contractor on as
required basis.
v) Marshalling cabinets separate from system cabinets for terminating
inputs/output from/to field, MCC/SWGR etc., for further wiring to control system
for the system described above shall be provided by the Contractor on as
required basis.
vi) Relay cabinet-housing relays shall be provided for interposing relays of
solenoids. These relay cabinets shall be located in respective PLC I/O room.
Alternatively, these relays can also be mounted in marshalling cabinets.
vii) Typical interconnection with transmitters, switches, solenoids,
MCC/switchgear, etc shall be as per drg. No. 0000-999-POI-A-065.
viii) Redundancy in binary outputs for drives shall be provided for HT types of
drives. The on/off status of HT drives of DDCMIS will be wired to two DI modules
in parallel.
ix) All the applicable system related inputs like controller failure, fan failure,
power supply monitoring for each system / marshalling, relay and network
cabinet incomer feeder failure, temperature monitoring for remote I/O
cabinets, fuse monitoring (for fuses of modules and any fuse, blowing of
which affects multiple channels of I/O modules) etc shall be provided on as
required basis. For these system related I/O’s separate modules shall be
provided by the contractor.
x) The power supply for energizing solenoids in the field shall be routed through
contacts of the interposing relays. The group monitoring of power supply extended
through contacts of the relays shall be done. The no. of drives per group, can be
maximum 16. One contact of power supply monitoring device (relay/ MCB with
contact or equivalent scheme, as approved by Employer during detailed engg.
stage) shall be wired to PLC, and the same shall be used for ‘drive disturbance’ for
all the drives in the group.
3.06.05 All required civil/ mechanical/ electrical works for new control room, remote I/O
rooms in order to accommodate new PLC cabinets / battery charger cabinets / UPS
cabinets shall be in the scope of Contractor.
3.06.06 Logic Diagram: - The contractor shall furnish comprehensive logic diagram
showing all interlock, protection, sequence and alarm requirement of complete
system to the Employer during detailed engineering stage. In this logic diagram,
tag no. corresponding to I/O list and drive list shall be clearly indicated. The format
of this logic diagram shall be informed by Employer during detailed engineering.
The recommended write up and logic diagrams shall match fully.
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 Mimic diagram / graphics for ash handling system shall be provided and
implemented in HMIPIS for control, operation and monitoring from HMIPIS.
Contractor shall furnish I/O list, drive list along with KKS code and all the required
details/ drawings/ data/ information like write ups and detailed logic diagrams for
controls, interlocks and protection of Contractor’s equipment, mimics/ graphics.
The Contractor shall furnish termination details for all I/Os to be connected to
Control System Cabinets as per philosophy approved by Employer during detailed
engineering stage. The format and exact details by Contractor shall be as
approved by Employer during detailed engineering.
3.07.00 ELECTRICAL ACTUATOR
Electrical Actuators with integral starter shall be provided as required for ON/OFF
and inching duty type valves/gates/dampers alongwith necessary interface to PLC
as detailed out in Sub Section-Electric Actuator, Section-VI, Part-B.
3.08.00 TYPE TEST REQUIREMENT
The type tests to be conducted for C&I systems & equipments shall be as detailed
out in Sub-Section-IIIC-05, Part-B, Section-VI of Technical Specification.
3.09.00 TOOL & TACKLES
The Contractor shall furnish a complete new set of all special tools and tackles of
reputed make and model which are required for erection, ease in maintenance to
have minimum down time, testing and calibration of all the equipments and
systems to be provided by the Contractor under this specification for C&I systems.
3.10.00 GROUNDING SYSTEM
Contractor shall provide suitable grounding system for all C&I
equipments/panels/devices of Contractor scope. The exact details shall be as
finalized during detailed engineering. Also refer tendering drawing no. 0000-999-
POI-A-19A and Sub-section-IIIC-01 (Basic Design Criteria)., Section-VI, Part-B.
3.11.00 SCOPE OF DISMANTLING SERVICES
Contractor’s scope of services shall include scope of dismantling, installation &
commissioning and other services as specified and as required to meet the intent
of specification.
3.12.00 SCOPE OF INSTALLATION & COMMISSIONING
3.12.01 The Contractor’s scope shall include Installation, interconnection (including laying
and termination of impulse pipes/ tubing, cables, solenoids, instruments,
pneumatic actuators), testing and commissioning of all equipment/ systems in the
Contractor’s scope, alongwith interface piping, tubing, hardware etc so as to make
the system complete for ensuring satisfactory operation of PLC equipment as per
intent and requirement of this specification.

3.12.02 All required civil/ mechanical/ electrical works, air conditioning, etc. for control
room, remote I/O rooms in order to accommodate new PLC cabinets / battery
charger cabinets / UPS cabinets shall be in the scope of Contractor.

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3.12.03 Receiving, unloading, handling, storage at site, installation, testing, termination
and checking of continuity of instrumentation / control cables under scope of work
of this package.

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