DISTRIBUTED CONTROL SYSTEM

Distributed control system is considered for the Monitoring, operation Alarm, Logging
and Control of the following major equipments in the Captive power plant

- Boiler and its auxiliaries (Supplier scope)

- Turbine, generator and its auxiliaries
- Fuel handling and conveyor systems
- Water treatment Plant systems
- Main and Auxiliary cooling water system
- Dense phase ash handling system
- Air compressors
- Power generation related details
- Details pertaining to breaker status and synchronization with grid
- Communication with Governor, Vibration Monitor, ESP and other third party devices.

All hardware and software necessary to meet the specified functional requirements, as
per the control system architecture of the Distributed Control System.

All type of alarm shall be displayed in a single page including operator log for
analysing and purpose.

System shall be suitable to configure trend for all the signals and all the signals shall be
configured in the trend grouping.

Maximum of 16 channel module shall be considered for analog signals and maximum
of 32 channel module shall be considered for digital signals.

All system furniture required for mounting and operation of the system including
consoles for monitors and printers shall be supplied. Furniture for operating personnel
shall also be considered

System configuration

Four operator stations, one engineering cum operator station, one three in one printer
(print, scan & copy) and one A3 size printer for alarm shall be accommodated along with
DCS panels in the main control room Screen) shall also be installed in the
main control room and required mounting arrangement shall be considered in the bidder
scope.

One number of operator stations shall be considered for the EMS system in addition to
the above and the same shall be located in the main control room with necessary
hardware.

All operator stations including engineering station shall have dual monitors and size
System configuration drawing is attached elsewhere in the RFQ.

Control rooms shall be interfaced through fiber optic cable with armor type and two
runs fiber optic cable to be considered through different cable routes. Fiber optic cable
shall be laid through conduits and cable tray. Ehernet switches shall have built-in fiber
optic ports and switch type shall be managed one for easy system related diagnosis. Other
accessories like LIU, connectors etc shall also be in bidder scope of supply.

Remote monitoring facility with minimum of four client license shall be included in
bidder scope.

Shape of the console shall be semi arc. Dual monitors shall be placed as side by side in
the console and suitable mounting arrangements shall be considered in bidder scope.

UPS capacity and its configuration shall be as below

2x25 kVA UPS with individual battery back-up for one hour shall be considered at main
control room

Two independent terminals shall be provided in each UPS of parallel redundant

configuration to PDB connectivity.

Bus-A and Bus-B of power distribution at PDB cabinet shall be connected by individual
cables from UPS.

Two earth pits for instrument earth and two earth pits for panel earth shall be supplied for
new control room.

Minimum 25A- 24VDC dual redundant power supply units shall be considered at each
control rooms for field instrument or solenoid valve powering.

DCS I/O SUMMARY

Total number of IO counts shall be finalised considering the following

a. Instruments, final control elements and motorised actuators indicated in the approved
P&IDs
b. All the electrical drives including all the electrical breakers to be hooked upto DCS.
c. 20% of spares shall be provided for each type of IOs and the same has to be wired
upto the terminal blocks as per typical loop diagram.
d. 64 Numbers of digital inputs shall be considered for integral SOE function( 1ms time
stamping) and these digital inputs are exclusive of the above IO count.
e. Energy management system in DCS

f. Two numbers of MODBUS RTU Protocol module with two RS485 ports shall be
included in the DCS BOM at boiler and turbine area in addition to the EMS
requirements.
g. 20% of spare terminal blocks shall be provided for each type.
h. The system loading for controllers and data acquisition sub-system shall not exceed
50%. The loading as indicated is the worst case of high system activity referred to the use
of memory, CPU time and communication capacity for this sub-system.
i. Total numbers of IOs for turbine section shall be 600numbers

Maximum of 16 channel module shall be considered for analog signals and maximum
of 32 channel module shall be considered for digital signals.

System shall be suitable to configure trend for all the signals and all the signals shall
be configured in the trend grouping.

Alarm history

The history of alarm conditions shall be maintained in the database for alarm history
display and printed on shift-wise basis. All type of alarm shall be displayed in a single
page including operator log for analysing and purpose.

