RENNOVATION AND MODERNIZATION (R&M) OF PLANT

DISTRIBUTED CONTROL SYSTEM (DCS)

POWJS ZC425T: Project Work

By

LAKSHMIKANTHA REDDY

ID No: 201535TJ505

Project Work carried out at

Energy Limited, Toranagallu,

Bellary Dist, karnataka

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE

PILANI (RAJASTHAN)

JANUARY 2019

Annexure A
 RENNOVATION AND MODERNIZATION (R&M) OF PLANT
DISTRIBUTED CONTROL SYSTEM (DCS)

POWJS ZC425T: Project Work

By

LAKSHMIKANTHA REDDY

ID No: 201535TJ505

Project Work carried out at

Energy Limited, Toranagallu,

Bellary Dist, karnataka

Submitted in partial fulfillment of B.Tech. Power Engineering degree

programme

Under the Supervision of

V.VEERESH,
Dy. Manager (C&I),
JSW Energy Limited, Toranagallu,
Bellary Dist, karnataka

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE

PILANI (RAJASTHAN)

JANUARY 2019

Annexure B
 ABSTRACT

This project describes Renovation & Modernization of Plant DCS. The

Existing System of Plant DCS is of M/s. ABB make Infi-90 system, which was
installed in 1998 in SBU-1 both units 2 x 130 MW. Recently we are observing
more problems in DCS system such Processor failure, I/O card failures, Power
Supply failures and Operator console server failures and we use to replace the
faulty modules with spare one. When we approached M/s. ABB for solution, they
requested to upgrade the system. So to avoid spare cost which too high due to old
type processor / IO modules, we planned to do R&M totally, where we could
bring the old system to latest technology and which can run for next 10 years.

The reason for doing DCS R&M brings us system which is latest and user
friendly with lot of features. Operator consoles will be running with latest
windows flat form and system can be maintained easily.
 INTRODUCTION

1.1. JSWEL BACKGROUND 

JSW Energy Ltd is a fast growing power services company that is part of the
prestigious, $4 billion valued Jindal South West (JSW) group. The group has expanded
interests in areas ranging from steel, energy, minerals and mining, infrastructure and
logistics, cement and IT. Formed in the year 1994, as a joint venture between the JSW group
and Tractable S.A. of Belgium, JSW Energy commenced operations in the year 2000 as an
Independent Power Producer (IPP), setting up a 260MW power generating unit. The company
was initially called ‘Jindal Tractable Power Company Ltd’, but after Tractable S.A. sold their
stake in 2001, the company was renamed as ‘Jindal Thermal Power Company Limited’. The
company secured its current name is ‘JSW Energy ‘once the JSW group secured a 100% stake
in the company. The company had the distinction of being the first Independent Power
Producer (IPP) to set up operations in the state of Karnataka, initially installing units of
130MW each, with both units generating power using corex gas and coal. In addition to power
generation, the firm is also involved in power trading (playing the role of a power supplier to
JSW Steel Ltd. and other Power Trading Corporations), power distribution, providing and
maintenance services, mining and the manufacturing of the super critical boilers. The
company follows very strict environmental standards and its Environmental Management
System (EMS) has been certified as an ISO 14001 compliant by BVQL. JSW Energy is also
an ISO 9001-2000 and ISO 18001 certified company.

Till FY09, the company’s source of power generation was limited to its 260MW
(2x130MW) unit in Vijayanagar, Karnataka (JSWEL SBU 1). In July 2009, the company
added to its power generation portfolio by commencing the first of its 600MW (2x300MW)
coal plant (JSWEL SBU II). This plant too is located in Vijayanagar. The second unit
(2x300MW) was operationalized in September 2009. Power transmission is another power
related area that the firm has been involved in, rendered through yet another subsidiary
JSWPTC (JSW Power Trading Company).

1 
 
Through its transmission lines the company transmits power from power generation units to
the states and national grids.

1.2. OVER VIEW OF JSWEL GENERATING UNITS:

The power plant at Toranagallu has total 8 generating units as of present. The
installed capacity is 1690 MW.

• SBU-1, Unit-1 & 2 – 130 MW each

• SBU-2, Unit-1 & 2 – 300 MW each
• CPP-1 – 100 MW
• CPP-2 – 130 MW
• CPP-3&4-300 MW each

2 
 
2. Existing DCS System Architecture

2.1 Overall DCS System Architecture

 

 
 

3 
 
 

2.2 BELOW FIG SHOWS THE SINGLE LOOP CONFIGURATION OF EXISITING PLANT C-NET LOOP

LOOP-2 LOOP-1
UNIT-1 COMMON
LOOP-3
UNIT-2

LOOP3 & LOOP-1

BRIDGE
COMMUNICATION

LOOP2 & LOOP-1 BRIDGE COMMUNICATION

UNIT-1 & COMMON LOOP

No. of Nodes consist in a Loop

LOOP NODES Remarks

COMMON
LOOP-1 7 3 PCUs + 1 SEM + 1 EWS + 2 Bridge

LOOP-2 UNIT-1 24 15 PCUs + 4 HMI + 2 EWS + 2 RIO + 1 Bridge

LOOP-3 UNIT-2 24 15 PCUs + 4 HMI + 2 EWS + 2 RIO + 1 Bridge

 

   

4 
 
   

Abbreviations: 

C‐Net: Control Net is a Highway path of coaxial cable where all nodes can talk each other through soft 
including HMI, where Operator Can Monitor the Process graphics real time data and to control process. 

HMI: Human Machine Interface is a PC, where operator can view /control/analyze the process by seeing 
real time data or Historical data 

PCU(Nodes): Processing Control Unit, where controller of reside, which controls the process as per 
predefined logic downloaded in it. 

Loop: where set of PCU’s are interconnected each other via coaxial cable say Unit‐1 

Bridge: It is an interface module to allow from different loop to talk each other say Unit‐1 loop and unit‐
2 loop can exchange data vice versa  

EWS: Engineering work station, where process logic will be build, edited and downloaded to 
controller(processor) and same time backup of controller’s logic can be taken. 

RIO: Remote Input and output signals which are located away from DCS control panel say CW pump 
house I/O signals 

IMMFP02/03/12: Multi‐functional Processor, where Logics will be residing, Function codes, C++ 

INNIS01/21: Network Interface Module to communicate with Other PCU(Nodes) 

INNPM01/11/12: Network Processor Module, which take the data from Processors and send to other 
Nodes via INNIS01 

IMMASI23: This is a Analog input Module which accepts RTD/TC/mAps signals – 16 channel module 

IMMFBS01/FEC01: This is an Analog Input Module which accepts mAps/Mv/Volt signals – 15 channel 
module 

IMMDSI01/02/13: This is a Digital Input Module of 16 channel either 5V or 24V DC potential signals 

IMMDSO04/14: This is a Digital Output Module of 16 channel  

IMMFCS01: This is a Pulse input Module for turbine speed signals 

IMMTKM01: Time Keeper Module which manage the time of SOE signals 

IMMSED01: Sequence of event digital Input module with 1 milli seconds resolution. 

