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Project : Nagpur Grinding Unit

TECHNICAL SPECIFICATION FOR CONTROL &


INSTRUMENTATION

16/12/2011
Rev - 0

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 DCS
4.3. 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

ANICPL

Engineering & Procurement Tender Document

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Project : Nagpur Grinding Unit

TECHNICAL SPECIFICATION FOR CONTROL &


INSTRUMENTATION

16/12/2011
Rev - 0

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) :

1.6.

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

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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TECHNICAL SPECIFICATION FOR CONTROL &


INSTRUMENTATION

1.7.1. Design Temperature for Indoor Equipment

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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

1.8.

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

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.

: Profibus/ Hardwire

Sub Control Systems

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

IS 1554 (Part 1)

ANICPL

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


PVC insulated (Heavy Duty) electric cables for working voltages up to1100V.

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TECHNICAL SPECIFICATION FOR CONTROL &


INSTRUMENTATION

3.0

IS 1951

IS 3975

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

Rev - 0

PVC sleeving for electrical purposes


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

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 symbol
libraries, 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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TECHNICAL SPECIFICATION FOR CONTROL &
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3.4

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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.
DOCUMENTATION

3.9

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, writeups, 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


DESCRIPTION OF PLANT CONTROL CONCEPT / SEQUENTIAL CONTROL

4.1
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, alarm
generation, 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 only
for 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 of
respective 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 cement
silos 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 and
supervision 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 through
audio-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 .C temperature 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 on
Purchasers 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 shall
furnish 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 automatically
once 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 abnormal
conditions/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 inrush 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
put for close loop operation.

give relay out

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 sensing
because 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 input
channels 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 group
isolation 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 be
software 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 and
offline 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 main
memory 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 is
referred. 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 over
the 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 be
easily 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. There
shall 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, bit
unpack, 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 Colour
monitor (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 name
and 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 EANICPL

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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 & time
stamp. 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 applicable
and 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.
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.

4.2.8

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 the
alarm 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.
4.2.10 ACTUAL 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 various
drives 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
- Motor Normal & OFF

:
:

Green fill
White fill

- Motor fault while running


- Motor fault Acknowledged

:
:

Flashing red symbol


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.
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.

4.2.15

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 tool
shall 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 can
be 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.
4.2.17 GENERAL 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 for
changing 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:
-

ANICPL

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 searching
tags, 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.
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 station
shall 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.

4.2.19

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 take
back 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 like server
to be provided by supplier.
4.2.21 SALIENT FEATURES OF CONTROL SYSTEM

I/O Panel
I/Os in Panels or integrated to MCC shall be connected to department level processor through
redundant serial link(Profibus). Such redundant cables are to be routed in two different routes. Usage
of Armoured data cables shall be considered instead of unarmoured cables in conduits. However the
effect of noise, EMI etc, in an industrial environment is to be taken in to consideration. Armoured OFC
is suggested for this purpose.
High-density I/O modules with modularity of 16 channels shall be provided.
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The output channel shall be suitable for 5 Amp. Current capacity (Potential Free).
All I/O modules including spare I/O modules shall be complete with all accessories like wiring arms /
terminals, mounting base etc. It shall be in ready to use condition.
The I/O and their interfaces shall have provisions to be configured either as remote I/O or as
distributed I/O. The minimum speed of the I/O data communication shall be 10 Mbps. The protocol
envisaged for this purpose is profibus which is widely used, industry standard and open protocol. The
same shall be clearly mentioned in the offer.
There shall be a provision for control system interrogation from anywhere in the network especially
connecting the portable programming terminal (laptop configured as an engineering station) at the I/O
network level for accessing and programming, editing, diagnosing, monitoring the respective
programmable controller through the network. Such interface can be provided one per departmental
level controller at the point of maximum I/O concentration like I/O in MCC. Any way the I/O data
communication will have higher priority than this terminal communication.
TRANSIENT, STATIC & EMI/RFI PROTECTIONS:
The complete technical data for all types of proposed I/O modules including EMI / EMC aspects,
Electrical environment & disturbance immunity compliance, insulation resistance, protection against
impulse voltage, HV electrical noise / surge, burst disturbance, electrostatic discharge, radiated
electromagnetic field disturbance, Radio interference, RF interference according to the applicable
standards (like IEC 60255, EN 55022, EN 50082).
The system shall be internally protected against system errors and hardware damages resulting from
Electrical Transient on power wiring
Electrical Transient on signal wiring
Connecting and disconnecting devices or removing or inserting modules in DCS
The DCS system shall be capable of accepting various signals for its direct use while preventing noise
errors due to Electromagnetic Interferences (EMI) or Radio Frequency Interferences (RFI) including
nearby Radio stations, hand held two way radios, electrical storms , Solenoid valves, relays ,
contactors carrying heavy currents. RFI/EMI noise immunity shall be as per SAMA standard PMC 33.1.
The surge withstands capability for input & output modules shall be as per IEEE 472.
Departmental Level Processor
Memory capacity
I/O Handling Capacity

Remote I/O Communication Ports


Connectivity to MMI layer

Remote I/O

ANICPL

: Minimum 32 / 64 MB (Highest available)


: Minimum 2MB words in free mix combination of various
I/O types (digital /analog / Profibus bus / AC drives/
from other systems like sub control system PLCs /
I/Os, optimization systems, EMS, X-ray system, etc.)
: Minimum 5Nos and the speed shall be minimum 10 Mbps.
: Min. Two, redundant Ethernet ports, 100 Mbps, TCP/IP.
The failure of anyone bus / node shall not affect the plant
operation.
:

