3_Specific Job requirement in Package Boiler.pdf

7/18/2019 3_Specific Job requirement in Package Boiler.pdf

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SPECIFIC JOB REQUIREMENTFOR INSTRUMENTATION IN

PACKAGE BOILERTOYO ENGINEERING INDIA LTD.

ISSUED : 20.07.2009 JOB NO. : 6261 DOC NO. : 6261-KA-403

Rev 1 Sheet 1 of 18

C O N T E N T S

1. GENERAL

2. CONTROL SYSTEM SPECIFICATIONS

3. VENDOR LIST

4. SCOPE OF WORK

5. SCOPE OF SUPPLY






Rev 1 Sheet 2 of 18

1.0 GENERAL

1.1 Introduction

This document describes the Project Specific scope of work / supply to be carried outby Package vendor for Package Boiler plant for DHT/HGU/SRU Process facilities ofHPCL Visakha Refinery, at Vishakhapatanam (AP) - India.The package vendor’s scope includes Design, Engineering, procurement, supply,Fabrication, Inspection, Transportation, Storage, shop testing, site installation, site

supervision, commissioning & Documentation .

1.2 Definitions:

a) Owner : HPCLb) PMC \ EPCM : TEIL

1.3 This document identifies the specific job requirements / specifications pertaining to thescope of package vendor. This document shall be read in conjunction with the latestrevision of Package specification no. 6261-KA-102, MMS specification 6261-KA-303,UPS specification no. 6261-N-137 (attached under electrical section of theEnquiry) ,Interface Block diagram IST-403, standards / documents / drawings andother documents attached else where in the bid document. The requirements, whichhave not been specifically identified in Scope of Work & Scope of Supply but requiredfor completion of package or referred elsewhere in these documents, are in packagevendor’s scope.

1.4 In the event of any conflict between this document and any other document attachedto package enquiry , the package vendor shall follow the following documents in orderof their priority.

a) Statutory requirements and codes & standards.b) Specific Job requirement for instrumentation in Package Boiler.(This Document)c) Engineering Specification for control and instrumentation in package units( 6261-KA-102)

In case of contradiction among documents, package vendor shall refer to EPCM(Toyo) for clarification. However most stringent specification / latest proventechnology / owner’s specific requirements shall be followed with EPCM / Owner’sapproval . Owner’s / EPCM decision shall be considered as final.

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Rev 1 Sheet 3 of 18

1.5 Package Boiler A & B shall be controlled from a remote control room(MOI CR). APackage vendor to provide ‘BMS PLC’ (as per details below) for Burner managementand “Yokogawa CS3000” DCS for Boiler & balance of plant. The BMS PLC & CS 3000DCS (Cabinets) shall be installed in Boiler Rack Room(BRR) located near the BoilerArea (as indicated in Plot Plan). A common UPS for Package Boilers shall be providedby package vendor & same shall be installed in BRR. Also an Engineering station withSOE for Burner management shall be provided & installed in BRR. The Operatingwork stations ( OWS ) and the Auxiliary Console with Annunciator shall be installed in‘MOI control room ‘located remotely from BRR. The SWAS and Stack Analyzercabinet / container with AC Unit shall be installed in field.The ‘Interface cabinets’ for interfacing MCC signals shall be installed in Substation. All

required construction material i.e signal & power cables, cable glands , cable duct /tray, cable duct / tray supports, junction boxes, Instrument air manifolds / header etc.for Boiler & for all equipments supplied along with Boiler to BRR Substation, betweenBRR & substation, between DM Plant-II CR to BRR & between BRR to MOI CR shallbe in package vendors scope. The MCT blocks, MCT Frames, GI cable tray insideBoiler Rack Room, inside substation(MCC), inside MOI control room. UPS forYokogawa CS3000 DCS , BMS PLC, MMS & Instruments in package vendors batterylimit shall be supplied by Package vendor. All necessary interconnecting power,signal, system cabling inside Boiler rack room between package vendor suppliedYokogawa CS3000 Control System, BMS PLC & MMS cabinets & from/to operatorwork station(s) & Engineering station shall be in package vendors scope of design,supply, installation.Refer Boiler Plot Plan attached in the Tender for location of mentioned Controlroom/Rack Room & substation.

1.6 Henceforth for this specification, unless otherwise mentioned:

‘DCS’ shall mean the Yokogawa CS 3000 system

‘PLC’ shall mean BMS PLC

Vendor shall mean Package vendor.