   

5 
 
 2.3 LOOP TOPOLOGY REPORT

2.3.1 UNIT-1 LOOP TOPOLOGY

NO. OF NODES : 22 + 2 RIO

B : BRIDGE

C: CONSOLE/COMPUTER HMI

P : PROCESS CONTROL
UNIT

41
44 C 40
C C
42
C 15
43
RIO
C
16
P
22 LOOP-2
B
UNIT-1 15
P

2
P
13
P

4
P
50
C

3
P
10
P

1
P 11
P

  9
P 12
  9
  P
7
RIO P 6
8 5 P
P P

6 
 
 2.3.2 UNIT-1 LOOP TOPOLOGY

NO. OF NODES : 22 + 2 RIO

B : BRIDGE

C: CONSOLE/COMPUTER

P : PROCESS CONTROL
UNIT

41
44 C 42
C C
40
C
43
C 15
16 RIO
P
33
B
LOOP-3
UNIT-2 15
P

2
P
13
P

3
P
10
P

4
P 50
C

1
P 11
P

9
P 12
  P
8
P 5
  7  6 P
9
P P
RIO

7 
 
 2.3.3 COMMON LOOP TOPOLOGY

Note: c-net flow from one node to other node as mentioned below fig is not confirmed,
fig shows only physical present nodes

NO. OF NODES : 07

B : BRIDGE

C: CONSOLE/COMPUTER

P : PROCESS CONTROL
UNIT

T : TIME MASTER
2
P

1
P LOOP-1
50
COMMON C

CONNECTED TO
LOOP-2 (UNIT-1)
VIA BRIGDE

21
B

5
P
 
19
T
8 
 
3. Exisitng DCS Room Panel layout:
 

 
 

   

   

9 
 
4. Node/Functional wise Equipment List:

Sl  Node  List of Functional/Equipment control 

1  A PANEL, CCS Panel  CMC MODE, BOILER MASTER, RUN BACK/RUN DOWN, FUEL MASTER, 
COREX  & COAL DMD 
2  B Panel, BMS Panel  MFT TRIP LOGIC, SEAL AIR FANS, SCANNER AIR FANS, IGNITOR TRIP 
VALVE, LFO ATOMISING AIR, IGN GAS PRESS, MFT, HFO / LFO TRIP 
VALVE, AX1 / BC OIL VALVES & IGNITORS. COREX HDR TRIP / VENT VLVS, 
UNIT GOGGLE VLV, X3‐IGNITORS,  X1 / X2 / X3 NOZZLE VLVS, CORNER 
VENT VALVES,  N2 PURGE VALVES. 
3  C Panel, Mill‐A Panel  MILL‐A GROUP START / STOP SEQ , CONTROL / TRIP LOGICS,  LUB OIL 
SYS., SEAL AIR VLV, HOT / COLD AIR GATE , FEEDER ON / OFF,  MILL 
DISCHARGE GATES , MILL STEAM INSERTING VLV , MILL A COAL DUST 
FIRING., SOME SIGNALS OF MILL B DUST FIRING & ALSO U#1 DUST 
FIRING. 
4  D Panel, Mill‐B Panel  MILL‐B GROUP START / STOP SEQ , CONTROL / TRIP LOGICS,  LUB OIL 
SYS., SEAL AIR VLV, HOT / COLD AIR GATE , FEEDER ON / OFF,  MILL 
DISCHARGE GATES , MILL STEAM INSERTING VLV , MILL B COAL DUST 
FIRING.. 
5  E Panel, Mill‐C Panel  MILL‐C GROUP START / STOP SEQ , CONTROL / TRIP LOGICS,  LUB OIL 
SYS., SEAL AIR VLV, HOT / COLD AIR GATE , FEEDER ON / OFF,  MILL 
DISCHARGE GATES , MILL STEAM INSERTING VLV. 
6  F Panel,  ID FAN‐A/B BREAKER, O/L & I/L GATES, LOP‐A/B, EP ‐ A/B O/L & I/L 
ID/FD/PA/APH  GATES. PA FAN A/B BREAKER, LOP A&B, PA O/L DAMPER, FD‐A & B 
BREAKER , LOP'S A & B, FD O/L DAMPER, ETC. 
7  G Panel, SOOT  SB SEQUENCE & WALL BLOWER  1 TO 34, HFO PUMP 1  & 2,   NEW 
blower  ALARMS  FOR BFP/CEP/CW,  HW/DEA,   EITHER  ID/FD/MILL/PA TRP,  
CUTIN/BYPASS ISLAND @ ANNUNCIATOR. 
8  H Panel , Water &  DRUM LVL , FW FLOW , BFP A/B/C SUCTION FLOW,  BFP INTERLOCKS, 
Steam, FW flow  DRUM LVL FULL / LOW LOAD  CV'S, BFP A/B/C SCOOP, BFP‐A/B/C‐RCV, 
CEP‐A WDG TEMP. DEARATOR LVL & PRESSURE , HOTWELL MAKEUP 
CV'S, LPH 1,2,3 DRAINS , HPH 5,6 DRAINS , CEP MAIN & RCV, HOTWELL 
LEVEL, HPH‐5,6 &  LPH‐1,2,3 LEVEL, LPH‐1,2,3 PRESSURE, DEARATOR LVL 
TX, AUX STM CV TO DEARATOR. 
9  I Panel   PRDS‐ LO &  HCV ( PRDS SPRAY & PR CONTORL) ,  STG‐I O/L TEMP., STG A 
CCS RH TEMP  / B / C SH. SPRAY BLOCK VLVS,   STG 1A / 1B,  IIA / B,   ASLD,   RH TEMP,  
CONTROL  MS O/L TEMP,   MS FLOW TO HPBP,  LPBP‐ POSITION 1 & 2,    MS FLOW 
  TO PRDS,    INST. AIR PRESS,   LPBP SV1 TRIP,   LPBPSV2‐TRIP VLV,   
CONDENSER PRESS V.HIGH, LPBP CV 1 & 2, GLAND STM PR CONTROL 
VLVS + OPEN & CLOSE INTRELOCK GENERATION LOGIC FOR WARM UP 
DRAIN VLV,   SPRAY VLV‐ 1 / 2,  RH PROTECTION ,   RH SPRAY L/R CV'S,     
BURNER TILT,    HPBP PRESS CV CONTROLS,   MS PRESS BEF HPBP(TO 
TSE). HPBP SPRAY CV'S,   LPBP SV'S. 
10  J Panel, Turbine Misc  LIFT OIL PUMPS 1 &2,    LOP 1 , 2,    CONTROL OIL PUMPS 1 &2 ,      OIL 
VAPOUR EXT PUMP,   TURBINE TURNING GEAR ,   SEAL OIL SYS ,   GS  EXT 
FAN 1 , 2 ,   CONTROL OIL‐ RECIR PUMP,  CEP A / B BKEAKER , HSU‐  
PRESSURE LIFT / LOP PRESSURE , MOT OIL TANK , VACUUM PUMP 1 &2 ,  