Controller Sub-system
The control function of the system shall be executed by 64 / 32 bit microprocessor based
controller switch minimum 64 MB RAM consisting of power supply modules, processor
modules, communication modules and I/O modules (if applicable) and a set of
algorithms which are easily field configurable using user friendly software.

Controller shall be provided with redundant power supply, redundant processor and
redundant communication modules.

Controller processor memory shall be non-volatile. However in case volatile memory is

provided, battery backup shall be provided with a minimum of 48 hours/15 Days to keep
program storage intact. A battery drain indication shall be provided when the charge in
the battery dips below 50%.

Controllers shall be able to scan all close loops in less than 250
milliseconds and scan open loop in 500 milliseconds. Digital close loop scan time
shall be less than 100 milliseconds for all loops. The scan time shall be freely
configurable from 5 msec. to 2000 msec. for individual loops / interlocks.

Loop integrity shall be maintained in controller sub-system architecture by providing one

to one controller back-up. In case failure is detected in the active controller, all the loops
of the failed controller shall be transferred to the back-up controller. The controller sub-
system shall have automatic control transfer switching, which shall transfer the entire
configuration and data base of failed controller to the back-up controller. The transfer
should be bumpless & shall be of the order of 10 msec or better.Design must ensure that
data integrity is maintained during switch over and no portion of data to be transferred is
corrupted before and during switch over to the back-up controller. The same shall be
done during normal operation. The indication of the failed controller shall be displayed at
local level as well as on the central level.

Data acquisition sub-system

Data acquisition sub-system shall interface and multiplex analog and discrete inputs from
open loops. The inputs shall include 4-20mA DC, thermocouple, resistance temperature
detector and discrete contacts.

The system shall be capable of processing linear and non-linear analog inputs,
linearization and compensation for thermocouple, linearization of RTD inputs and square
root extraction for flow inputs.

Data acquisition sub-system shall have a power supply and communication module
redundancy. The redundant component shall take over in case of main component failure
automatically.

All communication modules shall have redundant communication bus.

I/O module sub-system

Each analog Input / Output channel shall be isolated from the external control circuit by
optical / galvanic isolation.Each I/O shall be protected from short circuit and reverse
polarity of power voltage. Each input shall be provided with filters to filter out any noise
in the input line and contact bouncing noise.

All digital input to the system shall be routed through individual relays and relays shall
have two change over (2NO + 2NC) contact.

Each output shall be short circuit proof and protected by fuse. Visual indication of fuse
blown must be provided for all digital inputs and outputs.All digital input / digital
output channels shall have a facility to force the input or output.

Analog and digital modules shall be of the same family.

Controller & IO Modules shall be G3/equivalent Compliant at the source of

manufacturing as per ISA 71.04.

Analog modules shall be of maximum 16 Channel and digital modules shall be of

maximum 32 Channel. Deviation in number of channels per modules shall not be
acceptable.

Redundant analog IO modules shall be considered for all analog closed loop IOs. No
foreign module shall be provided for achieving the IO module level redundancy.

Communication Sub-System

The communication sub-system shall be a digital communication bus that provides a high
speed data transfer rapidly and reliably between the operator station, process I/O devices
and other devices connected to it.

Communication system shall be dual redundant, consisting of two separate

communication buses and two separate communication system interfaces for each device.

The overall system performance shall not be degraded whether communication sub-
system is 10% loaded or 100% loaded. Communication speed on the communication bus
shall be sufficient to update the operator station database once in every second.

In case of main bus failure or any communication device failure, the transfer to the back-
up device or bus shall be automatic without

Information about the failed device/bus shall be displayed on the operator

station.

It shall be possible to switch over the communication from main bus to the redundant bus
manually without disturbing the system operation. It shall also be possible to connect or
disconnect a device form the system without disturbing the operation.

Ethernet Switch configuration of the same shall be L1 / L2 Split. Ethernet switch shall
have in built FO port for other area controller or remote IO panel connectivity.

The operator interface sub-system shall consist of number of operator stations and its
configuration as per the enclosed DCS architecture.