1.7 A common dedicated PLC for ‘ Burner Management System ‘ (BMS) to beprovided .And a common DCS ‘for Boiler & balance of plant items shall beprovided .The’ PLC shall be ‘TMR ( TRIPLE MODULAR REDUDANT) OR alternativelyQMR , with TUV AK5 ,SIL3 certification. The PLC shall have redundant processors ,redundant power supply, redundant Input/Output cards & redundant communicationcards. The total scan time of PLC shall not be more than 300msec. The DCS shall bedesigned as per clause no. 2.0 as a minimum. All the signals from PLC shall beavailable in DCS on serial link. All the machine & motor vibration & temperaturesignals shall be wired to MMS. If vendor is supplying multiple MMS racks ,then allRacks shall be supplied as fully interconnected & ready for connecting to DCS through

serial link. Common Alarm/Trip signals shall be hardwired from MMS to DCS/PLC. Allthe signals from MMS shall be available in DCS on serial link. All the signals fromAnalyzer control cabin / container shall be available in DCS on serial link.






Rev 1 Sheet 4 of 18

The DCS, PLC & MMS cabinet shall be in vendors scope of design, supply &installation and commissioning . DCS , PLC & MMS rack shall be installed in separatecabinets. All interconnecting cables & cabling between all the vendor suppliedcabinets shall be in the vendor scope of design, supply ,installation & commissioning.The DCS as well as PLC & MMS chassis / rack shall be separate for each Boiler.Grouping of signals from two Boilers in the same chassis is not acceptable. (E.g Ifthere are three chassis for Boiler A then Boiler B shall have identical three chassis.)

A common Engineering PC for PLC (server grade) of latest configuration with SOE &color printer shall be provided & installed in BRR and one Operator work station PCfor each Boiler (total 2 nos) with one Aux. console . MOI control room as a minimum.

Additional requirement of OWS and Aux. Consoles shall be decided by vendor &brought to EPCM’s /Owner’s notice.

1.8 Loop philosophy

1.8.1 Sensor / transmitter for shutdown purpose shall be separate from that of control.Two out of three (2oo3) voting shall be considered for critical signals (i.e shutdown).

1.8.2 The shutdown valve needs to be separate from control valve. If Manual Reset onSolenoid valve is required then vendor to provide separate field station forthe same.

1.9 MCC Interface.

1.9.1 MCC shall also be in the vendor’s scope of supply, for more details refer electricalsection of this enquiry.

1.9.2 Start/Stop for all drives with RUN indication & Auto / Manual switch shall be providedon LCP.

1.9.3 All MCC related cables (status & commands) shall be wired to interface cabinet . The

interface cabinet shall be provided by vendor & shall be installed in Substation(MCCRoom).

1.9.4 Vendor to provide “Motor RUN indication” & “Motor Trip Alarm indication” for alldrives(HT & LT). Two separate contacts shall be provided for each drive. One set ofcontact will be wired to purchasers DCS / ESD by others & another set of contact shallbe wired to Vendor DCS & any signals required for Interlock purpose shall be wireddirectly to PLC by vendor. If these status indications are also required on LCP thenvendor to multiply the contacts in the DCS/PLC cabinet.

1.9.5 Following Relay contact rating shall be followed,

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Rev 1 Sheet 5 of 18

1) All status indications shall be hardwired for all LT & HT drives. The Pot free contact

shall be provided in MCC. The 24V DC contact voltage shall be provided fromDCS/PLC.

2) Commands to MCC- LT Drives (below 55 KW) :All commands to MCC shall be hardwired. The pot free contact shall be provided fromDCS/PLC. The relay contact shall be suitable for 240 V AC.

3) Commands to MCC- For Drives(above 55 KW):All commands to MCC shall be hardwired. The pot free contact shall be provided fromDCS/PLC. The relay contact shall be suitable for 110V DC.

1.9.6 Vendor to study the Interface Block Diagram – Package Boiler ‘IST-403’ attached withthe specification and provide full compliance to the same.

1.9.7 Relay based logic in any of the package vendor supplied control panels shall not beacceptable.

1.9.8 Along with technical offer, Vendor shall provide the total quantity of cabinets withdimensions for following.a) DCS ; b) PLC ; c) UPS ; d) Battery Rack

2.0 Control System Specifications

2.1 General :

The Boiler & balance of plant Distributed Control System (DCS) shall be designed forreliable, effective and optimum control and monitoring of a process plant. The DCSsystem shall be minimum “fault tolerant”. The DCS, by employing distributedintelligence and database techniques, shall provide highly secure, safe, reliable,maintainable, effective process/ safety monitoring and control of the production/ancillary facilities from existing MOI Control Room .