10 
 
      
11  K Panel, Electrical SW  GT BKR‐1 / 2 ISOLATOR,   GT BUS ISOLATOR,   GT BAY SIDE ISOLATOR, GT 
gear  TAP POSITION LOW/RAISE,  GT BKR,    GEN ACT / REACTIVE MW,    GT 
OLTC,    ENERGY METER READINGS. 
12  P Panel Turbine  TURBINE PROTECTION‐ CHANNEL‐1,   LO PRESS,   MS TEMP,   HP 
Protection Panel  EXHAUST,   AXIAL DISPLACEMENT,   SPEED,   IP STEAM,   PROTECTION 
LOGIC,   TSLLE ,   HOME LOAD,   MOT LEVEL V.LOW, CHANNEL‐1  HP / IP  ‐ 
CV / SV TRIP COILS. 
 

   

11 
 
5. List of Installed Module:

Sl.No  Type of Module  Description  Quantity in Nos 

1  IMMFP02/03/12  Multifunction  88 
Processor 
2  INNPM01/12  Network Processor  30 
Module 
3  INNIS01/21  Network Interface  30 
Module 
4  IMMASI01/23          Analog Input  51 
Module(RTD/TC) 
5  IMMFBS/IMFEC12     Analog Input  70 
Module(mA/mV/V) 
6  IMMDSI01/13/22  Digital Input Module  202 
7  IMMDSO04/14  Digital Output Module  130 
8  IMMFCS01  Pulse Input Module  06 
9  IMMSET01  Timer Keeper Module  01 
10  IMMSED01  Sequence of event  15 
Module 
 

   

12 
 
6. Existing DCS Input & output Signals list:

 
   

13 
 
  
 

   

14 
 
7. TECHNICAL SPECIFICATION OF DCS R&M WORK

TABLE OF CONTENTS

CLAUSE NO. DESCRIPTION

7.01.00 Introduction and General Features

7.02.00 General Requirement

7.03.00 System Basic Design,

System Structure and
Basic Features / General
Requirements

7.03.01 System Basic Design/

System Structure

7.03.02 Process Station (Automation System)

- Analog Input Module / Input

Processor

- Binary Input Module / Input

Processor

- Analog Output Module / Output

15 
 
 Processor

- Binary Output Module / Output

Processor

- Drive Control Module for

Analog Controls

- Drive Control Module for

Open Loop Controls

- Functional group control module

7.03.03 Operator Station, Operator

Control, Plant Information &
Monitoring Station / Operator

7.03.04 Master Clock System

7.03.05 Performance Calculation

7.03.06 System Documentation submission

7.03.07 Programming & Engineering Work Station

7.03 08 Power Supply System

7.03.09 System Grounding

16 
 
7.03.10 Spare allocation

7.03.11 Documents to be submitted along

with the Offer

7.03.12 Documents to be submitted after

award of contract

17 
 
SECTION-2

DISTRIBUTED CONTROL, SYSTEM

7.00.00 Distributed control system(DCS) shall comprise of modulating control,

sequence control, Interlocking and Protection, monitoring and Information
system, data archiving, performance calculation and operator interfacing
units.
7.01.00 Introduction and general features:
DCS shall include the following sub systems, operating in a completely
integrated manner employing preferably of the same family of hard ware
and software.
i) Process stations / subsystems: -
For realizing the functions of measurement systems (signal acquisition,
conditioning, distribution, transmission, Indication and recording) closed loop
control system (CLCS) and open loop control system OLCS)

ii) Operator station /subsystem / Human Machine Interface (HMI)

This subsystem together with its associated computers, DISPLAY based operator
consoles and other peripherals performs control and monitoring function including
alarm monitoring, display functions logging functions, data archiving functions,
performance calculations functions and alarm monitoring etc. The Unit database
shall support industry standard accessibility for data access by other standard
system / software. The MMI shall be proven with latest industry available.

iii) Programming, on-line diagnostic, Engineering and Maintenance engineering

stations / subsystems: -
For realizing the functions of programming, configurations, tuning, maintenance
and modifications and also for the detection and reporting of internal and external
system failures and malfunctions and trouble shooting.

iv) High-resolution sequence of event recording:

For sequence of event monitoring with one milli sec. resolution.

iv) Master clock system: -

18 
 
 A master clock system, capable of receiving time signal broadcasted by National
Physical Laboratory, processing it and then transmitting and synchronizing this
time with DCS systems: - Clock Module and SOE (Sequence of events) system
clock Module shall be provided.

v) Communication networks:

Comprising of Process station bus (Local bus), and data highway, and other
communication Networks and interfaces for exchange of data and instructions. The
Distributed Control Systems shall have the features for adopting “Open
architecture” to enable the Owner to avail benefits of future expansion and also
have the flexibility in choosing hardware and software from different sources.

vi) Alarm annunciation system for presenting alarm on conventional fascia windows
may be independent standalone system or may be configured as a part of DCS
using the same family of hardware as depicted in Drg no 2.01 that of main system.
It is the Bidder’s responsibility to marshal the inputs and share it between the two
systems.

7.02.00 General requirements

The Distributed Control System shall be supplied with latest state of art
technology and having proven design. The system shall incorporate
modular system design approach to facilitate easy system expansion. The
functions of DCS System are achieved through bus communication units,
bus interfaces, process controllers, I/O modules and computers. PLC
based concept will not be acceptable at any level.

7.02.01 Spare capacity:

a) Over and above the equipment and accessories required to meet the
fully implemented system as per the specification requirement DAS / DCS
shall have spare capacities and necessary hardware and equipment for
future expansion at site
a) 10 % spare channels generally uniformly distributed over
each of the I / O modules fully wired up to buffer terminal
cabinet / marshalling cabinets shall be provided by the bidder.
19 
 
 b) Wired in space for 20 % modules in each of the system
cabinets for mounting electronic modules wired up to
corresponding spare terminals in buffer termination cabinets /
marshalling cabinets shall be provided such that
implementation of any additional functions can be achieved
only by insertion of necessary electronic module / modules.
c) 10 % spare relays of each type and rating shall be provided
by the Bidder. All contact of relays shall be terminated in the
terminal blocks. Provisions of 10 % spare terminals shall be
provided so that additional relays shall be mounted and wired
in all respective I / O and DCS cabinets.
7.02.02 System shall have appropriate redundancies built in for all system functions
both at the processor and device level. Any failure of a single unit or element
of DCS shall not result in degradation of system performance. It shall have
redundant data highway operating on “Masterless Principle”. Client
server (Master slave) based concept is not acceptable.
7.02.03 The system shall be freely scalable / expandable. The system shall have
capability and facility for expansion through addition of station / drops, controllers,
processors, process I/O cards etc., while the existing system is fully operational.
The system shall have the capability to add any new control loops in CLCS
and new group, sub group, drive functions in OLCS while existing system is
fully operational.

