ACL_EP_GU _Part VI B1 Design Criteria and Technical Specification for Control & Instrumentation

8/21/2019 ACL_EP_GU _Part VI B1 Design Criteria and Technical Specification for Control & Instrumentation

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Project : Nagpur Grinding Unit 16/12/2011

TECHNICAL SPECIFICATION FOR CONTROL &

INSTRUMENTATIONRev - 0

ANICPL Engineering & Procurement Tender Document Page # 1

CONTENTS

1.0 BASIS OF DESIGN

2.0 DESIGN STANDARDS

3.0 SCOPE OF SUPPLY

4.0 DESIGN DATA & TECHNICAL SPECIFICATION

4.1. PLANT CONTROL CONCEPT

4.2.

DISTRIBUTED CONTROL SYSTEM DCS4.3. ENERGY MANAGMENT SYSTEM

4.4. MANAGEMENT INFORMATION SYSTEM

4.5. PLANT OPTIMISATION

5.0 UPS- UNINTURRUPTED POWER SUPPLY

6.0 FIELD INSTRUMENTS

7.0 SPECIAL INSTRUMENTS

7.1. GENERAL CCTV SYSTEM

7.2. MILL ELECTRONIC EAR SYSTEM

7.3.

TELEPHONE SYSTEM

7.4. PA SYSTEM

8.0 ENVIRONMENT INSTRUMENTS

8.1.

OPACITY MONITOR

8.2. AMBIENT AIR QUANTITY

8.3. ENVIRONMENTAL DISPLAY BOARD

9.0 INSTRUMENT LAB TESTING INSTRUMENTS

10.0 ERECTION HARDWARES

10.1. CABLE TRAYS

10.2. TUBE FITTINGS

10.3.

CABLE GLANDS

10.4. ACCESSORIES FOR ERECTION

11.0 ENGINEERING ACTIVITIES


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1.0 BASIS OF DESIGN

1.1. Continuity of power supply facilities for inspection, testing, maintenance, cleaning and general

repairs will be of prime importance in the design.

1.2. Standardisation of equipment and its components to reduce the necessary stock of spare parts.

1.3. All electrical equipment shall be designed for operation at the required capacity in ambient air

temperatures (49 C)in a dusty plant environment.

1.4. The design shall include the necessary provisions for the safety of man, machine and environment.

1.5. The voltage, frequency and symmetrical short circuit levels for supply and distribution shall be as

follows: -

1.5.1. Incoming power (Grid Power) : 3 Ph, 220 KV 10%, 50 Hz 3%

1.5.2. Medium Distribution Voltage : 3 Ph, 11 KV 10%, 50 Hz 3%

1.5.3.

MV Fault Level : 40 KA at 11kV

1.5.4. MV System of earthing : Non-effectively earthed

1.5.5. LV Distribution Voltage (TN-S) : 3 Ph, 415 V 10%, 50 Hz, 3%,

50 kA min.

1.5.6.

Lighting, plugs socket and aux. eqpt. : 230V, 1 Ph + E + N , 50 Hz

1.5.7. Welding Outlets : 415 V, 3ph + E + N, 50 Hz

1.5.8.

Emergency power : 415V, 3 Ph +E + N, 50Hz

1.6. Auxiliary control voltage

1.6.1. HV & MV switchgears : 110 V-DC & 220 V-AC + E + N, 50Hz

1.6.2.

MCC : 220 V AC 1 Ph. + E + N, 50Hz

1.6.3.

Control supply

(Actuators, Solenoids, and Proximity etc) : 220 V AC, 1PH. + E + N, 50Hz

1.6.4. Automation control

1.6.5.

Digital Input / Output : 220 V AC 1 Ph. + E + N, 50Hz

1.6.6. Digital Input / Output : 220 V AC 1 Ph. + E + N, 50Hz

1.6.7.

Analogue Input / Output : 4-20mA

1.6.8.

Uninterruptible voltage :220 V, 1 Ph, 50 Hz.

1.6.9.

All variable speed motors shall be squirrel cage with VVVF drive.

1.7. Environment Conditions


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1.7.1. Design Temperature for Indoor Equipment : Min. 06C

Max. 49 C

1.7.2. Design Temperature for Outdoor Equipment : Min. 06C

Max. 49 C

1.7.3.

Degree of Protection for Indoor Equipment : IP4X

1.7.4. Degree of Protection for Outdoor Equipment : IP55

1.7.5.

Degree of Protection for Field Instruments : IP65

1.7.6.

Degree of Protection for Push Button Stations : IP65

1.8. Signal Communication and Interface with plant PLC

1.8.1.

MV Switchgear Meters & Relays : Profibus/Field Bus (Profibus is preferred)

1.8.2. Switchgear Meters & Relays : Profibus/Field Bus (Profibus is preferred)

1.8.3. LV Switchgear (PCC) Controls : Hardwire/ Profibus

1.8.4.

Motor Control Centre (MCC) Controls : Profibus

1.8.5. Process Monitoring Instruments : Profibus/ Hardwire

1.8.6. Machine Safety Instruments : Hardwire

1.8.7.

Sub Control Systems : Profibus/ Hardwire

2.0 DESIGN STANDARDS

In general, the equipment/components shall conform to the latest edition of relevant standards of the

Bureau of Indian Standards, IEEE, and NEMA & IEC.

Some of the standards that are applicable are given below.

IEEE: 519 - Recommended Practice and requirements for harmonic control in Electrical Power

Systems

IEC 61158 - Digital data communication for measurement and control field bus for use in

industrial control systems

IEC 61784 - Profile sets for continuous and discrete manufacturing relative to field bus use in

industrial control systemsEN 50170

IEEE 802.3 Ethernet

IEC 61131

IEC - 60255, EN 55022, EN 50082 (EMC, Noise immunity)

IS 1554 (Part 1) - PVC insulated (Heavy Duty) electric cables for working voltages up to1100V.


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IS 1951 - PVC sleeving for electrical purposes

IS 3975 - Mild steel wires, formed wires and tapes for armouring of cables.

IS 5831 - PVC insulation and sheath of electric cables

IS 8130 - Conductors for insulated electric cables and flexible cords.

IEEE 472 - Surge with stand capability for Input & output modules

SAMA PMC 33.1 - RFI/EMI for Noise Immunity

3.0 SCOPE OF SUPPLY AND SERVICES

The scope of supply and services shall include design, engineering, manufacturing, software

development, testing, documentation and handing over of the following:

3.1 PLANT DCS & INSTRUMENTATION SYSTEM:

The Plant DCS Scope shall be comprised complete system with programmable controllers

(PCs); power supplies; Ethernet switches; distributed / remote I/O panels, Supervisory

computers (HMI); computers for process optimization, Management information System,

peripherals;

Field mounted instruments and their accessories.

Special Instruments and their accessories.

Laboratory Automation Package,

Online UPS 1 x 30 KVA Centralised Un-interrupted Power Supply systems (UPS) supply

As per details shown in enclosed drawing No.A0-ANICPL-NGP-CFGD-I4-01-Rev-00& Scope of Supply &

Price Schedule Annexure-IV-B-1

3.2 SOFTWARE:

Licensed OS & Application software bundle for online & offline programming, configuring, diagnosis,

troubleshooting, firmware update of flash PROMs of the department level controllers along with

necessary drivers and interfaces.

Licensed OS & operator station software / HMI software for graphics development, tag configuration

& management, data acquisition, plant viewing, plant operation, plant control, real time & historian

trending, alarm generation and log, Reporting, event log, historian, PID and other process loop manual

& auto tuning, interfacing & access for Field bus devices / drives, interfacing & access for X-ray

analyzer system, bulk solid analyzer, refractory management system & process optimization systems,

OPC interface, ODBC interface, Web interface, Data link for MIS system Etc. with necessary drivers and

interfaces.

Engineering station software consisting of Item 3.1 & 3.2 of above.