This section defines the minimum requirements of system design including hardware& software, configuration, manufacture, engineering, programming, of Distributedcontrol system (DCS). The scope shall include as a minimum- Manufacture, procurement , supply, testing, installation, handling and

commissioning of all equipment, System Cables and accessories.- Building of all operator interface, screen displays, database and reports.- System Hardware & Software configuration.- FAT of all hardware / software and system integration testing under simulatedconditions.

- Supply, install, test and commission marshalling racks, system cabinets andconsoles /printers. Including cables, terminals, IS barriers, power supplies and

cubicle internal mountings.- Supply of all system as well as control room furniture and Buyer requirements.- Proving of DCS system functionality as per requirements.

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Rev 1 Sheet 6 of 18

- Training of Buyer’s personnel at factory and at site on functional, operational and

maintenance aspects of the system.- Supply of complete technical and as built documentation in electronic form as wellas hardcopy.

- Supply of all software on CDs along with required software licenses.- Preparation (with Contractor’s inputs) of a FDS (Functional Design Specification)

2.2 Design & Construction

This system shall be designed ‘fault avoidant’ as a minimum by selecting high gradecomponents of proven quality and proper design of system electronics. Redundancyshall be provided, as a minimum, as specified below, to improve the system

availability and reliability. Due considerations shall be given to the environmentalconditions also.The system shall be able to operate satisfactorily in the climatic conditions asspecified in tender. Wherever required, the components shall be tropicalised to suitsite conditions.The system shall be of modular construction and expandable in future by addingmodules. The type of modules shall be kept to the minimum possible in order to haveinterchangeability and low inventory.The system software shall be governed by the operating system running in a real timemode and shall be able to meet all specified functional requirements as a minimum.Any other standard / special software package, if available shall also be offereddescribing the full capabilities.All system software including operating system software, network software and anyother proprietary software supplied shall be with suitable number of Licenses.On-line replacement of any module shall be possible in such a way that removal andaddition of a module shall be possible without de-energising the system. Furthermore,there should not be any interruption of the system while replacing a faulty modulewherever redundant modules are provided.The system shall be upward compatible i.e. new enhancements can be incorporatedin the system for future up gradationThe complete monitoring & control of Package Boiler shall be from MOI Control Room

(However, the I/O Subsystem shall be segregated Boiler wise i.e. separate I/O cardswith separate chassis shall be considered for each Boiler. Mixing of I / O counts insame card or same chassis shall not be acceptable. The same shall be located inremote Rack Room termed as BRR further .(i.e Boiler Rack Room).Throughout Boiler-wise segregation shall be followed for the Controller Sub-system,I/O sub-system, Relay ,Barrier & Marshalling Cabinets etc.The MOI Control Room shall house the vendor supplied Workstations, printer and Auxconsoles. The control system cabinets containing the field I/O cards, controllers,gateways and all equipment shall be installed by vendor in BRR .Communicationbetween BRR & MOI CR shall be through existing redundant data highway . Theexisting data highway cable is already available from existing Yokogawa CS 3000

system cabinets in DM -II CR. (refer to the plot plan attached with tender where DM- IICR & MOI control Room locations are indicated).






Rev 1 Sheet 7 of 18

All equipment shall be placed in HVAC (Heating, Ventilation and Air Conditioning)

controlled rooms.The redundancy requirement for various system components shall be as follows:

Controller system 1 : 1 redundantInput / output systemFor closed loops and critical I/Os 1 : 1 redundantFor open loops and non critical I/Os Non-redundant

Communication system 1:1 redundantPower supply 1:1 redundant

2.3 Spares :

Systems shall be designed with 15% installed pre-wired spares with all requiredhardware such as relays, barriers, terminals etc. In addition, 15% spare space shall beavailable throughout the system for allowing future expansion including systemcabinets, Marshalling cabinets.Communication networks & controllers shall not be loaded more than 60% as aminimum. Wherever possible, all equipment shall be standardized to ensurecommonality of spares, minimal training and greater economies as far asmaintenance and additional procurement is concerned

Mandatory spare module of 10% or one module of each type, whichever is highermust be supplied for each type of modules being used including in consoles. This shallinclude spare modules for hardwired instruments, relays, barriers, assignablerecorders, personal computers, programmable logic controllers etc.