7.02.04 The basic systems shall be connected through redundant data highway / bus
systems. The local bus system with bus couplers / interfaces shall be provided for
communication between different I/O modules and processors. The
communication system shall be designed keeping in view the integrity and security
aspects for the control system.

7.02.05 The DCS shall be fully capable of taking care of the plant in all regimes of plant
operating conditions, including emergency operation / trip conditions, The DCS
shall be capable of bringing the plant to safety state automatically without operator

20 
 
 interventions. However, in order to meet the emergency conditions arising out of
any failure in the system there shall be sufficient hardwired push button stations
for bringing the plant to safe state, though in normal course all manual control shall
be realised through DISPLAY operation.

21 
 
7.02.06 Controller Redundancy:
All functional controllers for sequence control and functional controllers
for closed loop and Open loop controls shall be provided with hundred
percent hot standby controllers.
All the 100% hot back up controllers shall be identical in hardware and
software to their corresponding main controllers. Further each of the 100%
hot back up controllers shall be able to perform all the tasks of their
corresponding main controller.

7.02.07 Redundancy in input / output modules:

a) Redundancy in input / output modules for close loop control systems.

i) Wherever redundant sensors are employed in CLCS each
sensor shall be wired to a separate input module so that even
if one input module fails, the parameter will be available from
the other input module.
ii) If only one sensor is provided for CLCS control, then
redundant input cards shall be provided
iii) Redundant output card shall be provided for the signals from
CLCS going to final drive control elements.
b) As regards redundancy for drive control functions the following philosophy
may be adopted.

i) For close loop controls, a system which employs individual drive

control/interface modules, redundancy for drive control/interface
module, is not required, Redundancy shall be provided if the system
is multi-channel drive control module based.
ii) For open loop control system, redundant drive control modules shall
be provided with not more than four drives connected to one set of
redundant drive control module. However, single channel drive
control modules need not be redundant. In case a system which

22 
 
 employs input/output I/O modules for realising drive control
functions redundancy in input / output and processing modules shall
be envisaged.
c) Redundancy in I /O cards for interfacing Push Button modules on Desks /
UCP is not required.

7.02.08 The system shall be provided with extensive diagnostic features so that a system
failure can be diagnosed down to the module level giving location and nature of
fault. Ease of maintenance and troubleshooting shall be a primary consideration in
equipment selection.

7.02.09 The system shall provide inherently safe operation under all plant disturbances
and component failures so that under no circumstances safety of the plant
personnel or equipment shall be jeopardized. The DCS hardware shall be suitably
sized to ensure that the implemented scheme meets the desired requirements.
The Bidder through detailed calculations shall establish the adequacy of the
system selected and demonstrate the same during shop testing and site testing,
etc.

7.02.10 Response times:

The system shall have adequate speed of response through all

regimes of system loadings. Typical response times are indicated below: -

a) Key board command to field equipment shall be executed and its

confirmation on display shall be displayed within 2 seconds.

b) The response for operator requested display time between pressing of last
key and appearance of last character on screen shall be of the order of one sec.
under all loading conditions.

c) Dynamic parameters in the displays shall be updated in one-second interval.

d) The Loop Cycle time for open loop and close loop control

1. The cycle time for closed loop controls shall be of the order of 50 (Fifty) milli
seconds. Bidders are requested to note that response time mentioned
herein above is indicative.

23 
 
 If the response time is less, preference may be given by MSEB to the Bidder
if prices happens to be same

ii) Open loop control system cycle time shall be less than 200 ms. and for
protection it shall be 50 ms.

e) All analog inputs to CLCS shall be acquired and database updated within an
interval of 250 milli seconds. Data for Critical loops shall be acquired and
database updated at a much faster rate to suit the requirement of “d” above.

f) In order to realize optimum response from the system the Data Acquisition and
upation may be classified in to different scan rates depending upon the
functional requirements.

7.02.11 Hierarchy of Control System:

The control system shall be functionally structured in three main levels of
control hierarchy as follows-
a) Primary Level Control: Controls of primary elements like shut off
valves, control valves, dampers, vanes, motors and associated
interlocks.
b) Secondary Level Controls: Controls of function groups coordinating a
group of primary elements.
c) Tertiary Level Control: Coordination of several function groups
including all task of block controls.

7.02.12 Measurement Using Multiple Transmitters:

Multiple Transmitters and monitoring concepts shall be envisaged wherever
specified to ensure that failure of single transmitter does not lead to
maloperation or reduced availability of related control system.
I) Measurement using triple redundant transmitter
The control system shall select the median value for normal control
purpose. In the event of failure of one of the transmitters, the remaining two
transmitters shall automatically form two transmitters measurement

24 
 
 configuration and control system shall remain in Auto and receive average
value of the transmitters.

25 
 
 7.03.00 SYSTEM BASIC DESIGN, SYSTEM STRUCTURE AND BASIC
FEATURE / GENERAL REQUIREMENT
7.03.01 System Basic Design / System Structure:
The different modules indicated there in are only representatitive of
functions required to be performed. In practice the structure and the module
may vary from manufacturer to manufacture, and the same is acceptable to
the owner provided all the functions and features are fulfilled.
The Basic Subsystem of The DCS is as follows.
a) Process Station (Automation Station)
b) Operator Station (operation and Monitoring)
c) Programming, diagnostics, Engineering Station
d) Communication Network
e) Interface with other computer Stations
f) High Resolution Sequence of Event Monitoring System
g) Master Clock System

7.03.02 The analog / binary input / output modules, drive control modules for analog
control / open loop control. function group control module etc. shall form
part of the process station. The control system should not have more than
five or six different type of modules viz. analogue input / output module,
binary input / output module. Analog drive module / binary drive control
module, Analog / binary functional control module. Multipurpose input
module and multipurpose control module will also be acceptable, where the
input module shall accept all sorts of analog and binary inputs and the
control module shall perform all drive functions. group control functions and
process control function and the modules shall be programmed according
to the type of function. The system with reduced no of different types of
modules has the advantage of easy servicing, modification, and reduced
spare inventory.
7.03.02.01 Analog Input Module / Input Processor, Analog signal conditioning and
distribution:

26 
 
 Analog signal conditioning and distribution may be performed using distinct analog
input modules/processor and shall have the following features and functions: -

a) Measuring circuit for all analog signals (RTD, T/C, 4 – 20 mA, voltage signals,
etc.) shall be fully floating type w.r. to ground. Power supply to transmittes
shall be short circuit proof design or shall be separately fused.
b) Analog input modules/processor shall have features for signal filtering,
validation, error checking, reference correction for T/C, limit value monitoring,
correction computation etc. In case of wire break, or ground connection, the
signal is immediately flagged as invalid then the system operates with either
the last valid value or default value.
c) Indicating and recording instruments may be connected through analog
output modules. Alternatively, 4 – 20 MA signal if available directly from the
analog input modules itself may be used for indicators and recorders.
d) Galvanic isolation for input and output signals, if required, for inter facing with
the systems supplied by other vendors shall be provided.
7.03.02.02 Binary Input Module / Input Processor, Binary signal conditioning and
distribution:

Binary signal conditioning, processing and distribution may be performed using

distinct binary input modules/processor and shall have the following features &
functions: -

a) Binary inputs are monitored and conditioned in binary input module and also time
tagged wherever applicable.

b) The modules shall process different inputs such as volt free contacts, proximity
switches and logic signals.

c) The field contact inputs signals for control & protection shall be monitored in the
binary input modules for non-co-incidence, wire break, ground, short circuit, etc.
This feature however may not be mandatory for signal required exclusively for
monitoring purpose. After signal conditioning, all signals are set with their validity
status and acquisition time where required before being marshaled to the bus
system for further functional processing.

27 
 
7.03.02.03 Analog Output Module / Output Processor:

It shall have the following features

a) High insensibility against noise and other disturbances realized by

integrated circuits, A / D converters etc. It shall be immune to walkie –Talkie.

b) High insensibility against over voltages. It should be equipped with an

overload protection

c) All output modules should be short circuit proof

d) Test connection facility for each output in the module

e) Monitoring facility for output signal wire, short circuit, open circuit, ground
connection etc.

f) The module shall have redundancy capabilities

g) One Binary input / out put shall be provided for redundancy switch over.

h) Each analog output shall have separately configurable functions

- Current / voltage output

- Live / dead zero

-Rising / falling characteristics)

i) Cyclic function check shall be provided in the module.

7.03.02.04 Binary output module / Output Processor:

The Binary output module shall be provided with features as described for binary
input module in addition, following contact outputs shall be available wherever
required.

7.03.02.05 Drive control module for analog control:

The individual drive control module is responsible for positioning of final control
element in a closed loop control system. To ensure high reliability, all the

28 
 
 input/output signals associated with a single actuator positioning circuit are
combined in one unit. These include analog position feed back input, torque and
limit switches inputs where applicable, as well as command outputs to actuators
and input and output of hardwired auto/manual station.

The analog drive control module shall have the following features: -

a) Facility to communicate with bus system for transfer of input / output signals
for control & signalization.
b) Facility to accept wired analog as well as binary signals from transmitters,
position feed back devices limit switches, feed back contacts from switch
gears etc.
c) Facility to accept priority inputs for protection criteria of the controller drive.
d) Possibility to wire remote conventional auto/manual station directly to the
module to enable operation of the final control drive in the event of digital
control system failures.
e) All functions necessary for reliable operation such as tracking facility for
bump less transfer from automatic to manual and vice versa shall be
possible.
f) Provision shall be provided for configuration for out puts for continuous
position controller or pulse output.
g) Facility for continuous supervision of controller output signal and actuator
position signals for discrepancy monitoring.
h) Manual position facility provided locally from the card for testing purpose,
either through front mounted push buttons or by portable hand station. The
drive module shall have the features to ensure that, the final control
element shall remain in stay put position after tripping the control loop to
manual under the following conditions.
1) Transmitter failure
2) Controller output failure
3) As required by interlocking conditions/over riding commands.
i) The module shall have facility for storage of input output data with a re-
freshing time of 50 milliseconds or less to match with requirements
indicated under the heading “Response Time” above.

29 
 
7.03.02.06 Function Group Control Module:

Close loop control functions

Following control Algorithms shall be possible as a minimum in respective of mode

of control

i) P, PI, PID

ii) Square Root

iii) Addition / Subtraction

iv). Lienerisation

v) Multiply / Divide

vi) Ratio (Scale), Exponential, Logarithmic

vii) High / Low Signal Selectors

viii) Totalizes

ix) Manual Loading

x) Lead – lag compensation

xi) Feed forward controller

xii) Override

xiii) PI adaptive gain

xiv) Multivariable control

xv) Non-linear control algorithms

xvi) Biasing

xvii) Mean (Average)

xviii) Median Value Selection- Analog

xix) 2 out of 3 logics – Digital

30 
 
7.03.02.07 Open Loop Control Function:

The open loop control system shall perform the functions of sequential operation,
interlocks and protection of Boiler, Turbine and various unit auxiliaries, valves.
dampers etc. For sequence control and interlocking ,2 x 100 % redundant function
group controllers / processors shall be used.

It is intended to control the unit automatically through a number of sequence with

operator’s intervention for initiation of each sequence.

The sequence shall be executed as per the defined programme which typically
may be as under: -

The following modes of sequence control shall be envisaged:

i) Automatic Mode: In this mode sequence shall progress without involving

any action from the operator but all indications of completion of various
steps, etc. will be available on DISPLAY.
ii) Semi-Automatic mode: - In this mode step progress shall be displayed on
DISPLAY but the step execution shall be through manual intervention (from
key board) after ensuring that logic criteria have been fulfilled.
It shall also be possible to bypass some criteria by key operation and all
the bypassed criteria shall be reported in logs.

iii) Operator guide mode: - during operator guide mode no active command
for operation of final control elements is issued, but sequence will run its
course with check backs and criteria indication appropriately.

31 
 
 7.03.03 Operator Station, Operator Control, Plant Information

7.03.03.01 Operator Station:

Operator Station shall perform operator control function, plant monitoring and
display function, alarm functions, logging functions, performance calculations and
optimisation functions, historical data storage & retrieval functions.

Minimum 32 bit computers of adequate numbers along with all the computer
peripherals shall be envisaged for operator stations.
The Man Machine Interface System shall be of the latest state of art technology,
latest industry standard and of proven design.

Operator station shall have, in addition to its own computers, a set of

DISPLAY’s and associated key boards. These stations are interfaced to the
system bus/data high way and in addition, may be connected together
through a LAN. The task of the station is supervision and control of the unit.
Individual Electronics Concept for all MMI station is must

7.03.03.02 Operator Control:

All functions required for supervision & this station shall perform remote manual
control of the unit. The supervision & control functions shall be performed with the
help of standard pictures on DISPLAY, which shall include plant mimics. Issuance
of control command may be realized through function keyboard and through
mouse. Remote control using DISPLAY screen/Key board operation for all
remotely operated final control element has been envisaged.