750 meter or above distance. The maximum distance


that can be allowed for these I/O interface for the

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selected media at the selected communication speed


are to be mentioned in the offer.
Scan time

0.1ms/1k
word
including
I/O
as
well as program scan.
Serial port
:
At least one serial port per controller.
Smart / intelligent, digital process transmitters shall be interfaced with respective department level
processors on Profibus. Protocol details shall be furnished to supplier. Necessary hardware and
software shall be included. Those protocols and field bus that supported by the controller offered are
to be indicated in the offer. While calculating the I/O requirement those additional diagnostic and
status parameters / data like sensor temperature etc. from such intelligent transmitters are to be
taken in to account. The system shall be so designed and engineered such that these field bus enabled
transmitters are accessed for two-way read / write communication from the MMI level. The necessary
software, drivers and interfaces required for the filed bus instruments like FDT, DTM etc, GSD, EDS,
DDL files, device / transmitter specific software for calibration, configuration, diagnosis, maintenance,
function block changes are included in the scope. 20% spare components like linking device / segment
coupler, repeater, Power supply, field bus JB, Ts, terminators etc and field bus cables are included in
the scope As for as possible field bus devices / transmitters are going to be used. For any application if
such devices / transmitters are not available, then they will be with 4 20 mA DC analog signal with
HART communication. Hence the I/O and the programmable controllers shall be HART pass through.
Maximum of 15 PA Devices per DP/PA coupler segment and maximum 3 segments and DP/PA
communication through OFC up to the Spur Junction Boxes are envisaged for field devices.
All MCC Feeders and AC drive (LV & MV) shall be connected on bus level (Profibus) in each department
level processor. Necessary hardware, protocol and special cable shall be provided. All SCS panel shall
be provided with the standard interface with plant control system. Details of the interface shall be
provided by the Purchaser. Separate Bus and its communication board for MCC, Drives, SCS and field
devices shall be considered.
Those open network protocols and profibus, those are required for such drives interfacing and
supported by the controller offered ,are to be included. This bus level communication to the controller
shall be direct without gateway. While calculating the I/O requirement those additional electrical
variables, diagnostic, alarm, status data (like winding temperature, motor thermal utilization, heat sink
temperature, last fault occurred etc.) from the drive and the parameterization data that are required
by the drive (like over load setting, speed range, ramp setting, critical speed setting, current limit etc.)
are to be taken in to account. As a safety measure, only the start / stop / EM stop commands/Analog
Setpoint/ are to be interfaced through I/Os also apart from the profibus network.
The system shall be designed and engineered in such a manner that this two way digital open
communication interface shall support and enable reading of process & control data like drive current,
speed, KW, winding temperature etc, status, alarms, faults and diagnostic messages from the drive
and writing of drive parameter, set points etc to the drive from the MMI.
All sub control system shall be connected on bus level(Profibus) in each department level processor
unless & otherwise specified. Necessary hardware, protocol and special cable shall be included.
The programmable controller, the I/O and communication modules shall have the intelligence to act
as independent nodes on the network and need not have to have a controller to perform bridging &
routing, also multiple processors, I/O and communication modules can be mixed and used.

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Minimum speed of communication for the profibus should greater than 1.5 MBPS.
Data Highway
Open system Interconnection type data highway shall be provided (e.g. Ethernet)
Communication speed shall be Min. 100 MB/ sec.
Topology: Bus topology with (two) redundant network having 48 (min) port Manageable Ethernet
switches. 25% spare ports shall be available in Ethernet switches. The failure of any network card in
the MMI station or failure of any one Ethernet switch / anyone Ethernet bus shall not affect the
operation of the plant in any manner.
Redundant OFC Shall be used for monitoring packing plant operations.
Computers for Supervisory Control (MMI), Optimization, Engineering station and
Process
Engineers Room
The machines shall be of rugged and industrial grade version only.
PC placed in process engineers room shall have Internet connectivity with necessary software and
hardware.
The computers at supervisory (MMI) level shall have the following capacity:
No. of tags Unlimited
Multiple window
Limited only by OS capability
No. of trend display pages
Not Specific
Multi trend display
Not Specific
Event list length
20000 events (practically no limit and user
configurable for a specified duration. Only the memory or hard disk space is the limit)
Alarm list length
1000 process alarms and 100 system alarm
(practically no limit and user configurable for a specified duration. Only the memory or hard disk
space is the limit)
Screen change (in secs)
< 1 secs
Display updating (in secs)
< 1 secs
CPU loading
Shall be less than 60% at all times expect
during system startup
Memory loading / utilisation
Shall be less than 60% at all times expect
during system startup and graphics page change
HMI SPARE TAGS
40% spares tags license shall be available
after plant commissioning.
4.3 ENERGY MANAGEMENT SYSTEM

Electrical energy management system shall include supervision of the main electrical feeder and
control of loads with the target to minimize energy cost. The supply of the EMS shall be as per the
Scope of supply & Price schedule.
Relevant data as power factor, peak demand shall be taken into account.
Load control shall be based on production/maintenance planning and shall include priority programs
for selective alarming. Key parameter shall be integrated into the normal operator station display.
Minimum specification required for EMS shall be as per mentioned in Scope of Supply & Price
Schedule.