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Any other software required for the reliable & successful operation of the system offered. The

Suppliers shall provide original licenses for all software each and every stations.

Computers at process optimisation and MIS level shall have adequate capacity to support the

following software, other than plant control software with high processing speed. -

Mills optimisation packages

Software & Hardware (at DCS end) required for interfacing of Electrical Energy Monitoring including

with plant control system, OPC interface, ODBC interface, Web interface, Data link for MIS system Etc.

Software for auto tuning of control loops. Windows based software for integrated online

documentation to create / modify control schemes, I/O charts, addressing, tag listing, loop diagrams,

termination schemes, having electric, electronic, logic gates, pneumatic, hydraulic, ISA / IEC symbollibraries, link to manuals, drawings, help menus etc. either locally hosted or available in the network.

Listing of tags, I/O, objects with selective filter and export to MS Excel.

Software for MIS server including remote client licenses, drivers, interfaces, Web connectivity, security

and Hardware firewall. License for MIS and Engineering software shall be valid for 5 remote (Web

display clients) & 5 Local clients with view of online plant overview and critical parameters.

Software for making auto and routine system backup of programs, database, history, logs etc from

controllers and MMI.

All user configurable, user defined software developments like programmable controller logic,

sequential and other process / plant control programs, group / drive interlock, MMI graphics,faceplates, trends, alarm, event, MIS interface configuration, reports, log sheets, Field bus instruments

/ drives interface & configuration using their respective software, EMS configuration, reports, Mimic,

optimization package loops, strategies etc are to be carried out at plant site along with purchasers

engineers.

The Supplier shall support and upgrade free of cost all the firmware / software meant for the

controllers, I/O sub system, Engineering station, programming tools, communication interfaces, MMI

stations, expert / optimization systems, MIS, documentation software, other system interfaces, Field

bus components, specific software for field bus instruments / drives and any other firmware of system

/ software that are in the scope of the Supplier and supplied by the Supplier including OS up to 3 years

from the date of commissioning and handing over of all systems to the purchaser by the Supplier for

same version. These upgrades, revision level changes, patches, software additions, fixes that are

released either by the Supplier or by the OEM shall be provided for upgrading the purchasers systems.

All software, user interface, drivers, utilities shall be in English language only .All software original CD

with license certificate to be provided for C & I system software (MMI, drives, MIS, EMS, smart vision

etc)

3.3 ENERGY MANAGEMENT & MANAGEMENT INFORMATION SYSTEM(EMS & MIS)

One separate server shall be there for EMS and MIS.


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3.4 ERECTION, TESTING AND COMMISSIONING

Erection, testing, commissioning and handing over of equipment and application software supplied by

Supplier bought out items by purchaser and Sub-control systems procured through main machinery

Suppliers. List of such sub-control systems and brought out instruments are placed at Scope of

erection and price schedule.

3.5 SPARE PARTS

List of spare parts as required for all the systems, for two years trouble free operation shall be

furnished by the supplier and spare support shall be available for 10 years.

3.6 C & I ENGINEERING

Complete C&I Engineering like I/O List Preparations & assignments , development of graphics , Logic

developments for plant controls , Log /Trend & report generations software and Hardware

engineering for Controller / I/O,MIS ,EMS & other panels.

3.7 C & I CABLE ENGINEERING

The complete C & I cable schedule & interconnection engineering shall be carried out by C & I Supplier.

ANICPL shall furnish necessary cable engineering inputs to C & I Supplier like C & I cable concept, sizes

of cables procured & engineering drawings required for cable schedule & interconnection details

preparation.

3.8 TRAINING PROGRAMME:

Hands-on training of 08 (Eight) Man week duration for plant personals through a comprehensive

training program covering programming/fault diagnosis and maintenance areas of the supplied

hardware & software at Supplier's / OEMs works

These training shall be designed to the specific need and shall be with hands on / simulation

experiments. These trainings are apart from those imparted on site during installation &

commissioning. These training sessions shall be facilitated by persons with design / engineering /

commissioning / servicing experience to the fullest satisfaction of the trainees.

Necessary and sufficient documents, manuals, drawings, catalogues, work sheets, circuit diagrams,

block diagrams, standards, case studies and write-ups are to be provided to improve understanding

and for future reference. The hard copies (6 sets) of the as built programme.

Training shall be on selection, applications, engineering, configuration, installation, commissioning,

tuning, setup, diagnosing, troubleshooting, calibration, software installation, integration of different

software, program development, online / offline programming, graphics development, field bus basics,

usage of field bus tools, network configurations, network calculations, network troubleshooting and

maintenance as applicable.

Training to be provided on widows OS, Ethernet, I/O, field bus network, filed bus fundamentals,

controller and its software, controller programming, editing, various I/O, interface modules, power

supplies, MMI system complete, MIS, EMS system, Optimization packages, field bus devices /


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transmitters supplied, field bus devices software like FDT, DTM, GSD, EDS, DDL etc, UPS, Surveillance

CCTV Systems etc.

3.9 DOCUMENTATION

Furnishing of information, drawings and documents, which fully define the equipment technology,

application software instructions, installation and operation requirements, performance

characteristics, warranties and QAP.

Complete As-built documentation of detailed engineering drawings and software.

All documents viz. drawings, GA, block diagrams, schemes, circuit diagrams, bill of materials, write-

ups, instrument list, test & calibration reports, loop diagrams, PID, interlocking diagram, field bus,

control layer & MMI layer network diagram, network calculations, I/O charts, specification sheets,

manuals, installation / operating instructions, catalogs, hardware / firmware / software manuals,

testing / setup / configuration /calibration / tuning / commissioning / maintenance instructions or

manuals, tag list, EMS, MIS, Documentation software etc. controller & MMI software listing shall be in

English only

Four sets of all the above said documents shall be supplied in hard copy. Three sets of complete

documentation as mentioned above including as built drawings and documents should be provided as

soft copy. All drawings, GA, circuits, loop diagrams etc. shall be in Auto cad format and other

documents in PDF/ HTML / XML as applicable.

4.0 TECHNICAL SPECIFICATION OF CONTROL & INSTRUMENTATION

4.1 DESCRIPTION OF PLANT CONTROL CONCEPT / SEQUENTIAL CONTROL

4.1.1 DESIGN DATA AND TECHNICAL SPECIFICATION

Plant operation shall be monitored & controlled in automatic mode by operators from Control Rooms.

There shall be two control rooms for cement grinding unit. The 1st control room is Central Control

Room (CCR) and the other control rooms will be in the packing plant. Entire plant operation will be

from CCR. Apart from independent operation of packing plant, it should also be possible to monitor

and control them from main plant CCR.

The process departments shall be controlled from the control rooms through distributed control

organised in the following hierarchical order:

All the departmental level controllers alongwith I/O Panels pertaining to respective areas will be

distributed throughout the plant and located adjacent to motor control centers and in the field as per

the requirement, for real time acquisition of process parameters and plant safety and fail safe

operation.

Human Machine Interface through operator stations connected to department controllers via

redundant high speed Ethernet network data highway.

The Drawing Nos. A0-ANICPL-CHD-CFGD-I4-01-Rev-00 shows overall structure of control system

envisaged.


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At each control Room, plant operation shall be monitored and controlled from a control desk

comprising colour monitors, normal keyboards, mouse etc. Sequential logic controls, interlocks, alarmgeneration, analog signal processing, process loops and analogue monitoring shall be done by

department level Controllers associated with these control desks.