2.4 System Component / Instrument Enclosures

All the equipment covered in this specification shall be located in general purposenon hazardous area, in control room/rack room. All control room/rack room mountedequipment shall be weather proof to IP-43.Hazardous protection philosophy of field instruments is generally by EExiainstruments for which intrinsic safe barriers shall be considered .Explosion proof

(EExd) instruments suitable to area class may be used in case ‘IS ‘instrument is notavailable with EPCM/Owner’s approval.

The Main UPS (redundant) is under Package vendor scope of supply. PackageVendor to decide the UPS capacity as per the plant load .As UPS is in the Package Vendor scope, power distribution for complete system alsoshall be in the scope of Package vendor. Each consumer shall be provided with aseparate MCB of proper rating for isolation and protection of the system. On event ofany of the following conditions , system shall go to fail-safe mode:Power FailureFrequency Variation

2.5 Heat load calculations

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Rev 1 Sheet 8 of 18

The control system vendor shall provide Heat load calculations for the total system ,

considering the installed spares as well as components which would be installed inspace reserved for future expansion.As the BRR i.e Boiler rack room is in scope of vendor , Package vendor to considerThe load of the system ,marshalling cabinets, UPS & any other accessories requiredto be installed in BRR for sizing the HVAC.

2.6 System Furniture

All system furniture required for mounting and operation of the system includingmounting of table top equipments shall be supplied.The system shall consist of the following major sub-systems :

a. I/O systemb. Processor systemc. Communication systemd. Operator interface systeme. Foreign device interface (if any)f. Hardwired instrumentation

2.7 Functional requirements

The system as a minimum, shall meet the following requirements :a. Controlb. Data acquisition and monitoringc. Alarmingd. Logging and report generatione. Historical data storagef. Trendingg. System shall have free memory space available for the user, and CPU shall haveadditional capability to perform advanced control functions, process optimizationPrograms or generate management reports.h. Communication with third party and/or higher level automation systems via theOpen Control Systems Network.

The DCS operator interface shall be the primary integrated window for operation ofthe control and safeguarding systems and shall provide access to:i. Process control. j. Sequence control status.k. Equipment status.l. Alarm overview.m. Trip status overview.n. Override status.o. Real time trending.p. Historical data trending.q. Fire and gas detection status.

r. Machine Monitoring.

2.8 Processor system

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Rev 1 Sheet 9 of 18

The control function of the system shall be executed by microprocessor basedmulti-loop controller consisting of I/O ports and a set of algorithms which are easilyconfigurable. This system shall be capable of executing following control functionsand set of algorithms as a minimum :a. General : Monitoring and alarmsb. Control : P, PI, PID, adaptive gain, ratio, cascade, feed forward, etcc. Arithmetic : Addition, subtraction, multiplication, division, averaging, square root,ramp,rate of rise / fall, etc.d. Linearization :Flow pressure / temperature compensation, linearization,polynominal etc.e. Dynamic : Lead / Lag, dead time, timer, etc.

f. Modes : Auto , Manual , Cascade or Computer.g. Limiter : Low Limiter, High Limiter, set point.h. Comparator : Less than, greater than etc.i. Selector : Low, High, etc. j. Logic : AND, OR, NOR, NOT, XOR, Start / Stop, etc.k. Miscellaneous :Bumpless transfers, direct / reverse output , Anti-reset windup , slowfast ramping of setpoint & output etc.The processor scan time shall be 1 second, with ability to select faster scan times upto250 msec.The controller shall be able to operate in either manual, auto, cascade or computermode. Mode change-over in either direction shall be bumpless. It shall be possible tochange set-point, tuning ,constant, operating mode, control loop configuration fromthe central level i.e. operator’s interface keyboard and engineer’s interface keyboard.In computer mode, controller shall be able to track computer generated set point andshall hold the last generated value in case of computer failure. In such case, controllershall fall back on auto mode and continue to operate at the last received set point, ingeneral. Other options like predefined set point operation and fail safe condition shallalso be possible. On the resumption of computer set point again, the controller shallnot return to the computer mode automatically,Any addition/deletion of tag number should be possible without booting of the systemor plant shutdown.

Any changes in any portion of the database during running of the plant should bepossible.Downloading of the changed software to the respective sub system should bepossible in running condition of the plant. Saving, updating and taking back up of thedatabase with respect to the latest changes made should be automatic and withoutaffecting the plant running.The size of the memory shall be sufficient for storage of the program instructionrequired by the control schemes. Control system vendor Offer shall indicate theamount of memory occupied by the actual program and spare capacity available forlater program modifications or additions. A minimum of 40% spare memory spaceshall be provided at the time of handing over of the system to Owner.