The screen shall display a list of standard display areas on the top of the screen.
Selection of an area would then produce relevant mimic diagrams and associated
group control station in the screen. It should be possible to select the control
stations for any of the final control elements associated with this area arranged
systematically in the screen along with status indicators, analog value indicators
etc. It shall be possible to control many number of control loops and their
associated final control elements simultaneously, which are displayed on the
screen. It should also be possible to have separate detailed display of each group;

32 
 
 sub group and individual drive control modules. Each of these shall be arranged in
a hierarchical manner.

7.03.04 Master clock system:

A master clock system, capable of receiving time signal broadcasted by National

Physical Laboratory, processing it and then transmitting and synchronizing this
time with DCS systems: -Clock Module and SOE system clock Module shall be
provided.

7.03.05 Performance Calculations:

The system shall be able to perform online real e, performance calculations,
analyze boiler and turbine working conditions and identify actions for optimized
operations.

The performance calculations system shall include calculations of flows,

enthalpies, efficiencies, heat rates, deviations in heat rates, deviations in
efficiencies, saturations temperature etc. The performance calculations
shall be done using subroutine based calculations on latest ASME system
tables applicable to the particular plant cycle.

The prime objectives of the plant performance calculations is to provide the

plant operator, on a continuous basis with controllable losses in a tabular
form indicating deviations in a heat rate and efficiencies to the determine
the optimized operating conditions of the boiler and turbine.

It shall facilitate in brief the following functions.

I) Identify optimized operation for soot blowers and wall blowers.
II) Identify optimum combination of wind box tilt position and super
heater re-heater spray flows.

33 
 
 III) Identify optimum excess airflow in consideration of both combustion
requirement and superheat reheat temperatures.
IV) Allow operator to evaluate the effect of changing an operating
parameter on overall plant performance by way of providing “what If”
capability.
The performance calculations shall run on a nominal 10-minute period
except class 1 calculations which shall be performed at much faster rate.

34 
 
7.03.06 System Documentation

7.03.06.1 Scope of Supply

The Bidder shall furnish system and equipment instruction books and detailed
program design documentation. Books shall describe system operation, shall
include detailed system and components description and shall cover the
installation, operation, care and maintenance of all system components and
shall contain complete parts lists including detailed instructions for ordering.
All final system documentations as delivered to the owner shall be complete,
accurate and fully representative of the supplied system and its elements.
The copies of all documents except installation manual where five copies also
be furnished in source and object form as through back up tapes each.

7.03.06.02 Installation Manual

These books shall describe in general terms the systems operation and shall
provide all information necessary for handling, storing, unpacking, installing
initial powering and calibration of the system. Five copies of installation
manual shall be furnished.

7.03.06.03 System Operation Manual

This manual shall be control room operator oriented and shall contain an
overall system description, theory of operation, operating instructions and
detailed information on the use of the system. This manual shall also include
a description of all system / equipment failure indicators / enunciators and
what action the control room operator should follow when any one of them is
activated. The procedure on how to reset a “halted” processor shall also be
included in this manual.

7.03.06.04 Maintenance Documentation

The maintenance documentation packages shall include all information

required for the trouble shooting, repair and maintenance of the system. This
package shall include, but not be limited to the following:

7.03.06.05 System Maintenance Manual

This manual shall contain description of how the system and each of its
elements operates and shall include applicable schematics, diagrams and
equipment drawings. It shall include a comprehensive index of all other
documentation being furnished and the list shall include, as a minimum:

35 
 
 a) All manufacturer’s manuals for all commercial equipment furnished under
contract.

b) All major equipment drawings.

c) All major system drawings, including documentation on routing of all cables

and their identification.

d) All system interconnection diagrams.

e) All other manuals and system support documentation.

f) As built drawings.

All listings of drawings shall include a fully descriptive title of each drawing,
drawing number and its location.

7.03.06.06 Equipment Maintenance Manual

A maintenance manual shall be provided for each major piece of equipment.

These manuals shall describe equipment installation, operation, care and
maintenance, and shall contain complete parts list including detailed
instructions for ordering. At least the following drawings of the actual
equipment furnished shall be included:

a) Schematic diagrams for all elements of complete systems.

b) Schematic interconnection for each enclosure.

c) External connection diagrams

d) Parts layouts covering all components

e) Item designations corresponding to the parts list shall be shown on all

drawings.

Further, these manuals shall detail all calibration instructions and procedures,
wherever applicable. Sufficient documentation shall be provided to assure
efficient maintenance of all Bidders furnished hardware by owner’s personnel.
This documentation shall include point– to- point wiring diagrams and
schematic diagrams of all electronic assemblies, supplemented with concise
descriptions of theory of operation of individual subsystem.

36 
 
 The Bidder shall furnish documentation, which will assist the Owner’s
personnel in assuring a short mean-time-to-repair in the event of a failure.
This may be accomplished by documenting problem symptoms along with
possible repair solutions. The contractor shall recommend any special tools
or test equipment requirement.

Documentation shall be supplied to assist the Owner personnel in Software

development and maintenance. This documentation shall include
descriptions of all programming languages, editors, and utilities supported by
the system.

Programming documentation shall be included on two levels. One level will

be used for training personnel who have a programming background but are
unfamiliar with the particular language. The other level shall be used for
reference by personnel who are familiar with the language, but need concise
in-depth information for assistance.

7.03.06.07 System and Equipment Drawings

All drawings considered needed for effective maintenance of the equipment

shall be provided.

As a minimum the following drawings shall be included:

a) System logic diagrams

b) Schematic diagrams for all elements of the system

c) Parts layout covering all equipment’s

d) External connection diagrams

e) Wiring diagrams showing connections within each enclosure

f) Wiring diagrams showing interconnections between enclosures

g) All other electrical and mechanical drawings considered needed for system
maintenance

h) As built drawings

7.03.06.08 Software User’s Manual

This manual shall provide a detailed description of the system software, and
shall include all instructions required for the system programming, software
additions, software modifications and software maintenance and de-bugging.

37 
 
7.03.07 Programming and Engineering Work
Station:

i) Programming
The Central programming shall include all the function of programming /
configuration / modification / reconfiguration / documentation. / calculations
and graphic editing programming functions /diagnostics

ii) Engineering & Diagnostics

Engineering involves design, configure, monitor document or trouble

shoot and simulation the process activities as desired. by the
Engineer. This shall be used for designing and redefining control
strategy, configure system modules, modify the configuration, build
and implement computing logics, alarms and display functions, save
and retrieve system configuration schemes, monitor process
variable, tune or adjust process parameters, display and trend
information, produce system documents etc. The station shall be
able to produce generic logic control drawings, configuration
drawings etc.