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4.4 MANAGEMENT INFORMATION SYSTEM (MIS) FUNCTIONS

For the MIS system, a separate server having stable, reliable and comprehensive data archiving
capacity to act as a data warehouse & algorithms with client server architecture shall be used. The
server shall be connected to the redundant high speed Ethernet highway. The server shall Read / write
data as required from / to the respective controllers / the MMI stations / the X-ray system / Bulk solid
analyzer system / the EMS system / the refractory management system and any other system
available in the plant intra net that may have the data required by the MIS server like lab data.
The server shall have OPC 2.0 (or latest), programmable controller and other system interface
capability. It shall have its own advanced data archiving algorithms to minimize the size of the memory
used for archiving and at the same time maintaining the integrity of the data values. The server shall
have capability to read / write the data in the same format as available in the controller / MMI or
other system & does not require any conversion of data. It shall support 16 & 32 bit float, integer,
BCD, ASCII, binary, I/O image, string data. However for writing of data in to the controller / MMI the
`write attribute of the respective tag shall be enabled by the user. The server shall have auto archiving
mechanisms with backup. The information about other systems that are not in the scope but are
required for the server interface should be possible.
MIS Server suitable for entire plant shall be provided. It shall have the following features for the data
archiving. Data handling having tag name (this tag names shall be same as that used in the control
system), tag description, engineering unit, sample rate, scan classes, data type, range, zero, span,
filtering, dead band, square root, linearising, alarms, multiplication factors, compression and
expansion algorithms, buffers, snap shots, queue, data error reporting etc. The sampling and archiving
of data shall be designed and engineered to take samples automatically from the required system in a
fashion that wont unduly load the high speed bus, the controllers / MMI and also the CPU / memory
utilization of the MIS server. The server shall also have facility to enter manual data in to the database.
The servers hard disc shall hold at least 5 years of plant-archived data.
The server shall have its own maintenance & system management tools to configure the tags,
interface configuration, archive, server management, health check to check the functioning of the
drivers, interfaces, buffer status, archiving activity, read snap shot & archived data, manual archiving,
archive backup routines, archive deletion / inclusion, archive force shifting etc. the server shall have
API, ODBC, OLEDB, OPC interface and data link for RDBMS like Oracle and shall have Excel add-ins for
import / export of data.
Apart from archiving, the server shall have plant view graphics, trends, reports; log sheets as
mentioned below and clients having access privilege in the plant wide intranet can view these. The
same shall be available through World Wide Web. The server shall have powerful SQC, SPC &
calculation ability with performance equation calculation for report generation like production report,
electrical energy report, total & specific heat / power consumptions, operator efficiency, machine
efficiency, machine productivity, heat balance, false air, running hour, idle running hour, plant
stoppage report etc. These report configuration, development and generation shall be user friendly.
This server shall be an interface to the external systems through the plant intranet like user
department computers, ERP system like purchase, stores, maintenance, costing, finance, sales and
interface to the EDP data server. The server shall have necessary hardware, software, interfaces,
drives, security features & firewalls for web connectivity. Through this connectivity the plant
information & status can be made available for viewing at places across the country.
The Management Information software shall be developed for Production Sequence log, Field Statistic
log and Production reports as per the details furnished below. These reports shall be user defined,
user configurable & user modifiable. There shall not be any limit on the number of reports:
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4.4.1 PRODUCTION SEQUENCE REPORT

The production sequence log shall contain all operational messages, operational faults and EVENT
alarms in chronological order. EVENT alarms shall only be stored at their appearance. Operational
messages shall include important events only (e.g. start/stop of group on/off of a loop, etc.). A
minimum of 2000 messages shall be stored and printed out on request. Each message shall include
message number, plant reference code, designation of event, date and time.
EVENT messages shall be easily selectable to be displayed or printed. At least two search criterias (e.g.
plant identification code and period of time) shall be available for easy retrieval of stored messages.
4.4.2 FAULT STATISTIC LOG

Statistics shall be kept on all "FAILURE" and "WARNING-ALARMS and DIAGNOSTIC information of the
particular equipment.
The alarms for the particular plant departments and within the plant departments according to control
groups shall be logged. The following shall be printed-out for each of the alarm:
Plant identification code, clear text, counter reading. The statistic logs shall be printed-out on request,
without resetting of the counters.
4.4.3 PRODUCTION REPORTS

The system shall automatically generate a shift report after each shift, a daily report at the end of the
last shift and a monthly report at the end of each month. Print-out shall be on request, except the
daily report, which shall be printed-out automatically.
The reports shall contain all basic production and consumption figure sorted per department e.g.
integrated values of all products, storage capacities at the beginning and at the end of the report,
maximum-mean-and minimum production and process values, running hours, total and specific
consumption.
The production reports shall indicate a computer stop during the reporting period (if any). Printingout of any content available on the displays shall be possible.
It shall easily be possible to modify titles and the content of the report. It shall also be possible to
manually enter additional information to the finished report.
The operator shall also be able to request the following reports:
4.4.4 ACTUAL REPORT:

Report from the beginning of the current shift to the actual time.
4.4.5 SHIFT REPORT:

Report over any one of the last 3 completed shifts.


4.4.6 DAILY REPORT :

Report over the last completed day. (End of last shift)

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4.4.7 WEEKLY / MONTHLY REPORT:

Report over the last completed week / month.


4.4.8 RELATIVE REPORT:

Report from the last reset of relative values to the actual time.
The system shall also provide remote work place approach to interface with stores, purchase, finance,
maintenance for production related activities.

PLANT OPTIMIZATION PACKAGE

4.5

SCOPE OF WORK
Supply, installation and implementation of Optimization system in the following areas at our ANICPL
works, with supply of all software with original licenses, Hardwares, implementation and
commissioning

4.5.1

Cement Mill Roll Press with finish mode / Roller press with Ball mill circuit (optional) Main M/C
Supplier Details Shall be Furnished Later
Pre-configuration of the system will be taken up at your premises with proven strategy for a plant of
similar design and process. These approach concepts in conjunction with our methodology as
prescribed in our discussions shall be used as the basis for commissioning.
The equipment test should be conducted in fully integrated system. Initial performance tests will be
carried out using benchmark strategies. Both tests should be conducted prior to shipment.