4.1.2 LOGIC DESIGN FOR PLANT CONTROL

The logic scheme shall be designed as follows:

All machines feeders in MCC / drives / sub control systems shall be selected for Local/Remote (CCR /

control room) operation from the DCS by the operator stations (MMI). All the MCC feeders shall be

with intelligent modules with Profibus connectivity. Variable Drives ,Weigh feeders ,Belt Weighers, Bin

Weighers & Sub Control Systems shall be with Profibus connectivity. The local Mode is selected onlyfor machine maintenance and testing purpose. Only with permission from the CCR / control room

(DCS) it will be possible to start the machine from the local pushbutton station. Such Pushbutton

station at site will have one start (or forward , reverse incase of reversible drives) and one EM stop

lockable PB. Once maintenance is completed, the selection shall be put in REMOTE (CCR / control

room) mode by operators in CCR / control room thereby making the machine available for operation

in group or in individual mode through DCS with all interlocks operational as specified in BLOCK

INTERLOCKING DIAGRAMS. This local permission from CCR can be activated for any individual machine

or any group of machines. However the set point like speed reference etc, can be set from CCR /

control room or from the respective panels according to the selection in respective panels.

Every equipment / machine can be operated from CCR either individually or in group according to the

process. The process, machine safety and upstream / down stream sequential interlocks are applied to

the machines as per the requirement of the client and machinery supplier. The exact scheme / level /

type of interlocking, shall be finalized during engineering.

4.1.3 STARTING OPERATION

Each sequence shall have a fixed set of soft keys for group selection and start "Command".

Local/Remote selection of a drive shall be achieved from DCS. When selected for local operation the

start push button at local will be operative. In remote operation this push button will be ineffective.

However, any stop push button pertaining to that machine /drive shall be effective in both modes of

operation.

The control room MMI shall have the I/O status for the entire machine / equipment / drive / sub

control system in a group. The operators usually refer to this before any drive / group start or after

any trip or fault. This status shall be called in as a popup display / window within the main page by a

mouse click on that particular object.

Apart from the above each equipment / machine / drive / sub control system shall have a common &

universal colour scheme (border, fill, shade etc.) associated with animations / dynamic representation

(visibility, blinking Etc.) for operators to know the status / position of that particular object like

whether it is running or stopped, in local or remote mode, status is healthy or not (fault), fault

occurred while running or while at idle condition, stop switch and other safety switches activated or

not, selected in group or not, Whether safety, process interlocks are satisfied or not etc.

In addition, every equipment / machine / drive / sub control system shall have a similar popup window

for showing the status of the safety, process and sequential interlocks of that object stating the


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interlocks with clear text. This window shall have a automatic link with the controller program so that

whenever a change is done in the interlock at the controller, the same shall reflect in this window ofrespective drive / group.

Any fault / tripping while running or during starting shall be indicated in clear text in the alarm banner

and with a voice alarm wherever required which is recordable. The voice alarm shall be an inbuilt

feature of the system and not a separate add on software.

While initiating a group start, the controller checks all status & pre requisite interlocks. On group

START Command, controller shall scan all the inputs to that group and if any fault is noted shall

annunciate on the screen with its tag number. If no fault is there the hooters (located at important

locations for respective section) shall be energised for predetermined time. After completion of set

time, the starting command shall be given automatically and the equipments shall start according to

the designed sequence as per the Block Interlocking Diagrams. A positive feedback shall be available

for the operator as the entire group is started and running as well as for any failure to do so.

4.1.4 STOPPING OPERATION

For stopping, a drive / machine can be stopped individually after selecting out of group, or the whole

group can be stopped. Each group shall have a set of soft keys for the running group to STOP. When

STOP command is given the drive that starts last while group starting stops immediately. All other

drives of the group shall stop in a reverse sequence of start sequence in a staggered manner.

Each group / sequence shall have an Emergency Stop key to facilitate stopping of all equipment in

the group sequence at once without time delay.

4.1.5 STARTING AND STOPPING OPERATION FROM FIELD

For the individual operation of the drive / machine/ equipment / sub control system for test run/

maintenance, local push button station shall be provided near each drive. All the machine safeties will

be effective in local operation of drives. However the set point like speed reference etc, can be set

from CCR / control room or from the respective panels according to the selection in respective panels.

4.1.6 CONTROL ROOMS

Clinker unloading, Clinker silo, Gypsum, Fly ash handling, Cement grinding and transport to cementsilos shall be controlled from Central Control Room.

Cement extraction, packing, truck loading, shall be controlled from Control Room located at packing

plant but the same screens shall be available for monitoring and control of operations on main plant

DCS System.

For field instruments and drives interface, only bus powered, field buses, Profibus is to be used. Analog

4-20 mA shall be used only if such field bus enabled instrument / device is not available or where

explicitly mentioned.

The department level processors shall be programmed to achieve sequential interlocks for start/stop

of plant and machinery, process and safety interlocks, alarm generation & distribution, monitoring andsupervision of process parameters and PI/PID, fuzzy loop controls for process optimization.


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The processors shall have self-diagnostic features to ensure healthy working at all times including

memory, processor loading, status of communication channels and to give advance warning throughaudio-visual means for any fault in the same. Suitable programming devices to facilitate on-line

programme changes; storage of programme for safekeeping and hand held terminal shall be included.

Department level processors shall be controlling the sections independently & stoppage of one

department shall not effect in any way the operation of other unless otherwise they are deliberately

interlocked. However, these processors shall also communicate between themselves to take care of

the safety interlocks/process requirements, which are common between the process related sections.

Any programmable controller in the network can access the data and I/O of any other controller in the

same network.

The computers for supervisory control and optimisation shall have adequate memory for colour

graphics, system software and software packages as per Scope of Supply & Price Schedule.

The department level processors, I/Os, power supplies, interface modules & network communication

devices shall be suitable for operation up to 50.Ctemperature and computers for supervisory control

and optimisation shall be suitable for operation up to 35.C temperature but air conditioned room

with positive air pressure is preffered for automation system. The department level processors shall

also have the power supply unit to supply regulated power for the processor system. The power

supply unit shall have over voltage protection, its own diagnostic features to ensure its healthiness and

provide audio-visual alarm for under/over voltage, over current etc. faults. The power supply outputs

shall have protection against over voltage to connected load.

At the department level control, the tasks accomplished are acceptance of commands from the

operator from any of the operator station and giving feedback. Acceptance of commands from the

optimization packages, bulk solid analyzer, X-ray systems, refractory management system etc.

Interlocking and sequencing measures, carrying out of process control function & transmissions of

system fault annunciations to (MMI) supervisory control level. I/O and programme scanning, alarm

generation etc. The programming shall be so done that the controllers shall take the commands /set

points either from the MMI or from the / Mills optimization packages, bulk solid analyzer cum

blending control system, X- ray analyzer as the case may be. With in the MMI there shall be two

sources of set points, manually set by operator or by the PID/fuzzy loops in the controller. These

selections shall be seamless and bump less with necessary tracking of set point / process variable both

in manual and auto mode. For these selections soft keys are to be provided in the MMI

At (MMI) supervisory level there shall be PC based operator station. Each VDU terminal shall have its

own keyboard & mouse and be mounted on control desk.

In the normal course of event, the plant operation shall be done through any of (MMI) the supervisory

computer. However, in the event of any failure in any terminal, operation shall be carried out through

any of the other terminal without any interruption.

The computers for supervisory control shall be configured to achieve sequential start/stop of the plant

section-wise through department level control, colour graphics of the plant equipment/ flow,

consisting of a number of pages to give dynamic status of equipment/process in different colours; bar

graph indication of analogue parameters, real time & history trending, process & system alarm

logging, voice alarms, Reporting, SMS facility with required hardware of Critical alarms onPurchasers wireless communication system (cell phones) , Voice alarm event logging, set point


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change, tuning face plate of PID loops at operators discretion etc. The computer shall have adequate

memory capacity of SCSI hard disk, EPROMs, and RAMs with battery back up.

4.2 PLANT DISTRIBUTED CONTROL SYSTEM DCS

4.2.1 FUNCTIONAL ASPECTS

I/O MODULES OF GROUP LEVEL CONTROL

The Input/Output modules shall have the following features:

Indicators to show ON/OFF status of each input and output, Active and fault status for the module

Optical electrical isolation between Group level for all I/O modules shall be provided. Supplier shallfurnish the isolation voltage level for each I/O module type.