Control Engineering Software system include text, computer aided design,

ladder diagrams, logging data base, graphic package etc.

Combined with a printer, with the help of work station it will generate logic
control drawings configuration drawings, module list, specification list,
function blocks for cross reference list.

It works on-line and off-line. While on-line, connected to process, the work
station provides real time tuning and trouble shooting. On off-line, the work
station allows control system configuration.

38 
 
 The workstation can be used to implement or redefine process control
strategy for control computing, logic, alarm, list display of process
functions. In addition, the station shall have elaborate facility for diagnostic
functions.

The diagnostic station shall assist in detection of system faults and

malfunctions and faults in field inputs along with identification of their
locations. It provides automatic display and recording of such disturbance
and thereby enhances the system availability. Sensors, binary switches,
transmitters, input/output processing modules, controllers, peripherals and
multipurpose bus communication system etc. are fully and
comprehensively monitored. For this purpose, all processors, modules etc.
shall have self-diagnostic features and disturbance shall be communicated
to central diagnostic station. All failures, anomalies and missing functions
shall be automatically detected and alarmed & displayed with clear text,
showing the exact origin and the kind of failures. The failure shall also be
signaled at concerned equipments. It shall ensure that the faults are
detected before any significant changes in any processor output have
taken place. Failure alarms of any I/O modules, processor, data etc shall
be suitably grouped and annunciated to operate work station and for central
outputs for conventional alarm shall be given.

Detailed information of disturbance message shall be displayed in

Engineer’s or diagnostic DISPLAY and printout. Typically, a diagnostic
DISPLAY shall have facility to windows for progressive detailing of
diagnostic information wherein a permanently displayed window for plant
diagnostics shows disturbance of the overall system level. By activating a
cursor/key a station diagnostic window is opened to show the details of
station with all installed equipments. The diagnostic data for a item of
equipment identified as disturbed can be called up for subsequent windows
and finally the last window can be opened to obtain information such as
type, location and possible causes of disturbance and suggestion for its
rectification. Any alternative method of diagnostic display is also
acceptable, which provides the detailed information during disturbance.

iii) Software for Programming Station

Software shall include computer aided design (CAD), ladder

diagram, logging data base, graphic package etc. A symbol library
with symbols representing plant item shall be provided. It shall also
be possible to store and reuse micro pictures consisting of

39 
 
 assembled symbols. Editing of mimic diagrams for process
monitoring shall be accomplished with the above symbols and micro
pictures without requiring special knowledge of computer
programming.
Software for information system shall fulfill all functional requirements. All
necessary algorithms and macros shall be included in firmware. Besides,
standard software, software for performance calculation and other special
task shall also be included.

iv) System Diagnostic Software

The system shall have extensive diagnostic software to identify all

failures upto card level as well as field inputs. This shall include
failure of power supplies, I/O cards peripherals controllers etc. The
alarms regarding major subsystems shall be displayed on the alarm
DISPLAY. Further, details shall be available on the Engineer’s/
Programmer’s DISPLAY in the form of a graphic and in other display
formats. The field-input faults/failures shall be reported with nature
and type of fault/failure clearly identified.

40 
 
7.03.08 Power Supply System

Each electronic cabinet shall be equipped with redundant power supply units, with
an automatic switching device for input lines, with changeover time less than 10
ms in order to guarantee hold capacity of feeders for modules and I/O signals.
Each power supply unit furnish power supply to the equipment located inside the
cabinet, via. Selector circuit mounted on DC output, made of block back-up diodes,
with the aim of preventing energy exchange between power sources. A continuous
monitoring apparatus watches over the voltage and alarm power supply failures.
DCS shall work on 24 V DC supply and computers & peripherals shall wok on
single phase AC supply from UPS.

Power supplies for DCS

a) AC Supply Requirement:

i) The system AC power source wherever required shall be nominal 110V,

50 Hz, single phase, ungrounded power supplied from un-interruptible
power supply system (UPS) of the Bidder.

This power supply system may be subject to a period of potential

interruption of one cycle on 50 Hz basis which shall not lead to control
system malfunction process upsets or danger to main equipment being
controlled by the system.

ii) The Bidder shall furnish all necessary equipment required to transform,
rectify and regulates this uninterruptible power supply for use by the DCS
as per his system requirement.

iii) The system shall be arranged so that no more than 30 amperes shall be
momentarily drawn through any single circuit from the UPS system. The
normal current demand through any single circuit from UPS system shall
not exceed 24 amperes. If necessary, multiple DC power supply units and
multiple input AC circuits shall be used to comply with this maximum
current per circuit limitation.

iv) All equipment requiring power from the system power source (UPS) shall
not impose any ground connections on it. If ground connections are
required by equipment design the contractor shall provide isolation

41 
 
 transformers to prevent transmission of these grounds to the system power
source.

v) Any required isolation of control system from building structure shall be

accomplished by equipment provided by the contractor and housed within
cabinets provided by the Contractor.

b) DC Power Supplies

+ 24 V DC Power Supply required for DCS system is in Bidders scope

of supply. Bidder shall supply complete +24 V DC supply system
(Specified in the Section: 4 of this specification).

i) Upon power supply failure to a part of the control system, the affected loop
and the related loops shall be tripped to manual and alarmed. All other
control systems shall remain in automatic. A power failure which results in
an inability to operate final drive elements manually from CCR shall
produce separate contract closure outputs which will be used in the plant
interlock system.

ii) Components of power supply system shall be of the highest available

quality for reliability and long service life. Capacitors shall be of Tantalum
type and semiconductor devices shall use Silicon instead of Germanium.
Protective fuse shall be of indicating cartridge type mounted in fuse holders
with provisions for fuse failure indication and alarm.

42 
 
7.03.09 System Grounding

i) The automatic control system shall be designed for grounding to the station
ground mat at a single connection point. Insulated ground bus from this
point shall be furnished to the control logic cabinets and shall be connected
to an insulated copper grounding strap in each cabinet. The control panel
and local instrument cabinets shall be grounded to the station ground mat.

ii) Shields on electronic cables shall be grounded as required. When shielding

terminations are required in cabinets furnished under this specification,
suitable terminals and supports shall be furnished.

iii) The control logic cabinets shall be equipped to accept the single point
system ground, which at this point will be isolated from the building ground.
Any internal component grounds or commons shall be connected at the
system ground, which shall be kept isolated from the building ground.

iv) Any required electrical ground or common from Components not mounted
in the control logic cabinets shall be brought to a terminal block connected
within the component. This terminal block connection shall be located with
the other terminals and shall be available from connection through the
shield of the field wiring to the system ground specified within the logic
cabinet. Isolation from building ground and case ground shall be inherent
in the component design.