4.5.2 SOFTWARE MODULES

S.NO

DESCRIPTION

Expert Optimizer Basic Software and Toolkit license including

ANICPL

1 x Expert Optimizer Toolkit

1 x Operator Display Client (ODC)

1 x SPC Module

1 x Personal Assistant

1 x DCS Connectivity

1 x Cement Mill strategy

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4.5.3 DOCUMENTATION

The following documents shall be provided for reference of purchaser prior to dispatch of equipment:
4.5.4 HARDWARE C&I

Detailed descriptions, catalogs, O & M manuals, drawings and diagrams of all hardware supplied,
containing:
- Functional descriptions of systems, system manual (Complete DCS System)
- Functional descriptions of keyboard, MMI, I/O, power supplies, panels, etc.
- Procedure to operate and handle control equipment, controller, I/O, Data cabling, EMC
guidelines.
- Procedure to test, calibrate and trouble shoot.
- Maintenance descriptions
- Adjustment of ranges, parameters etc.
- Field bus, I/O bus, data highway system cable specifications, network calculations & procedures
for interface
- G.A, internal layout of the control desks, special furniture, and GA & wiring scheme of I/O panel,
processor panel, Field mounted I/O panel, power distribution board and junction boxes with
complete bill of material.
- System configuration diagram showing field bus instruments / drives, I/O, controllers, EMS, X-ray
system, bulk solid analyzer system, refractory management system & MMI stations showing
approximate distance, type of media used and other major components in the network.
- Service support policy with respect to hardware and software supplied.
4.5.5 SOFTWARE

Detailed functional description of all standard software packages including OS as well as the usersoftware for:
- Supervisory level system (MMI) including graphics / tag / trends configuration &
development, event, alarm generation, OPC interface, Active X controls, Library, control loop
tuning, backup utility etc.
- Department level system controller, I/O and communication channels, programming,
configuration, diagnosis, troubleshooting, instruction sets, and description
- Any other system containing Software packages like MIS, EMS system, optimization package etc.
- Field bus devices (Profibus) / drives
The Instruction shall include
- Information to carry out changes and adjustments, setting parameters, ranges,etc.
- Functional plans providing easy understanding of package.
- Functional descriptions of special systems, e.g. PID Loops, fuzzy controllers
- Procedures of documentation and storage.
4.5.6 PROCESS CONTROL DESCRIPTIONS

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- Detailed description of each individual process group of the plant.


- Procedure descriptions for Start and "Stop" Orders, group, individual drive (DOL / RDOL), path
selection, interlocking for safety / process, graphics coloring and animation scheme.
- Parameter setting and adjustment for set points, PID faceplates,
- Emergency procedures
With respect to documentation also refer to section 3.9
4.5.7 GENERAL

1. Number of nodes connected on profibus shall be as per Annexure-B enclosed in Scope of Supply
& Price Schedule
2. Profibus connector shall be with LED indication and suitable to connect diagnostic tool shall be
considered
3. Dualised servers in the system have been considered with parallel hot redundancy.
4. Processors shall be suitable for continuous running in 50 deg C room temperature.
5. Following shall be considered for profibus network
a)
b)
c)
d)
e)
f)
g)

I/O cubicle
MCC.
Transmitter.
Drive.
SCS.
MV Panels
Meters

Maximum DP nodes shall be limited to 30 Nos. and with repeater 60 nos. for MCC, 40 DP
node for SCSs & VFDs and execution of data within 500 msec to be ensured.PA nodes shall be
limited to15 Nos per segment with max 3 segments.
6. Minimum 1.5 Mbps speed shall be maintained between the following
a)
b)
c)
d)

Processor to I/O cubicle.


Processor to MCC.
Processor to Field DP.
One set of optical cable termination kit and testing equipment shall be included in the
scope.
7. OPC connectivity for CEM, Opacity, X-ray, SAP and Fire alarm shall be considered.
8. 40% spare tag license and 40% spare library function have been considered after handling over
the plant.
9. All DCS Controllers shall be placed in respective sub-stations Cabinets. For each department
separate cabinet shall be considered for processor.
10.Power shall be made available at 230V AC, 1-Phase, 50 Hz by customer. Other voltage, if
required shall be arranged by supplier.
11.The spares without change in the design and features shall be supplied for 10 years.
12.The time period for obsolescence for the presently manufactured hardware shall be providing
for 10 years.