Each output shall be a potential free relay contact isolated from other outputs of the same module.

Input/output (I/O) racks shall be capable of accepting I/O modules intermixed and shall be one

physical size throughout the system.

Plug in type I/O's are acceptable in place of rack mounted I/O's.

Every I/O module shall have a self diagnostic feature that would automatically identify, isolate and

report failures to MMI / controller like open wire, failed switch, short ckt., over current, over temp,

communication failure etc.

I/O racks shall have plug-in terminal assemblies, so as to allow I/O modules to be easily inserted or

withdrawn from racks while under power both on the I/O side and on the back plane. All I/O modules

and interface modules used shall be of hot swappable (remove or insert under power) type only. Any

module can be inserted in any of the slots and special arrangements / keying (electrical / mechanical)

are to be made to avoid plugging of a wrong field-wiring terminal / terminal base to a different

module. All field wiring terminals shall be finger proof. Each module shall have labels for each channel

for marking address etc. IO modules are to be configured as per requirement.

Termination units or terminal strips shall be provided for the termination of field wiring within each

field enclosure of the plant department. Termination of field wiring directly to I/O edge card

termination of I/O module is not acceptable. The field wirings can be connected / disconnected

without disturbing or removing the respective I/O module.

All the I/O modules shall be of plug & play type and shall be recognized by the controller automaticallyonce they are plugged in to the system. All I/O module related configuration shall be done through

software and no hard selection like dip switches / jumpers /POT are allowed. The addition of I/O in the

network /configuration of I/O shall be carried out while the processor is in online. I/O modules shall

have flash memory for firmware upgrades through network IO modules shall not have flash memory.

Replacement of a same type of I/O module but with a different revision level shall not require a

reconfiguration of the system. The response of individual channel of I/O shall be configurable

independently for its state / behavior during a fault.

In general, the number of different types of I/O modules selected for the system shall be kept

minimum in view of spares and inventory. The modules selected shall be of rugged construction, low

power consumption / heat dissipation and does not require forced cooling but even then min. two

cooling fans for each & every Remote I/O cubicle(IP65) is a must for taking care abnormalconditions/exigencies.


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The I/O modules should be suitable for following type of inputs and outputs:

Digital Input/output Modules

The input sensing voltage range and the current consumption of input should be suitable to avoid

malfunction.

There shall be interposing relays (DI Connection Unit) between field signals and DI modules. The

relay shall be Phoenix make with model no. OPT-60DC/48DC/100 (2966621) and relay base shall be

Phoenix make with model no. PLC-BSC-230UC/1/SEN/SO46 (2980348).

Status indication for each input shall be included. Each input (Hot) connection may be referred to a

common neutral connection. The inputs may be connected from different power supply sources &

this should not effect in anyway on the input channel or I/O Module as a whole. The common

neutral shall be wired to a terminal set.

Inputs signals may be from MCC/ HT Switchboards, LT Switchboards, VFD drives, Thyristor Panels or

any other field devices like Pushbuttons, pressure switch, DP switch, Limit switch, pull cord switch, belt

sway switch, proximity switches used for zero speed detection & material starvation / level detection

on belt conveyors etc. installed in the field.

Digital output shall be relay output and shall be suitable to drive contactors mounted in MCCs, HT

Switchboards, Drives and solenoid valves in the field.

For DO module interposing relays shall be Omron Make (Electro-mechanical relays) in Phoenix relay

boards. The interposing relays for both input and output shall have individual LED for indication,

replaceable glass fuse, varistor(voltage protector) for protection.

Each output shall have its own fuse protection plus blown fuse and output status indication. Outputs

shall be isolated from each other.

Each output shall have its own Hot, and Load terminals and shall be capable of driving solenoid

valves, relays and contactors having up to 5 Ampere minimum continuous rating and 10Amperes in-

rush current @ 250V AC

The same input and output cards shall be used for local and remote I/O racks.

Contact output module shall work in conjunction with PID/PI module to give relay out

put for close loop operation.

Receipt of binary signal for logging running time of some special machines through counters.

The frequency response of both digital input & output channels shall be selected so as to interface

pulses of 2 wire 230 V AC proximity switches employed for speed monitoring of screw conveyors,

rotary air locks etc. up to 10Hz, pulses from counters in weighing systems etc up to 2 Hz, having low

`on time in the order of milliseconds and pulsed outputs required for bag filter solenoid valves having

`on time of about 1 seconds. These timings shall be taken care including the I/O and program scanning

time of the controller. For pulsed outputs having very short duration, viz solenoid valves of bag filters

etc, Solid state switching modules having switching at high end (i.e. no hot line / power to solenoid coil

when the output is off) and negligible off state leakage current may be considered.

The DI connection unit relay voltage sensing range shall be above 150V AC, to avoid false sensingbecause of induction voltages.

Sufficient and necessary measures are to be considered for reducing the effect of false sensing of

inputs due to induction voltages associated with long multi core cables. Vitreous enamelled, wire


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wound bleeder resistance of suitable rating or any other device are to be used to offset, the off-state

leakage current effect produced by 2-wire AC proximity switches interfaced directly to the inputchannels of I/O like ZSS, belt starvation switches.

4.2.2 ANALOG INPUT/OUTPUT MODULES

Input modules shall be dual ended industry standard analog signals of at least 12 bit resolutions.

Signals from transducers will be 4-20mA DC for special cases and specifically mentioned, otherwise all

field instruments are interfaced with bus powered, field bus avoiding 4-20mA loop. 420mA Analog

input cards should be able to process signals within this range +/- 5%. Outside this range, signals

should be marked as bad quality. However they can handle up to 30mA. The supplier is to assume that

all transducers / transmitters will draw 24VDC from the system power supply and size the same

accordingly. The required 24DC Volt DC power supply shall be housed in each I/O cubical, having groupisolation and fuse protection for each channel.

Analog Outputs for special / specific cases shall be galvanically isolated signals each providing at least

16 bit resolution. Output signals shall be 4-20 mA into a load of at least 750 ohms. All analog output

requirements in general shall be catered by the field bus / digital network avoiding 420mA loops.

Input signals such as resistance temperature detectors (RTD) and other zero based signals will be

connected directly to the Suppliers special input modules. Such RTD module shall accept PT 100, 3 / 4

wire RTD with lead wire compensation. The response for sensor break shall be configurable. Their

configuration shall have scaling, filtering, range, linearising, rate of raise validity, alarms, differential

temperature between channels etc.

4-20mA & 0 10 V analogue isolated output for close loop control and reference value. All analog

output requirements in general shall be catered by the bus powered, field bus / digital network

avoiding 420 mA loops.

24V power supply pack for 2-wire field instruments shall be located in I/O panels and its power

distribution with necessary glass fuse protection and discharging diode to be considered. 24V DC

Power supply rating shall not be less than 10Amp for field transmitters.

The error of Analog I/O modules shall be better than 0.1 %

4.2.3 DEPARTMENT LEVEL PROCESSORS

The functions of group level processors shall be as below:

Remote starting and stopping of all plant equipment in predetermined sequential manner as well as in

individual mode

Staggering the starting and stopping movement of drives by internally programmable timers.

Normal operation of plant equipment in remote mode with necessary basic safety and process

interlocks

Process control with the help of PID/PI, fuzzy, cascade, & feed forward algorithms / controller built in

the PCs.

The processor shall monitor the input/output, interface and communication modules. As soon as the

processor senses any internal hardware failure or communication failure, immediately all

digital/analogue outputs shall be disabled. The status of the I/Os in case of such failure shall besoftware configurable. The processor shall have multi tasking (to communicate with XRF & Cross Belt

Analyser), multi slicing, parallel processing and shall have separate scanning for program & I/O done

parallel with adjustable scan time. That is read / write of I/O during program execution.