7.03.10 Spare allocation:

A minimum of 30 percent spare terminals and a minimum space for 20
percent additional modules shall be provided in excess of the total
requirement of control system design when the cabinets are delivered.
The spares space capacity shall be distributed through the cabinets as
uniformly as is practical.

a) Interconnecting wiring shall be provided between all electrical

devices mounted in the cabinets and between the devices and
terminal blocks / sockets for plug-in connectors, if the devices are
to be connected to equipment outside the cabinets.

b) All alarm contacts located within cabinets as well as inputs / output

from other related system shall be suitably terminated in cabinets.

43 
 
 c) All wiring in cabinets shall pass the vertical flame test for IPCEA S-
19-81.

d) The Bidder may submit details of his standard wiring practice for
similar applications for consideration and approval of Owner.

xvii) Interlocks shall be provided to prevent upset of unit operation when cards
or chassis containing controlling elements or logic elements are withdrawn
from their mounting locations or when they are reinserted.

xviii) The input / output cabinets shall have sufficient wiring and mounting space
to accommodate additional input / output to the tune of 20%.

xix) Wiring space in the SOE cabinet shall be provided for connection of 20%
inputs in addition to those specified as SOE inputs.

xx) The marshalling cabinets shall have 30% spare terminals to accommodate
additional inputs.

xxi) The DDC MIS individually shall be provided with the capacity and capability
to handle either 25% additional modules for each type of modules or 25%
over and above the specified number of modules connected to the system
bus without any additional hardware or software requirements. These
additions shall not result in decrease in system response time (i.e. control
response time display response time, SOE resolutions etc.).

xxii) 10% spare interface relays shall be mounted in the interface relay cabinets.

44 
 
 7.03.11 DOCUMENTS TO BE SUBMITTED ALONG WITH THE OFFER

1. Complete Bill of Material and Schematic Drawing for DCS including all
necessary accessories as applicable.

2. Detailed description of each category of hardware item furnished.

3. Design specification sheet for all hardware items (e.g. controllers,

input/output card etc.) including data pertaining to heat load, power supply,
power requirement etc.

4. Detailed write-up and drawings describing close loop, open loop control
system, measurement system etc.

5. Complete software bill of material for displays, logs, bars, curves etc.

6. Complete details regarding performance calculations and optimisation

systems including hardware and software.

7. Complete details of SOE.

8. Complete details about Master Clock System.

9. Complete details on computers and peripherals employed in DCS.

10. Complete details on remote multiplexers.

11. Complete details on IBM PC. /AT computer.

12. Complete details on computer system interface.

13. Detailed information regarding power supply, power requirements, power

supply system cooling requirement.

45 
 
 7.03.12 DOCUMENTS TO BE SUBMITTED AFTER AWARD OF CONTRACT
(DURING DETAILED ENGINEERING)

1. Detailed Bill of Material, Schematic drawing, Computer software &

Hardware for various packages of DDC MIS and associated
accessories.

2. DCS components outline and mounting drawings showing dimensional

details.

3. Wiring diagrams of all control loops, logic and cabinets.

4. All terminal details required for describing completely the input/output

cabinet connections.

5. Detailed input/output list for DDCMIS and sequence of Event Recording.

6. Detailed input/output list for open loop Control system and Close Loop
Control System.

7. Instruction manuals covering mounting, calibration, commissioning, normal

operation, diagnostic feature, trouble shooting, maintenance for all items of
hardware furnished by the bidder for DDMIS system as a whole.

8. Instruction manual covering details of programming, control system

configuration/modification procedure, start-up/shut-down programmers,
self diagnostic programme, system debugging (as applicable0 for the
DDCMIS system.

9. Schematic diagram, functional flow diagram and signal flow diagram for all
open loop, close loop and measurement loops.

10. Detailed description and wiring diagram of each category of electronic,

hardware, processor, peripherals etc.

11. Design specification sheet for all electronic hardware, processors and
peripherals.

12. Write-up on close loop control system and sequence control system.

46 
 
 13. Terminal board drawings indicating inputs and outputs.

14. Field communicated wiring diagram applicable to input/output device.

These shall include field junction box wiring drawing and interconnection to
terminal board (termination cabinet) and system cabinets.

15. Complete details of control algorithms and functional block.

16. Data sheets for logs, trends, curves, bars, X-Y plots etc.

17. Complete data sheets and details of mimic diagram.

18. Complete data sheets on performance calculation.

19. Details of quality assurance plan for complete system and components.

20. System general arrangement, outline and mounting dimensions of all

electronic system logic cabinets and computer cabinets sharing installation
details and floor openings.

21. All the other hardware documentation required as clause No. 2.03.14 of
this specification.

   

47 
 
10. Project commissioning activity report:

10.1 List of activities carried during plant shutdown. Which was shut down for the period 14
days

a) DCS panel arrived at site two days before.

b) Physical Inspection of DCS panel done

c) BOM quantity ensured.

d) DCS panels shifted from stores to DCS control room

e) After Plant shutdown, non-critical existing panel modules & termination units removed and new
DCS modules panel installed and wiring done.

f) Logic loaded to processors and continuity test of new wiring connection ensured by forcing
I/O’s Input and outputs.

g) Same way all existing DCS panel removed and new DCS modules installed and logic loaded
into processors and functional checks done.

h) New HMI server and Clients installed at control room. Functional checks of Graphics data
updating ensured and Operator commands and feedback of Digital and analog signals ensured
and handed over to Operator.

g) All Drives protection checks completed and handed over to Operator for operation.

h) PID tuning of some critical loops done such as ID fan VFP, Air flow system and Super heater
control system

i) OLCS (Open Loop Control system) and CLCS (Closed loop control system) signals testing
done.

j) Alarms and Events of all signals ensured.

k) History data storage of all analog signals ensured.

l) SOE Reports (sequence of event), daily Logs, Hour logs reports ensured by triggering.

48 
 
m) Finally DCS Redundancy checks of Processors, Power Supply, I/O module & HMI servers
checked found OK

n) Total DCS system handed over to operation for light up.

o) Unit synchronization done and unit is running successfully with full load 130 MW.

49 
 
11. DCS R&M Project Conclusion report:

a) DCS system modules are latest in technology with high speed and I/O handling capacity
increased.

b) high Spare cost reduced to buy old absolute modules

c) No. of processor reduced due to increase in I/O handling capacity. Earlier 88 processor installed
now it has been reduced to 27 processor

d) User friendly system for configuration of graphics and logics

e) System working on latest Operating system flat form

f) Current consumption reduced to 5o % due to latest electronic components used and heat
dissipation is also low.

g) Support for the system by OEM extended for next 10 years. Service legal agreement done with
OEM M/s. ABB for next 10 years

h) DCS R&M given to OEM, which was easy for conversation of Logics and graphics
automatically, no manual interface is required. Which made us to commission the project within
given time.

50