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13. Minimum five engineers and four Forman shall be deputed for engineering and site
supervision.
14. The disk capacity for data storage shall be for the period of atleast 3 months.
15. Release version of software of MMC level and group level processor shall be latest one.
16. Changes in supervisory software shall be effected through Engineering station & shall be
updated automatically to all operating stations. The operator shall remain active while such
changes are carried out.
17. Default status of outputs shall attain in the event of failure of any of the group PCs.
18. The system shall have multi window features simultaneously active.
19. Freely configurable trend graphs ready for instant use shall be made available during post
commissioning period besides pre assigned trends.
20. The system shall display the overview of the system hardware in block diagram and any
hardware fault shall be displayed by change in colour. A comprehensive diagnostic shall be
included to monitor hardware status on all the operator stations.
21. DP/PA coupler shall be supplied with end terminator.
22. For all I/O panel and processor panels, Thickness for load bearing member shall be 2 mm and
for non load bearing member shall be 1.6 mm.
23. Special tools, tackles, erection hardware etc. required for successful installation and
commissioning of the complete system shall be included in the scope of supply whether
specifically mentioned in this document or not.
24. The operator station shall be workstation grade PC with latest Configuration not ordinary
server/commercial grade.
25. For MIS & EMS separate Server/PC at the OS level should be provided with necessary software
and hardware for interface with Main Plant DCS. License for MIS and engineering software
shall be valid for 5 remote (Web display clients) & 5 local clients.
26. Surge suppressor will be provided on input as well as output side of each communication bus
of MTL/Phoenix make.
27. All operating system software (Windows (latest compatible with the offered system))
platforms shall be in single platform except server at OS / Engineering level.
28. Fire-wall with anti-virus software with license CD shall be provided for all OS/Server grade
applications.
29. MIS/EMS package Manager shall be suitable for energy management system.
30. All field digital signals shall be routed through a glass fuse of 2 amp rating.
31. The quantity / inventory or spare hardware, which would be maintained at site by the supplier
for instant replacement during the warranty period shall maintain by his own spares for
commissioning at site other than procured by the customer.
32. There shall be free upgradation of softwares with License and required hardware if new
SCADA and controller programming software in case the supplied software goes obsolete
within 3 years of commissioning and shall confirm to extend Product & Service support for 10
years from commissioning.
33. Heater with thermostat for all panels for 3 deg C shall be considered.
34. 1 no. Profibus board for EMS at all station shall be considered.
35. CPP data interface to view its MIS & Plant view software and hardware.
36. Future plant expansion data exchange for view & control with existing server & clients.
37. Auto schedule system back up facility.
38. Free training for 8 engineers at suppliers works for DCS.
39. Voice alarm facility shall be considered.
40. Forced IO list schedule updates & report to MIS.
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41. Signal forcing registration in system with time stamp & user name.
42. System configuration, SCS networking, DP/PA networking, Drawings / documents attachment
to object, fault navigation, asset management short notes on logic, plant overview pages to be
define & dynamically updated wherever possible.
43. Alarm event suppression for pin point information.
44. Plant efficiency calculation sheet shall be furnished after plant commissioning.
45. General purpose CCTV system shall interface to the LAN.
46. MIS/EMS shall be understood deeply with third party interface and protection against
unauthorised access & virus.
47. 20% spare networking hardware shall be considered.
48. Fibre & Networking cable shall be colour coded & meter marking.
49. AMC comprehensive for 1 year for UPS, Telephones etc.
50. Critical system finalisation with Technical recommendations from ANICPL.
51. EO commissioning starts within 3 months and final commissioning with in 6 months after plant
commissioning.
52. Commissioning spare kit shall be available with commissioning engineers.
53. Service agreement for 3 visits/3days per year for 1 year and two emergency visit.
54. CCR printers shall be IP printers & others shall be USB printers.
55. No settlement in between Project execution for anything required for system completion and
for best engineering practise to complete the system. Any settlement will be settled after plant
start up. Execution shall not suffer on account of it.
56. Dash board shall be provided in MIS for non reporting parameters.
57. Model predict control shall be part of EO.
58. Alarm/event suppression for pin point information
59. Totaliser updation time shall be configurable 10msec to 10 sec.
60. Battery back up capacity for controller shall be 360 Hrs.
Supervisory control level (MMI) shall be so configured that the operation, faults and alarms of Packing
Plant can also be monitored in operator station in CCR apart from control through packing plant
control room.
The computer platform for Engineering station, optimisation systems and process engineers system
shall be identical to plant supervisory control system.
Total numbers of close loop controls are estimated around 35. These closed loops are combination of
pulse / analog output.
The following redundancy schemes are to be followed for the control system. At I/O level redundancy
of power supply has been envisaged. For the network cabling, MMI level High speed Ethernet shall
have a hot redundant architecture. That is two data media are laid in two different roots. The I/Os in
different shipping sections of MCC are to be interconnected with similar two numbers of data media.
For the profibus bus cabling to the field transmitters / devices profibus cable are to be laid up to the
segment coupler / linking device. Each stub / branch need not to have redundancy.
Armoured type cables should be considered for OFC, UTP, STP, Coaxial, screened cables and all other
data cables which are going to outside the room. However, there shall not be any compromise on
performance, functionality, EMI / EMC aspects, Electrical environment & disturbance immunity
compliance, protection against impulse voltage, HV electrical noise / surge, burst disturbance,
electrostatic discharge, RF interference and availability.
Optical Fiber Cables shall have a rugged construction, excellent mechanical protection and superior
protection in adverse environments . The armoring shall be of aluminum or steel. It shall have
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protection from crushing, cutting and rodents. It shall be suitable for Industrial environments, Inter
and Intra Building Installations. It shall have hybrid compositions in loose tube or tight buffer
constructions. It shall have gel filled buffer tubes to prevent water migration and fiber sub-units shall
be colour coded for easy identification. It shall have length markings in meters for easy determination
of cable length.
4.5.8 SURGE & LIGHTNING PROTECTION DEVICES

Surge & Lightning protection devices at the input power supply line of UPS, PLC Cabinets, VFD panels
etc:
The device used in this application shall be of stage II/ Class c type. The surge current handling capacity
of device shall 20KA of 8/20 uS waveform and for the rated voltage. The device shall be pluggable and
shall have the necessary diagnostic functions like overload Indication and remote outputs. It shall
confirm to the latest IEC 61643-12.
Surge & Lightning protection devices for Profibus and Serial interface:
The device (for the required 2-wire or 4-wire Interface) shall have the surge handling capacity of 10KA
(Core-Core) and 20 KA (between Core- Ground). The device shall be pluggable and on-site testable. It
shall confirm to the latest IEC 61643-21.
Surge & Lightning protection devices for Ethernet:
The device for Ethernet networks (Along with RJ45 connectors) shall be able to protect all signal paths.
The discharge surge current handling capacity of device shall be 350 A/ 2.5KA (Between Core-Core/
Core-Ground) of 8/20 uS waveform. The protection adapter shall fulfill the performance requirement
and transmission quality in acc with class D (cat. 5e). The device shall confirm the test standards in acc
with IEC-61643-21.
Surge protection devices shall be considered for neutral also.
4.5.9 CONTROL DESK

Control desks have been envisaged for Main plant CCR, Packing plant control room & Associated DCS
Engineering room.
Central Control Desk and Local Desk
i) The basic frame work of control desk shall be made from 50x50x6mm MS angle or 30x30x3.2mm
Aluminum angle with extruded Aluminum members bolted construction. CRCA sheets of 2mm
thickness shall be used on all sides and at the bottom of desk and door shall be made from 1.5
mm thick CRCA sheets with suitable stiffeners. Supports for mounting, terminals, PC related
instruments, speaker, power supply units, Power Distribution Boards, etc. shall be provided.
Removable type undrilled cable gland plate shall be provided at the bottom. The aluminum sheet
shall be anodized.
ii) Control desk shall be sand blasted and shall undergo phosphatising treatment after
fabrication of desk. This will be followed by two coats of zinc chromate primer and thereafter