Memory shall be non-volatile. However, in case volatile memory is provided, batterybackup shall be provided for a minimum of one year to keep the stored program intact.A battery drain indication shall be provided at least one week before the battery gets

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Rev 1 Sheet 10 of 18

drained. A potential free contact shall be provided for hardwired annunciation in the

control room. Watchdog timer shall be a software device. The healthiness ofprocessors shall be continuously monitored by watchdog timer. Any hardware orsoftware problem in the processor system including CPU, memory, power supply,communication interface etc shall cause the watchdog timer to reportprocessor failure.In case Multiprocessor configuration is offered, the processors must be able tocommunicate with each other over the interconnecting data link.Loop integrity shall be maintained in processor system architecture by providing oneto one processor back-up. In case failure is detected in the active processor all theloops of the failed processor shall be transferred to the back-up processor. Theprocessor system shall have automatic control transfer switching (HOT Standby).

Design must ensure that data integrity is maintained during switch over and no portionof data to be transferred is corrupted before and during switch over to the back-upprocessor. The indication of the failed processor shall be displayed on the operatorstation.Loop integrity shall also be applicable to I/O system, power supply modules and anyother device associated with the processor system.While downloading any changes, made to a particular tag, from engineer interfacesystem to the processor system the controller output shall be maintained at its lastvalue and should not be driven to zero value even momentarily or even fail safe value.

2.9 I/O System

The I/O system shall be capable of accepting process signals from various processsensors preferably without requiring external or auxiliary signal conditioning devices.The system inputs shall include 4-20 mA DC, and discreteinputs, Pulse/frequency as a minimum. It shall be capable of processing linear andnon-linear analog inputs, providing square root extraction for flow signals,linearization. The system shall be able to generate 4-20 mA DC current signals foranalog outputs and potential free contacts for the discrete outputs as a minimum apartfrom others as specified elsewhere.

No. of inputs per Inputs/output (I/O) module shall be as followsa. Analog I/O Modules : 16 channelsb. Discrete I/O Modules : 32 channels

Essential and continuous control commands and statuses to the MCC shall behardwired and be routed via Interposing Relay Cabinets.Contact voltage of 24 V DC & 110 V DC shall be followed as per details provided inclause no. 1.9.5 of this document.Each I/O shall be galvanically isolated from external control circuit by suitable means.Each I/O shall be protected against the reversal of polarity of the signal. Reversal ofpolarity on I/O termination shall be indicated in DCS.

Each digital I/O module shall have a LED per channel to indicate the status of eachInput / output.

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All the inputs shall preferably be double ended i.e. two wires per input and not with

common return for all inputs.Each output shall be short-circuit proof and protected by fuse. Visual indication of fusedown must be provided for each output.

All 4-20 mA inputs shall be capable of being software configurable on an individualchannel basis to provide energizing power for a 2-wire transmitter or to receivepowered signal from an external device such as 4-wire transmitter. The 2-wire optionshall be capable of driving the transmitters plus an additional load of 600 ohms suchas that imposed by a local indicator.4-20 mA signals from Analyzers shall be hardwired to DCS. Analyser alarms, Analyserhouse door switch alarm etc. shall also be available via serial link to DCS.

2.10 Cabinets

Following cabinets shall be required in general:

a. Power distribution cabinets (for AC distribution and DC distribution).b. Processor system cabinets PLC & DCSc. Interface cabinet ( for MCC interface & powered digital outputs)d. Marshalling cabinets (DCS / PLC)

The signals shall be segregated in Marshalling cabinets as indicated below :a. IS Analog 4-20 mA cables (through safety barriers)b. Non-IS Analog 4-20 mA cables (if any)c. IS Digital contact / alarm signals (through safety barriers)d. Non-IS Digital contact / alarm signals) (if any)e. Power cablesf. System communication cablesg. MCC interface signals (Further separate terminal block shall be provided for

commands & feedbacks)(DCS & PLC marshalling cabinets shall be separate).

2.11 Earthing

A system earth & dirty Earth Pits shall be provided by others near the BRR. Vendor toprovide the common Earth Bus bar in BRR (separate for Signal & Body earth). Thesupply & laying of Earthing cable from system / marshalling cabinets to Bus Bar &from Bus Bar to Earth Pits is under vendor scope.For OWS in MOI vendor to connect the earthing cable in existing earthing pitsavailable near MOI CR.

2.12 Functional testing

This shall include the simulation of each input and output to verify proper systemresponse.

