CONTROL EQUIPMENT ENGINEERING DIVISION BHARAT HEAVY ... · Board size capability - 400 mm x 300 mm min. Placement Range - 0603 to SOIC’s , 0402 compatible 5. Dual wave Soldering

CONTROL EQUIPMENT ENGINEERING DIVISION

BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

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The specification is for the requirement of 1) COMPLETE DISTRIBUTION TRANSFORMER MONITORING SYSTEM and its associated Control room Server and 2) REMOTE MONITORING SYSTEM FOR TRANSFORMERS and its associated control room peripherals. These system are a combination of various Electronics cards assembly, communication protocol gateways, application logic and precession mechanical structure which shall be responsible for monitoring distribution transformers, sub-station transformers and its peripherals and communicate with the control room and cloud (internet) for parameter monitoring and report generation, etc. 1. GENERAL

This specification covers the requirements of infrastructure, quality of manpower considered essential for quality and reliability of design ,development , manufacturing testing & supply of various high tech Electronics cards/modules involving multilayer PCBs , ASICs , SMT components and digital electronics components like FPGA, DSP , Micro controllers , Micro-processors etc. The requirement also involves rigorous software development on various platforms and technologies. The supplier should confirm availability of the required infrastructure and manpower in technical bid as given in this specification.

a INFRASTRUCTURE FACILITIES The supplier should have the following manufacturing facilities: 1. Dust Free environment for card assembly. 2. Stencil Printer . 3. Automatic Glue Dispenser 4. High speed component placement machine Following features would be preferred :

Board size capability - 400 mm x 300 mm min. Placement Range - 0603 to SOIC’s , 0402 compatible

5. Dual wave Soldering machine 6. 4 zone Reflow oven 7. Digital / Analog Temperature controlled solder stations . 8. Component lead forming machines. 9. Details of Electrostatic discharge protection & ESD procedure adopted to be submitted with offer . 10. Semi-Automatic component insertion machines.



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b. TESTING FACILITIES :

The supplier should have the following test facilities :

(a) Digital oscilloscope Dual channel Min.100 MHZ Band width with following advance features would be preferred. .

Advanced signal processing

TDR measurement

Eye pattern analyzer

Cross talk and ringing analysis (b) Spectrum analyzer with following features preferably :-

Electromagnetic Interference Analysis.

High frequency analysis.

Harmonic Distortion Measurement.

AM / FM Measurement

(c) Multi channels / 100 MHZ band width logic analyzer (d) Multi channels Digital Pattern Generator. (e) Computer added Functional Testing facilities for electronic card.

c. Skilled Manpower requirement

The development shall require at least two engineering graduate (electronics) who would be responsible for execution of the order . Experience in multilayer PCB manufacturing using latest state of art technology components like SMT , digital electronics components, ASICS & microcontrollers and software application on .NET platform, Database Management System like ORACLE would be preferred. Technical persons responsible for the execution of the contract should be competent enough to substitute / suggest suitable alternatives for the components which are getting obsolete / not available in the market .

e. Willingness for Confidentiality Agreement

Supplier to confirm their willingness for unconditional confidentiality agreement on stamp paper as per the attached annexure A to qualify for their consideration in technical scrutiny of tender.

2. SCOPE OF WORK & Technical requirement



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A. SCOPE OF WORK: The Scope of this specification is divided into development of a common hardware and software platform which can be scaled up and down to realize two different monitoring systems architectures to meet different technical requirements. The scope shall cover:

1. Distribution Transformer Monitoring System (BH-BPL-DTMS) 2. Remote Monitoring System For Transformers (BHEL-REMOTRANS)

COMMON HARDWARE PLATFORM FOR MONITORING SYSTEM (SAN-trans) The common hardware platform shall be developed as per following architecture which shall be modular in nature to scale up or scale down the system based on the technical requirement.

a. Section-1 and Section-2 should be enclosed in a single EMI/EMC enclosure with

provision for LED / Local character Display. b. An external DIN rail mounted SMPS for powering section-1 & section-2 should be

present with battery back-up of atleast 10000mAH. Suitable connectors to be provided on the section-1 for external power supply input. Following topology is required to be adapeted for power supply:



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Two separate SMPS provision to be kept for a. Section-1 only and b. Section-1 and Section-2 combined.

c. The 4G module for wireless connectivity shall be part of Section-1.