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two coats of air drying nitrocellulose base synthetic enamel paint. The paint shade shall be
decided later in consultation with customer.
iii)Control desk shall be dust and vermin proof, totally enclosed, free standing type. Neoprene
gaskets shall be provided wherever necessary for complete dust proofing. The class of
protection shall be IP42.
iv) Industrial type compact fluorescent tube lights with proper diffuser shall be provided for
illumination of the interior of the control desk and shall have DP MCB for switching. Minimum
two nos of cooling fans shall be provided on the door of control desk for the exhaust of heat
dissipated by computer.
v) Earth bus bar shall be of 35x8 mm copper running through the desk and two numbers terminals
shall be provided for panel body earthing. All the sheet metal body parts, doors and metal
covers of equipments inside the control desk shall be earthed.
vi) Colour Monitors, Key boards, mouse, printers, Public Address System Master Unit, Walkie Talkie
Station, P&T telephone, intercom telephone, CCTV switching unit, Process Log Books etc. Shall
be mounted / placed on Control Desk in appropriate cutouts / suitable arrangements.
vii) Central Control Desk with colour monitors & keyboards shall be configured in U-shape and
sectionalized as per the process departments.
viii) Internal wiring of the control desk shall be done by 2.5 sq.mm PVC insulated stranded copper
conductor.
ix) PVC cable channels shall be provided for panels / desk power, data internal wiring. Data cables
are to be routed away from that of power wirings as per guidelines. Suitable openings are to
be provided between sections of the control desk for inter panel wiring.
x) PVC sleeve number ferrules shall be provided at both the ends of complete internal wiring to
identify their terminal details.
xi) 230 VAC UPS supply shall be provided of adequate capacity at one point of the control desk.
For power distribution tapping within the control desk suitable size copper bus with pre drilled
holes with bolt & nuts are to be used. Proper acrylic shrouding is to be provided for this bus.
Each section of control desk shall be provided with Necessary Incoming MCB, outlet MCB and
sockets for feeding power to PA system, wireless sets, and monitors, PCs, speaker and printers.
Each section of control desk shall also comprise MCB of suitable rating for isolation of power.
Similar arrangement shall also be made for 230 VAC Non-UPS supply to be provided by
purchaser at one point. Service sockets and lighting of control desk shall be done with Non-UPS
supply. Clear markings are to be done to identify UPS supply from Non-UPS supply. These MCB
and power sockets are to be placed having easy access.
xii) The control desk and the associated furniture shall be ergonomically designed as per standard
industrial practices for comfortable working to the operators. At the same time due care to be
taken for the aesthetic look of the same. The control desk shall have hinged doors both on
front and backside. Suitable intake & outlet louvers are to be provided for natural air-cooling.
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There shall be ample space in side for keeping the PCs, speakers, power supplies etc.
xiii) As per the configuration diagram enclosed the Main control desk at CCR shall house the PCs &
monitors for MMI stations, optimization package, One for refractory management system, one
for Quality control lab data, one for MIS, One for EMS, one wireless station, two or three
telephones, one or two PA stations, one PA master console and one CCTV switching unit.
The control desk for packing plant shall be identical and suitable to accommodate the touch
screen type monitor with additional protection from dust entry.
4.5.10 PROCESSOR AND I/O PANEL

For all I/O panel and processor panels, Thickness for load bearing member shall be 2 mm and for non
load bearing member shall be 1.6 mm.
with IP42 protection having solid base frame. They shall be internally wired up to 2.5 mm Sq. size
screwed terminal strips. Internal wiring of panels shall be done by 1 /1.5 mm sq. 1.1 KV grade, 90
Deg.C, PVC insulated stranded tinned copper conductors having tinned copper braided shield.
Analogue and digital signal shall be strictly separated. It is intended to have CPU and I/O in the
separate panel. The programmable controllers shall have separate panels and located in the
Distributed locations control room. The processor panels shall have sufficient space for keeping the
Ethernet switches, field bus interface cards, I/O interface cards, power supplies and the associated
cables. Suitable means of natural & forced ventilation ( with min. 2 nos. of cooling fans) are to be
provided for the panels to evacuate the heat generated in the I/O modules, power supplies, controller
etc.
Power wirings are to be laid away from I/O and data cables. For I/O panels that may have high density
of I/O, shall be of front & back opening front side the I/O, power supplies are mounted /accessed and
necessary terminals if any are to be mounted at the rear side for working convenience. For
programmable controller panels front opening is sufficient.
The I/O panels & controllers shall be installed in each plant area near to the respective motor control
stations / integrated to the MCC and shall be suitable for operation at site ambient temperature. I/O
panels that are required to be mounted at field away from MCC rooms etc shall have IP65 protection.
Controllers & IO panels shall be with RTD for monitoring of Room temperature.
Industrial type fluorescent tube lights with diffuser shall be provided for illumination of the interior of
the panels with DP MCB protection. Suitable rated DP MCB are to be provided for the incoming as well
as for distribution of power in side such panels. A copper earth bus of 25x6 mm with pre-drilled holes
is to be provided at the bottom of the panels. All the metal parts, doors are to be connected to this
earth bus. Special care has to be taken considering the EMC guidelines. All the necessary &
appropriate measures like providing of surge suppressor, filter, Ferrite beads, shielding etc. are to be
done for reducing the effect of EMI in the system and its components in an industrial atmosphere
All cable entries are from bottom. Removable, undrilled sheet steel gland plate to be provided at the
bottom of panels. No terminal block or any other components for that matter are to be placed up to
350 mm from the bottom for glanding and dressing of cables.
Sufficient and necessary measures are to be considered for reducing the effect of false sensing of
inputs due to induction voltages associated with 230V AC for interfacing and long multi core cables.
Suitable earth terminals are to be provided for tying unused cores. Vitreous enameled, wire 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 input channels of
I/O like ZSS, belt starvation switches.