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Testing as a minimum shall include :-

a. Complete system configuration loadingb. Demonstration of all DCS/PLC system functions.c. graphics and other views, report generation etc.d. 100% checking of logic’s configured in the PLC by connecting switch/ lamp at

input / output.e. Checking of all DCS console displays, keyboard operation, printer/hard copier

function etc.f. System redundancy check including correct change over of the backup unit in

case of failure of main unit.g. System diagnostic checking for all subsystems on local level as well as on

console including checking of the testing software for I/O modules signal

conditioning modules, when specified.h. Checking of output status on processor failure.i. Checking of first-out alarm generation. j. Simulation of power failure and system restart auto boot-up of system configuration

and program after power restoration

3.0 VENDOR LIST

All instruments and instrumentation items shall be procured from project approved

vendors given in a list for this purpose. In case, few of the items are to be suppliedfrom a vendor other than mentioned in the list, then package vendor to indicate thesame as a deviation.

4.0 SCOPE OF WORK

• Design, engineering, sizing & selection(type & material) ,installation &commissioning etc. of all instrumentation including signal ,power & system cable(including motor operated valve), cable glands , cable tray(FRP/GRP), cable traysupports, cable duct(FRP/GRP) , junction boxes, instrument air header

/manifolds, Steam & water analysis system(SWAS), Local control panels, FlueGas Analyzers ( STACK ), MCT blocks and MCT Frames, GI cable tray insideBRR, inside Substation/MCC room and inside MOI control room. DCS for Boiler& balance of plant, PLC, MMS ,UPS ,UPS PDB,OWS, AUX. Console & Boilerpackage Instruments and all necessary cables as per job specification.

• The Graphics for full package (including BMS) shall be developed by vendor.Same shall be provided for EPCM/Owner approval.

• Design, engineering, sizing, selection (type &material) ,installation &commissioning of all field instruments for Deaerator, BFW Pumps, Dosingsystem

• All dosing calculations shall be executed by vendor in DCS.

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• The FD Fan turbine shall be driven by Governor(Woodward make) mounted in

BRR cabinet. And shall be integrated with DCS.• Vendor shall supply Local gauge board ,which shall include Turbine start / stop &

feedbacks as indicated in Interface Block diagram attached with enquiry.

• Laying of all signal , power ,control system cables as per job specification.

• ll instrument cables shall be laid over the ground.

• Laying of earthing cables from system panels to earth pits outside Rack

room/control room.

• Laying of earthing cables from field to earth pits.

• Lay a redundant DCS link between BRR and existing Yokogawa DCS in DM Plant-II

control room . Install the OWS & Aux console in existing MOI CR, and integrate &commission it with the existing DCS network between MOI CR & DM Plant-II CR. All

necessary hardware/cabling required for integrating the vendor supplied control system

with existing System in DM Plant-II CR & MOI control room shall be installed by vendor.

• All critical signals/shutdown shall be executed in vendor PLC only.

• DELETED

• Site Installation, site supervision, calibration / testing, & commissioning ofpackage.

• Provide with a Boiler Control philosophy indicating the below requirements as aminimum.a. Start permissive conditions which are outside vendor’s battery limit but

required to be wired to DCS,& PLC to be identified by vendor & brought toEPCM’s notice.

b. Instruments which are outside vendor’s battery limit but required tobe wired to DCS & PLC to be identified by vendor & brought toEPCM’s notice.

c. DELETEDd. DELETED

• Vendor to provide the requisite data for

a. Hardwired & Softwired Interface of DCS & PLC with Plant DCS/ESD in theformats attached.(Refer Attachment-1).

b. DELETEDc. DELETEDVendor to provide the required information by filling in the details in the abovelisted formats after award of contract.

• Design the UPS for Package Boiler plant as per UPS specification attached withEnquiry.

• UPS shall be designed with 25% spare capacity.

• Design the power distribution system for control system , all Instruments &panels supplied by vendor.

• Vendor to prepare & submit all drawings and documents listed in documentschedule ( Attachment-11) attached with enquiry.

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• Vendor to provide the DCS graphics in[ (*.gif) or (*.bmp) or (*.jpg) ] format to be

further loaded by others on purchaser’s DCS operating system.• Vendor shall prepare and submit the as built drawings/ documents post commissioning

• Any other activity not specifically listed in this document but required as part ofcommissioning of the Package unit Instrumentation is also in vendor’s scope.