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Group level processor will be supplied in a configuration to ensure continuous and bump less

processing of data while permitting on-line changes to control logic. There shall be an online andoffline programming feature. The programmable controller shall have Remote, run, program, online

program & test modes(Simulation mode).

All processors will be sized for not less than 150% of the I/O requirement both in terms of physical and

memory size handling.

Group level processor (programmable controller) shall have at least 40% memory capacity left free &

unused after the final programming is completed and while handing over the system. Processor clock

speed shall be 133 Mhz minimum.

Any failure of the power supply shall be indicated as system alarm in the engineering station and MMI.

Suitable protections (Surge suppressors etc.) shall be provided to ensure trouble free operation of

Power supplies.These programmable controllers shall have visual indication for the processor / CPU status, backup

battery status, forced I/O status, activity status of all communication channels and I/O

communication. The system alarm / fault conditions are to be reported in the programming /

configuring software as well as in the MMI.

The programmable controller shall have Flash PROMS for upgrading the firmware through the

programming / configuring software. The processor configuration and user software are to be stored

in a battery backed up memory of sufficient capacity like RAM or non volatile memory for its

continuous utilization. The battery backup for memory shall be for at least one year with out power to

the controller. Also the controller shall have another memory storage means with in itself like

EEPROM / SCSI of sufficient capacity to restore the software backup in case of eventualities. Specific

means are to be made available in the controller for restoring this stand by backup in to the mainmemory even without the requirement of the programming station. How ever periodic backup are to

be taken in the programming / engineering station.

The controllers shall be of minimum 32 bit, high performance, RISC, multi task processing including a

capability to process in 16 bits and shall be chosen to have the following loading pattern while handing

over with the entire plant running in its full mode and configuration. The CPU load shall be less than

60% , the memory utilization shall be within 60% , the loading of communication channels like high

speed Ethernet, I/O channels, programming terminal channel if any shall be less than 60% .

For any tag whether it is of I/O, digital, analog, field bus, calculated, derived, MMI, MIS, EMS / load

monitoring system, expert system / optimization package based, tags from X ray / bulk solid analyzer

etc, the tag name or identification shall be unique and same throughout the system where ever it isreferred. There shall not be any tag name conversion or cross-reference required for the entire

system. Any inclusion and deletion of the tags, changes in the tag attributes, values etc. done on the

engineering station or any other MMI / station in the network are to be reflected and updated in all

the MMI / stations in the system and vice versa.

The programmable controller & its software shall be confirming to IEC - 61131 programming standards

having ladder, Structures text, statement list, functional block diagram & sequential function chart.

Intermingling use of these languages with in a single controller as per the requirement of the

application shall be enabled and permitted. The software shall have features for conversion of

program developed in one language to other. All these languages shall work in their native form

without translation from one to another language before execution. However with respect to the

controller and its functioning there shall not be any adverse or favorable effect for one language overthe other. The programming of the controller shall be object and tag based. The controllers / software

shall have pre configured library programs / functional blocks meant for process plants like cement

plant embedded in to them. These library objects can be used as many times as required in the


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system. Also these library objects can be modified as per user requirement and saved as a new object

in the library. Any library program or function block developed in any one of the controller can beeasily exported and used in another controller for monitoring & control purposes.

Licensed OS & Application software bundle for online & offline programming, configuring, diagnosis,

troubleshooting, firmware update of flash PROMs of the department level controllers along with

necessary drivers and interfaces are to be provided. This software shall be multi user windows based

engineering & commissioning tool and shall be of professional edition. Apart from engineering station,

one more MMI shall have all the requirements in terms of hardware and software to be utilized as an

engineering station. Such windows based software along with controller shall have the following

features.

Online and offline programming with drag & drop, cut / copy & paste, search & replace, editing and

both manual and auto backup utility

Object based programming using active-X faceplates, COM, DCOM. Pre configured Library / reusable

program modules containing process plant related functions. This shall support OPC.

Graphical Configuration of the controller, its memory, its DB, its functions, its status and modes,

Graphical Configuration of communication channels, I/O interface modules, analog and digital I/O

modules, Special interface modules, Field bus modules etc.

Creation and modification of tags. Searching with listing filters for tags, words, specific instruction,

block, forced I/O, used and unused tags etc

Diagnosing and troubleshooting of the controller, communication channels, I/O and other interfaces.

Firmware update in the Flash PROMs of the controller / I/O modules

Forcing of I/Os, Forced I/O shall be easily accessible with different colour at client stations. Thereshall also be provision for withdrawing a dedicated list of forced i/os controller wise. Mirror image of

I/O shall be available separately to confirm removal of bypass at the operator station itself. Force

activation tracking facility with access password and key data entry to get forcing activation shall be

provided.

Programming of logics, sequential controls, startup / safety / process interlock functions and timed

operations.

All of IEC 61131-3 programming standards.

Program & data base backup and restore facility. Up load / down load of program and DB Between

controller and Engineering station and between the RAM and backup memory with in the controller.

A browsing tool to navigate and locate different controllers, objects, programs, files, devices, I/O,nodes & tags

Integrated online documentation tools for creating of I/O charts, data base, documents for FBD, Tag

list with attributes

Analog input / output processing with dead band, scale, range, trigger, threshold, filter - first/ second

order & butter worth filters, sample rate, multiplication factor, hysteresis, rate of change, hi, (hihi) /

low (low low) / deviation alarms, clamp, square root, square, ramp, spike suppression, overflow,

linearising etc.

Functions / instructions like, relay instructions, immediate input, output latch /unlatch, one shot raise

/lower, type conversions, logic gates, flip-flops, multiplexers, decoders, on/off delay timers, retentive

timers, bi directional counters, high speed counters, clock, clear, High/Low selection, comparison,

absolute value, limit monitoring functions, Rate limiter, lookup tables, generation of curve, arithmetic

functions, logarithmic, trigonometric calculation, math, Averaging, max / min, SD, square root, sort,

integrators, totalizer, Ratio, PID, Enhanced PID, Predictive control, multi variable control, Fuzzy,


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totaliser, file operations like search / compare, copy, move, fill etc., if, for, else, next, break, jump,

return, end, label, FIFO, message, string, ASCII instructions, block data transfer, Bit shift, bit mask, bitunpack, rate of change detection, edge detection etc.

Auto tuning software for the control loops like PID / fuzzy etc.

The PID blocks shall have different set of controller parameters (Kp, Ti etc) to adopt for process

dynamic condition and any set of parameter can be selected by the operator with necessary authority

Subroutine objects for various applications like group, AC/ DC drives, DOL, RDOL motors, auto

calibration for damper, Solid flow meters, ZSS, bag filter timers, running hours and any other repeated

controls with input & output pins.

Modes for drives, loops Auto / Manual, Local / Remote

The following additional software are to be loaded and are to be used in the engineering station and

another MMI that is capable of working as an engineering station.

1)

All the necessary software, drivers and interfaces required for the filed bus instruments like FDT,

DTM etc, GSD, EDS, DDL files, device / transmitter specific software so as to read / write the data,

diagnose, configure, calibrate, restore factory setting, tune and access those field instruments

through the network. If HART instruments are used then the respective software are also to be

made available.

2) Necessary software, interfaces, drivers required for the AC / DC drive systems for applications like

drive monitoring, configuration, parameterization, trending, troubleshooting, upload /down load

of parameters etc through the network.

3) The softwares those are required for the configuration, programming, diagnosing, up/down

loading and troubleshooting of programmable controllers for the sub control systems in the plant,

supplied by different vendors along with necessary drivers and interfaces. This shall enable the

engineering station as well as the MMI to read / write data in to those controllers at site through

the network. No separate PC or configurator shall be used for configuring the above mentioned

devices & all the mentioned software shall be available inbuilt in the system itself. All of the above

software shall also be available in the Laptop also along with other software. The Processor

software shall be capable of communicating and setting of communication parameters for all

Profibus related software systems like Transmitters, VFDs, SCS PLCs, RS 485 Communication.