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These panels shall be sand blasted and shall undergo phosphatising treatment after fabrication of
panel. Two coats of zinc chromate primer and thereafter two coats of air drying nitrocellulose base
synthetic enamel paint shall follow this. The paint shade of processor panels and I/O Panels shall RAL
7035 of DIN.
SPECIFICATION OF CHAIRS
Chairs are envisaged for sitting of operational person in front of VDU in Control rooms.

4.5.11

Chairs shall be executive type and very comfortable to sit. It shall be revolving type. It shall be rugged
in construction. The design of chairs shall be as per ISO 9241, Part-5 standards. The chair shall be
designed considering below minimum specs

chair back strength of 150 pounds (68 kg)

chair stability if weight is transferred completely to the front or back legs

leg strength of 75 pounds (34 kg) applied one inch (25 mm) from the bottom of the leg

seat strength of 225 pounds (102 kg) dropped from six inches (150 mm) above the seat

seat cycle strength of 100,000 repetitions of 125 pounds (57 kg) dropped from 2 inches (50
mm) above the seat

5.0 UN-INTERRUPTED POWER SUPPLY SYSTEMS (UPS) & DISTRIBUTION BOARD


5.1

UNINTERRUPTED POWER SUPPLY UNIT


Un-interrupted power supply (UPS) system including switchboards with input isolation transformer,
output stabliser with power distribution Board for supervisory computers, group level processors and
field instruments, Lab Automation system etc.
System Details
The online UPS & power distribution panels shall be totally enclosed, free standing, dust and vermin
proof with enclosure class IP-42 with bottom cable entry. Sheet steel thickness shall be 2mm (min.)
with suitable base frame. Paint shade shall be RAL 7035 as per DIN. Battery stand color shall be RAL
7035. Minimum 350mm gap shall be maintained between Gland plate & Terminals / component
mounting. Panel size (minimum width & depth as 800mm) shall be adequate to have good
maintainability space. UPS and Battery Panel frame and Base frame shall be black with anti corrosive.
All the Cable entry shall be from bottom of panel only. At the bottom of the UPS panel (Air Inlet),
necessary filters shall be provided for avoiding the dust entry due to the cooling fan suction.
The input AC voltage of 415V +10%, -20%, 3 phase, 3 wires, 50 Hz + 5% shall be provided by the
purchaser. Isolation transformer shall be used for isolation of line voltage. The input AC voltage shall
be rectified to DC and filtered. The rectified voltage shall be fed to the inverter and battery bank. The
rectified voltage shall be converted in the inverter to a highly accurate stable & constant AC voltage &
frequency. UPS shall be designed for the operating temperature of 40 Deg C.
Both the UPS in each station shall be operating in parallel redundant configuration mode. They shall
have a redundant & faster mode of communication with optical link and placed side by side. Any one
of these UPS can be selected as master as required by the user / system. Suitable arrangements shall
be made to avoid reverse power flow from one UPS to other. However both UPS in this case shall be
considered as an independent UPS in all respects like separate dual input / output / battery
switchgear, inverter, converter, battery charging circuits and control electronics. These UPS can be
operated in all respects individually if required. Suitable control and switching scheme are to be

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considered for synchronization, sharing the load at the output, taking the entire load in the event of
failure of any one UPS, charging of the battery by any one of the UPS either the master or the one that
is live and without fault or both the UPS sharing the battery load. Each UPS shall have provision for
two incomers. The system shall be able to keep a single unit isolated either partially or fully in the
event of disturbances like a simple fuse failure to failure of the entire inverter (any type of one single
failure) without affecting the load. Once the faulty UPS is restored the same shall be put in line and
start sharing the load along with the other one without affecting the load. Paralleling either at DC level
for battery charging or at the AC output bus, the control shall be decentralized to maintain true
redundancy otherwise if independent control is used redundancy shall be considered there also.
Bypass arrangement shall be considered, in case of both UPS fails. Suitable Servo Control Voltage
Stabilizer (SCVS) with isolation transformer shall be provided.
UPS system of each station shall be designed in such fashion that in normal condition both the UPS will
work and each share 50 % of total connected Load and supplying to a common output bus. In the
event of failure of one of the UPS, entire load will be taken care by another UPS automatically without
any time delay i.e. bump less transfer so that none of the plant control system components /
equipments like controllers, PCs, I/O, communication modules, field instruments, X- ray analyzer, bulk
solid analyzer, EMS, MIS, optimization systems are get affected. The Plant Control & Instrumentation
Load shall connect to a common circuit of both the UPSs comprising static switches through main UPS
distribution board. In the event of failure of input AC voltage, power supply shall be made available
from battery.
Common Amarraja/HBL make 1.2 V NiCad battery bank with 02 / 01/ 0.5 Hr backup in hot redundancy
mode with normal operation load sharing having transparent Styrene acrylonitrile container & micro
porous ceramic vent plugs suitable for 60 minutes back up at 100% loading. The battery charging
facility shall be built-in the UPS unit.
UPS shall have individual Input & Output source selection panel. All the UPS shall be considered with
different incoming power supply considered for reliable / redundant operation. For better
maintenance / isolation the UPS output isolator shall be provided in source selection panel itself. In
the event of failure of any one supply second shall immediately take over. Changeover switch shall be
considered for input selection. Changeover switch rating shall be one step higher than the incomer
rating of the UPS panel. All the UPS ratings shall be at 40 Deg.C ambient. All the UPS systems shall be
of modular design and shall be of same platform or model / series except for the change in the ratings.
UPS batteries shall be initially charging through UPS.
Application:
To provide UPS to critical loads in cement plant control & instrumentation systems including nonlinear loads like computers, monitors, SMPS, Programmable controllers, I/O sub systems,
communication modules, X- ray analyzer, Bulk solid analyzer (BSA), MIS server, EMS, field instruments
etc.