• Inspection & testinga) Field Instruments as per doc no.6261-KA-102 attached with tender.b) Integrated Factory acceptance test (FAT) for vendor DCS ,PLC & MMS shall be

carried out by package vendor at vendors works. EPCM & Owner to witness thesame if required. All data inside vendors battery limit shall be simulated & tested

on HMI during FAT.

5.0 SCOPE OF SUPPLY

• All types of instruments including field transmitters and pressure / temperature /

level gauges, thermowells, thermocouples with transmitters, RTD’s (To be

supplied with transmitter if not wired to MMS), orifice assemblies, On-off /

shutdown valves with all accessories, control valves with accessories, safety

relief valves, servo gauges( if required ), level / flow / pressure transmitters,

mass flow meters, SWAS, Flue Gas Analyzer and any other special instruments

etc. as required for the package as per job specification.

• Vendor shall supply Coriolis mass flow meters on Fuel oil supply and return lines with flow

meter cum totaliser for fuel oil and fuel gas. Vendor shall supply Turbine flow meters for

fuel .Gas The Mass flow meter accuracy shall be ± 0.2 %FS minimum. The mass flow

meter must have the capability to periodically check the validation of the last calibration

through software without dismantling the meter. Coriolis Mass Flow Meters shall be

calibrated at NABL Accredited Lab like FCRI, Palakkad in India and the calibration of

Mass Flow Meters shall be certified by Third Party Agencies like EIL/Lloyds/BV. However

imported make Coriolis Mass Flow Meters shall be calibrated at the respective foreignvendor’s works, duly accredited by the respective country’s well known Accreditation

Authority like PTB, SGS etc and the same shall be certified by well known third party

agencies like SGS, LRIS, DNV etc.

• All pressure tappings shall be provided with a root isolation valve.

• All types of field instruments for Deaerator ,BFW pumps and Dosing System .

• Flow transmitters shall be provided for the air from the FD and ID fans. Straight

duct length for installation of flow transmitter shall be as per good

engineering practice.

•

Deaerator with level control valve, pressure control valve, HV on steam line,online oxygen analyzer at outlet of Deaerator.

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• UV/IR type flame scanners shall be considered for scanning of flames on continuous

basis. Withdrawal type Ionisation Rod flame detectors can be used for detection of pilotflames during start up of burners and same is to be withdrawn once the main burner

flame is established. Separate scanner to be provided for ignitor gun and main burner.

Minimum two numbers of scanners shall be provided for each main burner with 2 of 2

voting.

• For high-pressure steam drum application conductive type (“Hydra step” bicolour

type) level instrument shall be provided.

• For all the control/shut down valves in steam / BFW application body metallurgy of the

valves shall be WCC or equivalent and trim to be properly stellited. All shutdown valves

shall have Leakage class VI. • Block and bypass valve ( TSO ) to be provided for turbine meters ,vortex meters, PD

meters and mass flow meters.

• UPS with half hour battery backup shall be provided.

• All accessories & necessary hardware for power distribution

• DCS & PLC with barriers ,relays & all necessary hardware mounted in vendors

control panel. PLC shall be used for all the interlock requirements for package

• Governor(Woodward make) for Turbine driven pumps

• Engineering station & colour printer

• Operator Work Stations (OWS) and AUX console in MOI control room• Furniture for mounting Engineering PC & OWS in respective MOI control room /

Rack Room (with chairs).

• Machine monitoring system(MMS) -BN 3500 excluding System 1 ®

supply.

• Control System– The PLC , DCS & Governor shall reside inside BRR. All the

Local Panel Signals shall be hardwired to BRR. Data from MMS rack shall be

available in DCS via serial link. MMS alarms & trips shall be hardwired to

vendor’s DCS or PLC(as required) . DCS shall have redundant communication

to plant DCS. The DCS shall communicate to plant DCS through redundant

serial Link(RS 485)

• Vendor to provide two Separate earthing bus bars( one for Instrument Earth(i.e

signal earth ) & another for dirty earth (body/chasis) ) inside each control panel

and system cabinet.

• Vendor to provide two Separate earthing bus bars( one for Instrument Earth(i.e.

signal earth ) & another for dirty earth (body/chasis) inside BRR

• Vendor to provide suitable earthing bus bars in field area. For details, refer

electrical section of the Enquiry

• Vendor shall design ,supply & install the earthing cables suitably considering the

control system vendors requirement

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• For serial link to plant DCS the package vendor shall consider necessary Fiber

optic hardware in PLC cabinet for Fiber optic link ,i.e Interface unit, patch cords

,media convertor, etc as an option. The Fiber optic cable from BRR to plant DCS

shall be supplied by others

• Local control Panels (LCP), switches, lamps & other accessories.(With

Intrinsically safe Annunciator )

a. Soot Blower control panels

b. Local Start-up panels

1) The Local control panels shall be weather proof certified to ‘IP 65’. And shall

be purged type .Pressurisation shall be type X (as per NFPA 496 ). And all

internal accessories including switches and indication lamps shall be flame proof

type.