4.2.4 SUPERVISORY CONTROL LEVEL (MMI)

This shall consist of large capacity computers comprising colour monitor with keyboards, printers,programming aids etc. The MMI programming and configuration shall be enabled in all the MMI

stations with password privileges. Any creation, change or modification done in any one MMI shall be

reflected and updated in all MMI stations in the network. There shall be an automatically generated

cross- reference list in what display each tag is used. The database shall be global and available in all

MMI stations. The MMI stations shall have simultaneous multiple controllers support, so that all

controllers are accessed from any of the MMI station for control & monitoring. The OS shall be on

latest windows platform. There shall be tool tips for all GUI. MMI system shall be object based and

shall support / apply standards like ActiveX controls, COM / DCOM, OPC version 2.0 or later, ODBC,

advanced DDE, Web enabled - Microsoft Internet explorer, Microsoft visual basic, SQL & MS office

suits like Excel, Word and Access. All PCs are suitable for Workstation Grade.


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4.2.5 COLOUR MONITOR, MOUSE AND KEYBOARDS

Colour graphic terminals / MMI stations shall have 22 inches, anti glare, flat screen, sleek, LCD Colourmonitor (TFT) with keyboard. The pictorial information shall be displayed on the colour monitor in a

variety of colours.

Keyboard shall be normal windows 104 QWERTY keyboard and the mouse shall be Optical with scroll

button. They are used to perform the following functions, which are indicative only. The system shall

be so designed to keep the operator at ease for monitoring and controlling the plant effectively:

a. Group/path/standby equipment selection, group selection / start / stop / EM stop, Individual

drive selection in-group / out of group / start / stop, opening & closing of popup/pull down

displays for equipment / interlock status / trends and navigating between pages with soft keys

(hyper link) and mouse click. Intuitive navigation using short cuts, direct input etc.

b.

Introduce new set values for close loop control and provide set value for open loop control

with mouse click and entering values with key board.

c. Select, acknowledge and reset system and process alarms with mouse click

d. Activate or de-activate, Auto / manual selection of control loops and opting of expert /

optimization system control in / out for a particular loop using soft keys

e.

Select variables for single or multi-trend real time & log displays.

f. Call up various graphic or alphanumeric displays using soft keys. The MMI shall support picture

in picture

g.

Change maximum and minimum alarm and trip values of process variables, Forcing of I/O.

h. Display build time under all conditions is to be less than 3 seconds. Display update time under

all conditions is to be less than 1 second.

i.

Adjustments of the process parameters with software protection having different levels of

privileges. Suitable interlocking/safety features to be provided such that changes are carried

out by an Authorised Agency only.

j.

The colour monitor shall display the following in various combinations:

Process and plant conditions in flow sheet form with line and three-dimensional figures.

This shall consist of static and dynamic objects with animation like visibility, colour fill,

blinking, colour change etc.

Measurement value with engineering units, data, texts

Real time & historical Trend log display with scroll keys.

One mimic page for each group

Zoom facility for any section of the mimic page

Current and historical, acknowledged / unacknowledged system and process alarms

Current and historical events and operator actions.

Log sheet and reports

Integrated views of third party software packages

System Configuration

SCS Configuration

DP/PA Configuration

Drawing document attachment

Fault Navigation

Asset Management

Short notes on logic Plant overview

All pictures shall have a uniform frame consisting of:


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Heading

Dialogue lines Picture

The heading shall consist of the following description:

Description of section being displayed

Designation

Year, month, day and time in dd/mm/yyyy, hh:mm:ss format

Dialogue lines shall consist of:

Number of alarms so far not acknowledged

Selection and input error messages Selection and inputs.

The Alphanumerical Picture type of pictures shall be presented on colour monitor.

4.2.6 ALARMS:

This picture shall indicate the latest in-coming fault / alarm message from each plant section. The

alarm shall be displayed in different colours as per priority. Such priority levels are to be configured by

the user. The system alarm message shall have different colour from that of process alarms and shall

have the top priority. A flashing star shall be provided near the alarm message, which shall remain in

flashing condition as long as the alarm is not accepted.

The text of alarm message however, shall remain steady. Once the alarm is accepted, the star shall

become steady.

An alarm banner shall be incorporated in all main as well as zoom pages. This displays the latest alarm

with date & time stamp. The time stamping accuracy shall be less than 50 ms. System alarms &

machine safety alarms shall appear in all alarm banners irrespective of the process graphics page kept

open. For process alarms, the alarms that can be shown in the banner for that particular graphic page

are user selectable controller, group, section or department wise. Any popup window shall not

cover the alarm banner. The alarm text shall be user configurable. In case of process variables the

alarm banner shall display the value at the time of alarm with engineering units and the alarm set

point. This set point shall have hysteresis, alarm delay, alarm repeat time with set value in absolute

terms or in percentage terms to avoid multiple alarms. The alarm display shall also have the tag nameand priority number along with text. Every alarm shall have a provision for voice message, which will

be played during alarm (like wave file). This voice message can be user recordable and attached to

each alarm as required. This voice message shall also be acknowledged as the alarm text is

acknowledged.

The process & machine safety alarms shall be grouped process section wise or group wise and with in

that group they are sub-grouped as function wise (department Process, production, mechanical,

electrical, instrumentation, utility etc.) Both current alarms and historical alarms shall be called to

display either main group wise or sub group wise. These alarm display shall have filters with pull down

menus having check boxes & text fields / buttons for selecting or deselecting of all alarms / group /

sub group / specific equipment or machine, tag, process / system alarms, period with date and time,

priority, acknowledged / unacknowledged alarms, current / history alarms, alarms having operators

note Etc. The alarm list can be exported to MS excel. The alarm history can be archived using

removable media. The alarm list or a particular alarm shall have provision to send the same to E-


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mail/SMS recipients over the intranet or Internet as the case may be. The decision shall lie with the

operator.

Every alarm shall have one text field / file associated with it having space for up to 10 lines / 150

words or equivalent number of characters for operators to enter notes. The hard disk memory space

shall be occupied / utilized only if the operator uses that option for any alarm. This operator notes are

also shall be available in the alarm history. The present date & time and the operator identity are to be

attached to such notes when they are created / modified.

4.2.7 EVENTS:

There shall be an event recording system in the MMI. There shall be an event banner in each main as

well as zoom pages. This displays the latest event with, tag name / equipment name, date & timestamp. Events are displayed in a colour distinct from alarm messages. Event here means all operator

control actions like log in, security level changes, start / stop / EM stop of group / drives, set point

changes for loops / devices like weigh feeders / solid flow meters / VFD - speed / damper opening /

actuators etc, selection of equipment in /out of group, auto / manual selection of loops, selection of

expert / optimization control for any loop, blocking of process variable, bypassing of ZSS & other

signals and any status, acknowledging of alarms, online DB modifications, system restart messages,

activity that are not treated as alarms and at the same time required to be recorded etc.

For reporting the events, they shall have standard set of (library which is user created / modified)

texts as defined during detailed engineering like started, stopped, selected in group, bypassed, set

point changed from previous to current, auto selected, manual selected, increased, decreased, open

command, close command etc. Since the MMI is object based, those events that may be applicableand required for that object can be associated with it while configuring that object.

The events shall be grouped process section wise or group wise. The event display shall have filters

with pull down menus having check boxes & text fields for selecting or deselecting of all events /

group / sub group / specific equipment or machine, period with date and time Etc. The event list can

be exported to MS excel. The event history can be archived using removable media.