ITEM no. 1 Distribution Transformer Monitoring System (BH-BPL-DTMS)

The project scope is for development of Gerber, PCB, complete card assembly, firmware, software, testing and integration of the developed system with BHEL existing server. Bidder to Design & develop PCB manufacturing documents / PCB Gerber files & test jig and take approval on the same from BHEL before arranging the PCBs and testing of the card . The major implementation features of the Distribution monitoring system shall be:

1. Development, Supply, customization, installation, deployment and maintenance of necessary hardware, software and communication equipment at distribution transformer site to facilitate monitoring of Distribution Transformer for the purpose of centralized DT monitoring, data logging and data analysis.

2. Integrating the proposed DTMS system with BHEL Bhopal server. 3. DTMS Software should be scalable in nature, DTMS Software and associated

equipment’s should be capable of handling at-least 2000 connections, without any additional infrastructure and cost implication.

4. DTMS system should have complete interoperability for accommodating all types of FRTU/MFM and communication H/W and vice-versa should also be there for any future up gradation of hardware / software.

5. The proposed solution must efficiently enable all required interfaces and integration, including integration with the existing software infrastructure of BHEL server.

6. The supplier shall be responsible for providing all material, equipment and services specified or otherwise, which are required to fulfill the intent of ensuring



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operability, maintainability and the reliability of the complete work covered under this specification.

i. SYSTEM ARCHIETECTURE:

The proposed system will meet following requirements:

1. Monitor and transmit distribution transformer instantaneous and energy parameters at set periodical time intervals.

2. Monitor and transmit following parameters from distribution transformer. a. Electrical analogue (V, I, KW, KVAR, pF, Freq. etc.) and energy

parameters. b. Transformer oil temperature via thermostat (with required high temperature

set point). c. Transformer oil low level via digital input.

3. Monitor abnormal conditions and send alarm messages. 4. Generate alarms and events on following conditions:

a. Transformer overload b. Load unbalance in the transformer. c. Low transformer oil level d. High transformer oil temperature. e. High harmonics f. Phase failure

5. Communication shall be via cellular modem. 6. Parameters received from all distribution transformers will be saved in SQL or

other equivalent database in Control Centre. 7. Provide on-line parameters, trends and alarms. 8. Required reports and log sheets shall be provided. 9. Provide feature for SMS/Email alerts 10. All standard protocol supported i.e. Modbus/IEC 104 11. Secure M2M connectivity with IPsec/L2TP/VPN & 3 DES. 12. All the Electrical and Non-Electrical data from the DTMU shall be integrate with

Control Centre SCADA system



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Block Schematic for the Distribution Transformer Monitoring System

Smart Energy Monitoring unit with cellular modem will be installed at each distribution transformer site. DTMU will monitor all transformer parameters and transmit the same to Server at the control center. DT Monitoring Unit at Distribution Transformer Site: Smart Energy Monitoring Unit with cellular modem will be installed at each distribution transformer site. It should have following functions:

1. Monitor electrical parameters (instantaneous and energy) from distribution transformer.

2. Monitor harmonics (voltage and current) & Total Demand Distortion (TDD) 3. Monitor transformer parameters for limit conditions (alarm conditions):

a. Over load b. Load unbalance c. High harmonics etc. (up-to total sixteen set points can be set) d. Low transformer oil level e. High transformer oil temperature f. Phase failure detection

4. Monitor transformer oil level via digital input. 5. Monitor transformer oil temperature via analog input. 6. Send all parameters to control centre periodically as well as report by exception. 7. Send instant messages to control centre on alarm events mentioned above). 8. Communicate with control centre via cellular modem (3G/4G). 9. Multiple set point minimum 12, so that required alarm set point can be configured

and transmitted to control centre.\ 10. The scope also includes supply of following compatible sensors with cabling and

installation to transformer unit:



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a. Current sensor b. Voltage monitoring arrangement c. Oil level sensor d. Temperature sensor

DT Monitoring unit should have following unique features which are essentials for this project.

a. All the required electrical parameters are available on display and communication. b. PT input up to 690VAC (Line to line) c. CT input 1A or 5A d. PT Burden < 0.15VA. CT Burden: For 5A CT Sec. <0.1 VA, for 1A CT Sec.