2) LCP terminal blocks shall be supplied with Partition plates for higher electrical

voltages other than 24VDC.

3)Each incoming feeder shall be provided with appropriately sized 2 Pole circuit

breaker.

4) LCP shall be provided with removable gland plate, suitable for accommodating

all the cables.

5) The panel interior shall be designed as such keeping the power & other signals

cables away from each other, preferably on the extreme ends of the panel.

6) DELETED.

• Local Control Panel shall have Canopy/ Shed Provision at the top for

Monsoon/Sun Protection and also lighting arrangement outside the Local Control

Panel shall be provided at the top of the Panel in addition to the Lighting

arrangement inside the Local Control Panel.

• Automatic sequential soot blowing shall be provided through a PLC and MCC

along with a local start-stop push button for each soot blower.

• Local Gauge Board(s) alongwith the required tubing & fittings shall be in

vendors scope of design ,supply , installation & commissioning

• Auto start for all BFW Pumps & remote start / stop shall also be provided from DCS

• Flue Gas Analyzer for Stack ,with necessary sampling handling & conditioning system

(Flue Gas to be analysed for CO, O2 , SPM(suspended particulate matter), NOx & SOx

)shall be supplied by vendor

• Flue Gas analyzer (STACK ) and SWAS shall be located in control cabinet / container

with AC Unit. The SWAS panel shall consist of the following analysers as minimum:

AnalysersService pH Conductivity

Boiler Feed Water x x

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Boiler Water x x

Main Steam (S/H Out) - x

• In addition to the above, bidder shall provide analyzers for Dissolved oxygen,Silica and sodium / ammonia

• DELETED

• Hot extraction type stack analysers are preferable over the dilution one,However selection of Hot Extraction or Dilution type shall be decided as per theprocess data / conditions

• All installation and erection materials such as impulse piping, pipe fittings andvalves, tubing, cable tray and tray support including fire protection ( withinpackage vendor battery limit ) requirement, all types of consumables andaccessories for mounting all instruments and instrument supports / accessibleplatforms.

• All type of signal cables such as signal / alarm, control, thermocouple extension.From field to BRR, BRR to Substation, BRR to DM Plant-II CR,DM Plant-II CRto MOI CR(if any) & MOI CR to BRR

• All interconnecting hardware for DCS /PLC shall be supplied by vendor

• All types of system cables and communication cables including redundant DCSlink between BRR and existing Yokogawa DCS in DM Plant-II control room .Cabling for the supplied OWS & Aux console in existing MOI CR for integratingwith the existing DCS network between MOI CR & DM Plant-II CR. All necessary

system cabling for integrating the vendor supplied control system with existingSystem in DM Plant-II CR & MOI control room shall be in vendors scope

• All UPS & Non-UPS power supply /distribution cables

• Cable ducts & Cable trays(FRP/GRP) from field to BRR , from BRR to MOIcontrol room and from BRR to Substation(MCC room) &GI cable trays insideBRR , inside Substation(MCC room) , inside MOI control room & structuralsupports,consumable for cable laying and routing

• Separate Junction Boxes for different types of signals such as 4-20 mA dc, RTD,for solenoid valves, switch contacts, alarm, intrinsically safe and nonintrinsically safe instruments(with EPCM’s approval) etc.

• DELETED

• DELETED

• DELETED

• All instruments, junction boxes ,glands, LCP’s etc supplied by vendor shall becertified for “Zone 2 IIC T4 “

• All pipes and pipe fittings for instrument air supply distribution / Air Manifoldsand tubes and tube fittings for instrument air supply / steam tracing / Hook upsetc.

• Earthing strip for earthing of all instrumentation items like local panel, junctionboxes, cable trays / ducts, stanchions etc.

• FRP canopies for field instruments

• Any other erection material necessary for installation and commissioning ofinstruments and special instrument items

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• Each of mandatory spares(including 2/3/5 valve manifolds), list of 2-years

operational spares, start-up and commissioning spares for all instruments andany special instrument items.

• DELETED.

• DELETED.

Documents

3_Specific Job requirement in Package Boiler.pdf