4.2.8 OPERATOR INSTRUCTIONS:

Every object especially drives / machines and equipments shall have a facility to hold instructions,

operator hint (like note pad) which are specific to that, either temporary or permanent. This field can

hold equipment data, operating limits, cautions, taken for maintenance etc. These instruction field /file associated with the equipment shall have a space for up to 10 lines / 150 words or equivalent

number of characters for operators to enter. This can be considered as an attribute to that object and

can be invoked by right mouse click or with a soft key. The hard disk memory space shall be occupied /

utilized only if the operator uses that option for any equipment. The present date & time and the

operator identity are to be attached to such notes when they are created / modified. A privilege class

is to be created for such entry. A search feature to be provided for listing the tag / object for which a

operator hint is created / modified over a time period.

4.2.9 HISTORICAL:

The picture shall indicate all events & alarms occurred in the last 24 hours in chronological order. The

alarm history shall also be available section wise, Equipment wise.

Historical alarms should be displayed according to the filter settings as mentioned above while

opening them. The same can also be printed in A4 sheet. The alarm history shall be limited only by the


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hard disk space and not otherwise. The period of holding such alarm history is user configurable. The

purging of the history shall be FIFO once the period set is reached. The alarm history shall have all thealarm attributes associated with the alarms as mentioned above. There shall be a provision for backing

up of this history as soft copy if required and the same can be loaded in to the MMI for viewing and

printing.

Historical events should be displayed according to the filter settings as mentioned above while

opening them. The same can also be printed in A4 sheet. The event history shall be limited only by the

hard disk space and not otherwise. The period of holding such event history is user configurable. The

purging of the history shall be FIFO once the period set is reached. The event history shall have all the

event attributes associated with the events as mentioned above. There shall be a provision for backing

up of this history as soft copy if required and the same can be loaded in to the MMI for viewing and

printing.

4.2.10ACTUAL FAULTS:

The picture shall indicate fault of various plant sections still prevailing. The operator shall have to press

"Actual Faults" key. All faults prevailed in various plant sections shall be displayed and current alarm

message shall also be displayed.

4.2.11 LOG PICTURES:

There shall be different types of logs pictures played on the running hours specific energy

consumption etc. for shifts, daily and monthly basis.

The process calculations and performance calculations like running hours, specific heat / energy

consumptions etc, can be done in the controller and the same can be provided as a derived tag for

display as well as log sheet purpose.

These log sheets shall be user configurable and modifiable both in terms of structure, pattern and

data. The operator can view the log sheets shift wise, day wise and month wise. The operators can

create their own log sheets with the process variables & structure as required by them. The sampling

rate, time of capturing the data, range of data, format of data and any other tag attributes required

can be selected by the operator using a log sheet creation / editing utility which lists all tags in a tree

like structure with check boxes and selections.

4.2.12 START-UP CONDITION PICTURE:

Before starting a particular section of the plant, operator shall be able to learn from dialogue whether

all start up conditions have been fulfilled i.e. whether all local switches are in remote position if

applicable as in the case of VF drives, all drives of desired section are healthy etc. If any defective start

up conditions are found, the central processor PC shall inform the operator of the defective condition

via the display.

4.2.13 START-UP PROCEDURE PICTURE:

Before starting a particular section of the plant, the operator shall be able to learn from dialogue the

start -up procedure of desired section. A pull down window or a popup window shall be made

available for the same.

Semi-graphical picture


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4.2.14 PLANT SECTION:

This picture shall display the desired plant section in mimic form in colour. Status of the variousdrives shall be indicated by changing the fill / edge line colour of the symbol / visibility / blinking or

combinations as follows:

This scheme is given, as indicative, detailed and final scheme shall be complied during detailed

engineering. Also refer to section 3.1.1

- Motor ON : Green fill

- Motor Normal & OFF : White fill

- Motor fault while running : Flashing red symbol

- Motor fault Acknowledged : Steady Blue edges, red symbol

Some of the other conditions are Equipment / motor started from local, fault while running in local,

fault or statues unhealthy at idle condition, in group or out of group, start-up / safety / process

interlocks satisfied or not, tripped due to fault like overload / due to process interlock / safety

interlock, machine in simulation mode i.e. MCC module in test position, motor under pre trip alarm

etc.

4.2.15 ANALOGUE PROCESS VARIABLES:

Actual values, set points of temperature. Pressure, speed, flow etc. shall be displayed in Bar Graphics

form in addition to numerical display as required. Process variable at alarm condition shall be

indicated in different colour with blinking on the graphics. Bad process variable points are to be

indicated in different form. If required the diagnostic values like sensor temperature etc. apart from

the primary process variable from field bus or smart devices are to be displayed on the graphics.

4.2.16 TREND:

This picture shall display in the form pictures of curve measured or calculated values for process

variables, analog, digital / binary values over a particular period. These trend displays that are

permanent can be grouped and selected from a menu and also by using soft keys assigned and placed

near the relevant equipment on the graphic display page.

All the tags, points either I/O based or derived or from any other system like blending control system /

expert system /refractory management system / EMS etc. can be selected for trending. All such tags at

the discretion of the operator can be invoked for either real time or historical trending. An easy toolshall be available for configuring such trend displays with pull down windows / menu driven / wizard.

These trends can be temporary or permanent one if saved.

The trend page shall have minimum of six variables per trend display with different colours as selected

by the user. The tag, description, heading for trend, range of displayed variable, auto scale, the

engineering unit, sample frequency required for plotting, period, background colour, pen colour, grid

size etc are configurable by the user. The trend can use the objects like up / down arrow, right / left

arrow, double arrow etc for scrolling, pause, link buttons etc from the object library of MMI.

The trend display shall have a common time scale at the X-axis showing the date and time, different

scales for each variable selected on the Y-axis with engineering unit. Also the Y-axis shall be shown as

common for all variables in terms of percentage. The tag name, description, range, engineering unit,alarm priority for that tag, etc are to be displayed in the same colour as that of the variable in the

trend as legend. Here the description shall be either the tag description or a user defined one.


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Navigation keys are to be provided for the trends at the time scale axis like, forward / fast forward,

reverse / fast reverse, pause, historical display or current display etc. The period of trend display canbe selected from 1 minute to one month in a single display. On right clicking or by any other means, a

window shall appear to select the period of the trend with calendar, start date, end date, start time,

end time, duration of the trend, format (24 hours) etc. The trend can be seen seamlessly between

current as well as historical data. Both data presented together on a same trend. That is while

scrolling from the historical data up to present time; the trend display shall continue to update real

time values on the screen. There shall be time offset function to trace a signal in real time and

compare it with values from other day. There shall be area zoom within the trend. The trends shall

have facility to pick, calculate, mark and display the peak (max) low (min), mean and average values

for a selected duration.

A ruler function in which, the actual value of the trended variable at that time shall be shown on the

legend while moving the curser of the mouse over the trend curve. A dynamic display showing the

date and time (dd.mm.yyyy - hh.mm.ss) shall be available on the trend page and shall show the time

pertaining to the curser position. A suitable means shall be made to fix points / markers on the trend

curve with automatic value display if desired by the user for specific reasons like take print out or for

presentations. The trend curves shall show points of alarm with specific markers according to alarm

setting of that tag. There shall be a filter option to either select or deselect this option. The trended

variables can be shown either as merged or banded with or without grid lines as per selected option. A

suitable means shall be provided to show / hide (de clutter) individual traces as required with in a

trend display. The trend display shall use maximum area of the monitor screen for clarity. Trends shall

have provisions for operators to include annotations / smart clipboard. The trend values shown over a

defined period can be copied and pasted in to Ms word / excel. Also trends shall be saved as a soft

copy like captured display and also shall be printable.

The trend display shall be built as and when it is called for display, by taking the data from the

historian and current values and then can be seen seamlessly till the display is closed. The historian for

the trends shall be limited only by the size of the memory / hard disk and not otherwise. By default all

the analog tags / points are included for the historian. User can choose any point out of history at any

time and also can included those points if required in future including binary points. The sampling rate

of tags /points shall be user settable for individual tags as per the requirement.