All operator / engineering station shall be connected through fiber optic cable and
minimum four numbers of fiber shall be considered as a spare. Fiber optic cable outer
sheath shall have armour. Distance between the control rooms indicated elsewhere in the
bid document.

Each operator station shall consist of dual TFT monitors and keyboard and each driven
by independent electronics. Each TFT size shall
TFT data and display update rate shall be less than two seconds.

All the operator stations shall be interchangeable.

The operator/engineering stations shall be housed in the open consoles. All printers
shall be housed in open type printer console.

Historical data
Historical data shall be stored on the non-volatile memory device like hard disc in such a
way that such historical data can be utilized for archival storage and subsequent recall.

Historical data trends shall be displayed for a period of minimum six (6) months for a
data sampling rate of 1 Second for a data sampling rate as defined below
- 75% of total analog tags at 250 msec.
- Balance Analog tags at 1 sec.

History shall be stored in all operator stations for minimum 1 Year as per sampling rates
mentioned above for Node or station based system architecture.
Open System Connectivity

The system shall be capable of interacting with other plant systems and computers over a
well-established communication network like ethernet conforming to IEEE 802.3.

The system shall be provided with OPC software and it shall be with this system

for data transfer.

The system shall have provision for HTTP server and ethernet TCP/IP connectivity for
communicating with plant intranet, corporate intranet or anywhere around the world for
web enabling. The system shall have its own memory and file system that delivers real
time data to the web and allows end user customization.

Foreign Device Interface

Foreign device interface shall be capable of transferring data from the foreign devices
like Governor, ESP controller, TSI monitor, HP/LP bypass system, VFD etc., to other
sub-systems connected to communication sub- system and vice-versa.

Type of protocol for foreign devices shall be RS 485 MODBUS RTU and Profibus.

Global Position System

GPS system shall have one master clock and four slave ports. Three ports shall be
Ethernet type and one port shall be RIG-B type.

Miscellaneous

Cabinets

Cabinets shall be fabricated from cold rolled steel sheet of minimum 2- mm thickness
suitably reinforced to prevent warping and buckling. Doors shall be fabricated from cold
rolled steel sheet of minimum 1.6-mm thickness. Each cabinet shall be of maximum
2115-mm height and 1200/800 mm width. All Panels make shall be Rittal only with IP-
52 protection.

vent louvers backed by wire fly screen shall be provided to cabinet doors. In case louvers
are insufficient, ventilation fans shall be provided.Fan failure and temperature detection
unit shall be provided for System and IO cabinets and alarm of this unit shall be
connected to system for monitoring.

No components shall be mounted in the side panel.

Minimum 300mm distance shall be kept between marshalling rack cabinet gland plate
and field terminal blocks.

All IO Modules except thermocouple module shall be wired to individual terminal blocks
for field connection.

Type of terminal blocks field signals shall be as below

Analog input (4-20mA) : Disconnect

type Analog input (RTD) : Normal type
Analog output (4-20mA) : Disconnect
type Digital input : Fused type

Digital output : Fused type with fuse failure indication

Power supplies and distribution

For distribution of power from the UPS AC source, individual feeders to be provided for
the system panels, field instruments, analysers etc requiring 230VAC power, engineering
and operator stations, printers.

For feeding power in the system panel, individual 230VAC feeders with suitably
designed MCBs should be provided from separate UPS ACDB to the system panels
which are to be designated as supply for main and redundant equipments respectively.

For power supply distribution of 24VDC bulk power supplies, individual bulk power
supply should be provided with reverse diode protection and individual power supply
alarm is to be connected to the system. Common diode oring unit is not allowed because
failure of diode-Oring unit will bring down both the bulk power supply units.

Dedicated bulk power supply units shall be provided for controller sub system,
communication subsystem (if applicable), 2-wire type transmitters, digital input field
interrogation, wetted for SOV etc

Training

The training shall include the training of OWNER's engineering and training shall be 2-
Man weeks and operator training shall be 4 man weeks.

Factory Acceptance Test (FAT)

SUPPLIER shall submit their Factory Acceptance Test procedure for on approved FAT
procedure by Purchaser / PURCHASER. The Factory Acceptance Test shall be done in two
phases:
Phase I: Pre Fat &

Phase II: Final Fat.