<0.02VA e. CT primary and PT ratio are site configurable. f. All type of wiring is configurable at site. g. Four quadrant measurement. h. All parameters updated on cycle to cycle basis and sampling rate 128 sample per

cycle. i. Accuracy class 0.2S as per IEC-62053-22:2003. j. Input frequency: 45-65 Hz. k. Individual Harmonics for voltage and current till 39th harmonic. l. Internal RTC. m. Energy display of nine digits. n. Data log memory >= 135KB. o. Front panel LED for calibration check and communication status. p. Communication protocol: MODBUS RTU, ASCII, DNP 3.0., IEC 104 Required

communication protocol is selectable at site. q. User defined registers. Minimum 100 user defined registers should be available in

the device. r. Standard IoT’s of IEC 104 for configuration mapping with SCADA FEP (Front End

Protocol) server. s. All the parameters should be available as direct reading 32 bit registers. t. Power Supply: (Self powered) u. Ambient operating temperature: -10 to 60ºC. v. Ambient operating humidity: 0 to 95% non-condensing. w. Standard DIN Rail mounted. x. Input/output Signals:

a. 4 Digital inputs and 2 digital relay outputs for digital signal monitoring. b. 3 Analog inputs

y. Cellular Modem with antenna along with SIM card and monthly usage charges for entire project duration i.e. 24 Months

z. The system shall be mounted on wall or pole, outdoor ABS/Polycarbonate plastic cabinet.

aa. Required MCB



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Distribution Transformer Monitoring Control Room:

Software implementation in control room server should provide following unique features:

a. Collects, archives and analyses collected parameter from all sites.

b. Can handle 2000 of remote sites.

c. Multiple users are able to view the data in required formats for graphs, trends, tables and reports. This enables better monitoring and control of transformers.

d. Can be customised based on number of DTMU installed and number of user clients.

e. Each user can be assigned individual passwords and rights.

f. Graphic user interface.

g. View location of transformers on map

h. Real time instantaneous parameters.

i. Log energy parameters for energy reports.

j. View all parameters and reports via web clients.

k. Trends.

l. Alarms and events

m. required log sheets

n. Required reports can be configured by the user.



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o. Send alarm messages via e-mails to pre-defined users in case on events.

p. Send reports to pre-defined user at set intervals.

q. Results in saving capital equipment by early detection of expected faults.

r. Based on alarm messages received from remote DT sites.

s. Detect location of transformer faults.

t. Detect energy loss based on energy through DT and actual energy billed.

INSTALLATION & IMPLEMENTATION

a. The successful bidder shall be responsible for installation and configuration of software, hardware and other

equipment supplied to the satisfaction of the owner.

b. Post Go-Live, the software vendor shall provide support to fix any bug related to implementation. The entire

system would be considered as successfully installed when the software will run with actual live data at site

without any bugs (Bug is lacunae in the system that prevents/ delays an operation or performs a function

within the system at suboptimal level/ at performance level lesser than that specified in this specification or

provides incorrect operational data or provides incorrect results in any data format in the reports generated by

the users).

c. Demonstration of all the features of latest version of software; Acceptance testing of the system thus

implemented to the owner’s satisfaction.



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ii. Sub-Station Transformer Monitoring System (BH-BPL-REMOTRANS)

The Hardware architecture of BH-BPL-REMOTRANS shall contain two parts: a. Outdoor REMOTRANS unit b. Indoor REMOTRANS unit

ITEM no. 2 OUTDOOR REMOTRANS UNIT: The unit shall comprise of complete redundant set of SAN-trans along with accessories as mentioned in the following block schematic. The outdoor REMOTRANS unit shall reside in an IP rated enclosure.

NOTE:

1. The redundancy logic for all the channels and processor shall be finalized after taking BHEL’s approval. 2. Any other Accessories, ethernet cable etc not mentioned here but required for complete implementation

of the unit shall be under supplier’s scope.



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ITEM no. 3 INDOOR REMOTRANS UNIT:

Server Details: Processor: i7 RAM: 8GB minimum Hard-disk: 1TB Operating System: Windows 10 Port: 2 no. HDMI port, 2 no. USB3.0, ETHERNET Software: MSOFFICE latest version



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COMPLETE SYSTEM ARCHEITECTURE:



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NOTE: Stage-2 shall be implemented on the BHEL central servers made available to the supplier.

Software implementation in control room server should provide following unique features:

a. Collects, archives and analyses collected parameter from all sites.

b. Can handle 20 of Sub-stations.

c. Multiple users are able to view the data in required formats for graphs, trends, tables and reports. This enables better monitoring and control of transformers.

d. Can be customised based on number of Sub-stations installed and number of user clients.

e. Each user can be assigned individual passwords and rights.

f. Graphic user interface.

g. View location of transformers on map

h. Real time instantaneous parameters.

i. Log energy parameters for energy reports.

j. View all parameters and reports via web clients.

k. Trends.

l. Alarms and events

m. required log sheets

n. Required reports can be configured by the user.

o. Send alarm messages via e-mails to pre-defined users in case on events.

p. Send reports to pre-defined user at set intervals.

q. Results in saving capital equipment by early detection of expected faults.

r. Based on alarm messages received from remote DT sites.

s. Detect location of transformer faults.