X / Y plots shall be available to trend two values against each other to determine the relationship

between them

However control function blocks like PID controller shall have their own default trends showing PV,MV, set point and deviation / error for tuning and to learn the behaviour of the controller for different

settings.

4.2.17GENERAL VIEW:

This picture shall display the following current values of each control loop:

- Actual values

- Set point

- Manipulated value.

Every PID, fuzzy control functional blocks shall have a user-friendly faceplate for tuning and setup by

operators. Such faceplates can be displayed by a mouse click. A privilege class shall be included forchanging the values or tuning the loops. These faceplates shall have data values like PV, MV. Set point,

deviation /error, alarm points and text, auto / manual selection, local / remote set point selection,


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override, trend, All PID tuning values and their multiplication factors, auto tuning, bar graph display

etc.Application software instruction manuals shall be complete, correct, indexed, and current for the

system supplied. English language manuals will be provided to the End User. If interpretation or

clarification of instructions is required by the End User or Engineer, such assistance shall be readily

available at the End User or Engineer. This includes, but is not limited to, on line help menus,

telephone support, bulletin board or other on-line information, and access to technical specialists.

The software must include at least the following pre-programmed algorithms / function blocks:

- Square root,

- Characterizer (function generator)

- lead / Lag

- Averaging, max / min, SD calculation

- Integration (accumulator), tantalizer

- Exponential filters

- Ramp control, ramp function generators

- Arithmetic, logarithmic, trigonometric, calculations (floating point & integer)

- High/Low selection and limiter

- Time delays, queue for digital and analogue signals, clock

- AND/OR/XOR/ NOT gates, RS flip flop

- Logic (toggle) switch and analogue transfer switch

- Rate limiter

- PID (proportional, integral, derivative), derivative shall be selectively applied on the error

process variable signal. Face plate for manual tuning and calling in the auto tuning with

password

- Fuzzy control blocks

- Digital control blocks and /or elements

- Bit manipulations like shift, bit mask, unpack

- Rate of change / raise detection / edge detection

- Input block to accept inverted compound ranges for process variables, set points and

trending function

- Motor control DOL, RDOL, damper actuator (on shot & incremental), diverter gate, AC VFD,

DC drive, solenoid valve single / double coil,

- Sequence control

- Mode selection like Auto/ Manual, Local / Remote

- Analog input / output processing with dead band, scale, range, trigger, threshold, filter first/

second order & butter worth filters, sample rate, multiplication factor, hysteresis, rate of

change, hi, (hihi) / lo (lolo) / deviation alarms, clamp, square root square, overflow, spike

suppression, linearsing etc.

- Comparators

- Counters, speed calculators, multiplexers, decoders, demultiplexers, Running Hours,

Totalizer, Equipment Faceplate

- Absolute value generators

- Storing elements

- Auto calibration routine for damper actuators

- Auto calibration routine for solid flow meters / weigh feeders


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- Weigh feeder control for total set point with DP control and ratio control to individual

feeders- Zero speed detection function with pulse input from field proximity switches with adjustable

pulse rate / timing and with bypass / block facility

- Faceplate for timed operation of solenoid valves employed for bag filters etc. with operator

adjustable on, off and interval timings.

- The group timing settings like interval time between drives shall be available in a separate

faceplate and are user adjustable with login rights.

- Sequence of operation of silo extraction gates with operator selections

- Airflow volume calculations with DP transmitters with temperature compensations.

- Performance calculations like total power consumptions, operator efficiency, machine

efficiency, machine productivity, false air, running hour, idle running hour, etc.

Extensive user access rights and different level hierarchy & privileges with security features and

encrypted passwords are to be provided. The screen layout, opening of pull down menus,

information on the menus, access rights etc are governed by the password protection. Some of them

are Instrument Engineer to have access over all programming, editing, full privileges of operators /

process engineers, I/O/ network/ controller/ tag / alarm/ event/ historian/ control loops

configuration, interlocks, graphics development, Full access to field bus devices and drives,

documentation etc. Operator view graphics to all or selective plant, to operate, drive / group start,

stop, equipment selection, equipment in / out of group, give set points, mode change local/remote,

auto /manual, alarm acknowledge / reset, alarm, event list, select & view trends, select point / tag to

trends, alarm notes, equipment operator instructions, log sheets viewing, printing etc. Process

engineer All privileges of operator, tuning of PID, creation/ editing of calculation blocks,

performance equations, log sheet creation, configuration, modification, tag / point blocking,

bypassing of interlocks like ZSS, setting timings for bag filters, alarm voice message, alarm process

alarm priority, alarm / trip level etc,

There shall be a possibility / provision in the MMI system to integrate Live video information via

Ethernet. It shall be possible to use JPEG, JPG, GIF, and BMP images as background or as objects in

the graphics. There shall be one tag per object. The tag Database shall be global. The aspects of the

objects shall be available at aright mouse click including the tag name, attributes, status etc. The tags

Database shall be exported to MS excel by the user with filtering option. The number characters for

tag name shall be minimum 32.

The development of graphics, trends and process display shall be done in any of the MMI stations.

The tags shall be selected through browsing. A power full search tool shall be provided for searchingtags, objects and cross-reference where these are used. The cross-reference generation shall be

automatic within the network. A set of pre configured process related, electrical, pneumatic,

hydraulic, static, dynamic, 2D, 3D objects with attributes shall be available as library for use in the

process display. User can modify any of the library display and can save it to the library. User defined

display / object can also be included in the library.

The total system shall be with global timing including clients, server, controllers, etc.

4.2.18 PRINTER

With the help of collected data, the data logger at the HMI generates the following reports as and

when required and prints command given by the operator:- Alarm & event history reports

- Operating hours reports

- Production / packing reports


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- Thermal / electrical Energy Reports

- Operation reports / log sheets giving the main process parameters- Plant Graphics screen / trend

- MIS reports

All printers shall be laser jet ( B/W & Color) according to the system configuration drawing enclosed.

All the printers shall be network printers & should not be specific to a particular controller or device.

4.2.19 ENGINEERING STATION

PC based Engineering Station with 22 anti glare, TFT, flat screen, sleek colour monitor for program

development; modification in control strategies, configuration and debugging shall be provided. The

engineering station shall be able to upload/download developed programs and modifications thereof

to departmental level processors over high speed Ethernet data high way. The engineering stationshall be capable to perform all necessary functions for configuration of system. The MMI graphics

development, configuration and editing software shall be available in the engineering station. The

engineering station shall also be used as an MMI operator station in all respects. The engineering

station shall be provided with necessary cables and sockets connecting its peripherals. One PC among

the MMI stations shall be configured as an engineering station both in terms of hardware as well as

software, apart from functioning as MMI.

The computers for engineering station and operator stations (MMI), EMS, MIS server, optimization

packages shall be of HP/DELL Make only.

The engineering station and one of the computers of the MMI shall be provided with CD writer to takeback up. Apart from one Zip drive shall be provided for taking back up.

The engineering station shall be loaded with the necessary software required for MMI graphics

development, configuration and editing and software required for using it as an MMI station. All

software backup are to be taken in different media other than floppy disk.

4.2.20 PORTABLE PROGRAMMING UNIT

A laptop computer of latest configuration with necessary licensed software including OS loaded as

Portable Programming Unit for the programmable controller and other field instruments / devices /

drives. This shall act as a portable engineering station. This portable computer shall be loaded with the

necessary software. This laptop computer shall have DVD writer / DVD combo drive, external optical

mouse, USB 2.0 ports, serial and parallel ports, multimedia ports, 10/100 mbps Ethernet port,

necessary hardware, ports, cables and drivers. Any add on device required to take back up

ACL_EP_GU _Part VI B1 Design Criteria and Technical Specification for Control & Instrumentation

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Transcript of ACL_EP_GU _Part VI B1 Design Criteria and Technical Specification for Control & Instrumentation