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iii. SCOPE OF SUPPLY:

The supply against this specification shall include:

Item no. Description quantity

1 Distribution Transformer Monitoring System (BH-BPL-DTMS) Distribution Transformer Monitoring Unit as described in this specification with Various Software required for execution of the projects for DTMS and SERVER application

4 nos.

2 Sub-station Transformer Monitoring System (BH-BPL-REMOTRANS) OUTDOOR UNIT with Various Software required

4 no.

3 Sub-station Transformer Monitoring System (BH-BPL-REMOTRANS) INDOOR UNIT with Various Software required and centralized server application / implementation

2 no.

In addition to the above, any hardware/software required to complete the scope of work mentioned in this specification shall be in the supply scope of the supplier. The supplier to hand-over complete source code to BHEL for maintainability and future modifications. Comprehensive training to be conducted by the supplier on the source for BHEL to ensure working/operation knowledge of the source code to BHEL.

iv. Application software

The application software of the system shall be based on an interactive platform for easy implementation and understanding and shall be finalized after placement of order and supplier is responsible to fully implement and prove the same. The application software shall also have option for self-test of the system. Application preferably to be developed in JAVA/.NET Database to be developed preferably on ORACLE 11G Supplier to ensure Penetration testing to be conducted by CERT-IN empaneled agency on the application

a) Programming software for controller/FPGA/processor/DSP/DSC used in SAN-trans.

b) Application source code and its programming software for server application.

v. Test jigs/tools



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Complete test jigs/tools for complete system to be developed and supply along with clear test instructions for comprehensive testing on test.

Supplier to provide Programmable tools (supplier’s own or /and third party instruments, software/GUI) for downloading and modifying software for controller and server free of cost.

B. QUALITY OF ELECTRONIC CARD ASSEMBLY:

The module shall be used in power plant application, the quality of the assembly , soldering, handling of the components & assembled cards(EMI/EMC), sourcing of semiconductor components are of vital importance. Therefore, each of the above should be carefully monitored and sources of the components must be from OEM/reputed international farms who adhere to strict quality norm. To improve, maintain Quality, and highest level of reliability, it is essential to generate statistical data of any failure during testing and also after burn in, rework done. So, that improvement in the assembly and process can be analyzed. Supplier should provide the statistical report to BHEL.

C. FITTINGS OF CARDS & MECHANICAL ASSEMBLY:

As quality of soldering is predominant in performance of the individual electronics card, final assembly like fixing heat sinks with MOSFETS, fixing of vertically mounted cards, electrolytic capacitors, fiber optic connectors are crucial for reliable functioning of the modules in traction application. Supplier must ensure use of proper size of hardware and insulating fixing material. All hardware are of stainless steel. Each fixing screw must contain proper plain washer & spring washer.

D. CONFORMAL COATING OF THE PCB’S:

Conformal coating is very essential for long life and trouble free operation in dusty and hazardous environment. The conformal coating should be in line with ABB document, It is recommended multiple layers of coating is applied on each PCB’s and proper time delay between two layers of coating is followed. CAUTION: 1. Before applying coating, the PCB’s should be tested in all respect. 2. All contacts for connectors and test points & fiber optic ports must be protected thoroughly by providing suitable cover on it. This cover only be opened after the coating is dried up.



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3. Standard EMI/EMC protective norms must be followed during the entire process.

F. TESTING & TEST REPORTS:

The test schedule calls for testing of individual cards and complete assembly. Each module should comply 100% with the test parameters as per the test schedule. Each module has to be burn-in at 60 Degree C for minimum 2Hour. Test result shall be generated and complied for every module with each cards. Type Test compliance: The complete electronics rack should be complied with following type tests and certificate for the same to be provided by the supplier.

Type Testing / Environment Testing For electronics RACK

Sr.No Test Standard Specification

EMI / EMC Test

1 Conducted Emission CISPR 11 Class A Quasi peak: 150kHz-500kHz, 79

dBµV,500kHz-30 MHz, 73 dBµV Average:

150kHz-500kHz, 66 dBµV500kHz-30 MHz,

60 dBµV

2 Radiated Emission CISPR 11 Class A Quasi peak:30-230MHz, 40dBµV at 10m

measurement distance230-1000 MHz, 47

dBµV at 10m measurement distance

3 Radiated susceptibility IEC 61000-4-3 80 MHz-1000MHz, 30V/m

4 Conducted RF Immunity IEC 61000-4-6 Power port:0.15-80MHz :10Vrms 1kHZ,

80% AM Signal port:0.15-80MHz :10Vrms

1kHZ, 80% AM

5 Power Frequency

Magnetic field IEC 61000-4-8

100 A/m for continuous 1min1000 A/m for 3

sec

6 Ring Wave immunity IEC 61000-4-12

Power Port: non-repetitive damped oscillatory transients (ring waves) with 2 kV line to ground as voltage of the first peak (maximum or minimum) in the test waveform & 1kV line to line as voltage of the first peak (maximum or minimum) in the test waveform

Signal port: non-repetitive damped oscillatory transients (ring waves) with 1 kV line to ground as voltage of the first peak (maximum or minimum) in the test waveform & 0.5kV line to line as voltage of the first peak (maximum or minimum) in the test waveform

Environment Test

7 Damp Heat Test –

Steady State IEC 60068-2-78 +40°C / 4 days / 93% RH

8 Cold Test - Operating IEC 60068-2-1 - 40°c / 16 H



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9 Dry Heat Test –

Operating IEC 60068-2-2 +70°c / 16 H

10 Damp Heat Test Cyclic IEC 60068-2-30 +55°C,95% RH / 6 Days

Mechanical Stress Test

11 Vibration (during

operation and

Transportation)

IEC 60255-21-1

Vibration Response –

Powered ON, Class 1

Acceleration: 1g from 10 to 150Hz, 1

sweep in each axis total 3 axes

IEC 60068-2-6 Acceleration: 1g from 10 to 150 Hz 20

sweep

Dielectric Test

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Dielectric Test

IEC60255-27

Cl no. 10.6.4.3; cl

no. 10.6.4.3.3 table

no. 14

For Power Supply, Ct & PT – AC test voltage

2 kV

For digital I/O, analog I/O & 4 to 20 mA I/O

– AC test voltage 0.5 kV

3. DOCUMENTS TO BE SUBMITTED TO BHEL FOR APPROVAL . While executing the PO, supplier shall submit to BHEL and take approval for the following documents for each of the modules mentioned in the enquiry.

1. Test Certificate 2. Burn-in test report 3. Warranty certificate 4. Card Schematics 5. BOM 6. User Manuals 7. System Administrator Manuals 8. Technical Manuals 9. Installation Guides 10. Business Process Guides 11. Program Flow Descriptions 12. Sample Reports 13. Screen Formats 14. Toolkit Guides 15. Troubleshooting Guides 16. Frequently Asked Question (FAQ) Guides

4. WARRANTY. System along with all the components mounted thereon shall be guaranteed for 24 months from the date of supply or 18 months from date of commissioning whichever is earlier.



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5. SERIAL NUMBERING / INDENTIFICATION . All the individual cards and complete rack to be numbered as per following convention: CARD NAME or RACK NAME/WORK ORDER NO./MMYY-Serial no. Work Order no. shall be provided by BHEL 5. Document to be submitted with technical Bid Following document duly filled must be submitted by the bidder party as annexure to their technical bid (to be kept in separate sealed envelope) . Otherwise bid will be technically rejected. A. Infrastructure details

SNo. Description/Equipment Make / details #

1 Dust Free environment for card assembly Area to be specified with temperature& humidity information.

2 Automatic Glue Dispenser

3 High speed component placement machine

4 Dual wave Soldering machine

5 4 zone Reflow oven

6 Digital / Analog Temperature controlled solder stations

7 Component lead forming machine

8 Details of Electrostatic discharge protection & ESD procedure adopted .

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Semi Automatic component insertion machines

10 Digital sampling oscilloscope Dual channel Min.100 MHZ Band width .

11 Digitizing oscilloscope with Min.100MHz band width

12 Multi channel Spectrum analyzer -

13 Multi channels , 100 MHZ band width logic analyzer

14 Multi channels Digital Pattern Generator.

15 Multi channel temperature scanner.



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16 Computer aided Functional Testing facilities for electronic card.

# Machine details like model / Type No. make ,features ,capacity etc to be given. B. Confirmation for Confidentiality agreement

Documents

CONTROL EQUIPMENT ENGINEERING DIVISION BHARAT HEAVY ... · Board size capability - 400 mm x 300 mm min. Placement Range - 0603 to SOIC’s , 0402 compatible 5. Dual wave Soldering