Rectifier Type
Digitally controlled 3 phase full wave fully controlled, 12 pulses, Thyristor Bridge or IGBT active
rectifier with necessary isolation transformer, commutating line reactors, harmonic filters, incoming
isolators, fuses etc.There shall be a switching mechanism for adopting between two incoming supplies.
Input
Output
ANICPL

: 415Volt +10%,-20%,50Hz + 6%,3 phase, 3 wire,60 MVA (50 KA)


: As per design requirement (the rectifier shall be rated to handle up
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to 25 % of harmonic current at the input bus.)


: + 0.5%

Accuracy
Overload capacity

: i) 125% for 10 minutes


ii) 150% for 2 minutes
iii) 200% for 10 secs.

Input Power factor


Input total harmonics

: > 0.95
: < 10 %

DC ripple without battery : < 1 %


Converter efficiency
: > 95 %
Rectifier paralleling
Protection

: yes

HRC fuse at incoming side

Semi-conductor fuse with micro switch for thyristor/IGBT protection.

Electronic Overload relay including instantaneous over current and earth


fault

Surge suppressors/ protections

Isolation MCCB for battery

Inverter Type
Digitally controlled, sine wave, Pulse width modulated IGBT bridge with necessary output filters and
isolation transformer having voltage and frequency independent control operation.
Input
: As per design requirement
Output
: 230VAC as per requirement as mentioned
earlier, single phase (+5 % Adjustable)
Voltage regulationStatic
Recovery time + 1 % in 20 ms
Output voltage distortion
Frequency regulation
Frequency Syn. Window
Output
Protection :
Overload at 0.8 PF
Inverter efficiency
Crest factor
Non-linear load compatibility
Capacity to clear branch
circuit fuses
ANICPL

: + 1%, Dynamic:+5% for 100% load change


:

< 5 % with non-linear load


< 1 % with linear load

: Static: + 0.5%
: + 1 Hz
: True sine wave
Short circuit and overload including
Instantaneous overload and earth fault
Electronic sensing and operation
: 125%
overload
for
10
minutes,150%overload for 2 minutes,
200% overload for 10 secs.
: > 92 %
: 3:1
: up to 100%
: Yes

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Duty
: Continuous
Overall efficiency
: > 92 %
Losses at No Load
: Supplier to Furnish
Total harmonic content at output
: <5%
Noise level :
< 80 dB at 1 meter
%Load Sharing difference between
: to be furnished by Supplier
Parallel UPS
EMC / EMI compliance
: to be furnished by Supplier
MTBF
: to be furnished by Supplier
Transfer time from Bypass to UPS in Sync
: < 5 msec
Transfer time from UPS to Bypass in Sync
: < 5 msec
Transfer time from UPS to Bypass in UnSync
: < 20 msec
Communication interface
: profibus communication with main dcs
Software tool
Windows based software tool with necessary interface and cable for UPS monitoring & diagnosis
including remote monitoring and interrogation, monitoring of alarms, faults, metering indications,
data logging, status of UPS and battery, setup, tuning, commissioning & maintenance of UPS.
Alarm and Interlocking
Following potential free normally open and fail safe contacts 2A @ 250 V AC, shall be provided for
alarm / annunciation on central control desk:

Battery voltage low pre alarm


Failure of UPS - I
Failure of UPS-II (as the case may be)
DC low voltage
DC high voltage
Load on battery

Following indication shall be provided on the front panel. For these indications a comprehensive, fully
digital, alphanumeric LCD display with membrane key pad & audio alarm buzzer shall be provided for
metering, status / fault / alarm display, mimic, diagnosis, controls, issuing commands like On/ off,
setting up, tuning troubleshooting, testing and commissioning of the UPS. This display shall indicate
the status, alarm, fault etc. in clear text indicating the exact fault / alarm:
Indication

ANICPL

Boost charging
Normal charging (trickle)
Main supply connected to rectifier
Load connected to UPS I
Load connected to UPS II
Load Connected to both UPS
Failure of rectifier unit - UPS I
Failure of rectifier unit - UPS II
Failure of inverter unit - UPS I
Failure of inverter unit - UPS II

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General All other specific alarm / fault indication


Communication failure between two UPS
Battery voltage low / high
Battery low pre alarm / trip
Rectifier / inverter over temperature
Output overload
Converter & inverter on
UPS OK/ Fault
Battery earth fault

Metering & indication required for:


Incoming AC- 3 phase voltage, current, power factor, frequency, DC link voltage, battery voltage,
battery charging & discharging current, backup time (battery autonomy time), inverter output
voltage, current, frequency, KW, KVA, date & time, time on battery, and power modules heat sink
temperature. These shall be indicated in the alphanumeric display of front panel.
Controls:
Emergency stop, UPS on/ off, selection of metering display, UPS setup, tuning, acknowledge / reset of
alarm / fault, cooling fan controls, MCB, fuses, LCD display etc.
Servo Control Voltage Stabilizer with Isolation Transformer:
Input Configuration
:
3 Phase, 4-Wire
Input Voltage Range
:
365V to 460V AC
Input Frequency Range
:
47 to 53 Hz
Nominal Output Voltage
:
230VAC, 50Hz,
Output Voltage Regulation
:
+/- 1% of Nominal Voltage
Servo Motor Drive
:
AC Synchronous Servo Motor
Efficiency
:
> 95 %
Average Rate of Correction
:
20V/Sec
Class of Insulation for Isolation Transformer: H or better
Controls for Protections:
Output Over /Under Voltage : + / - 5 % of nominal voltage , Pot free Contacts
Isolator at Input: MCCB of suitable rating
Annunciation Panel:
Digital meter for I/p & o/p Voltage, Current & Frequency monitoring
Audio alarm with reset facility for Output High /Low/Overload.
Input /Output Terminations
Type of Cooling
System Features
Monitoring
System status on,
Mains on
DC system fault
ANICPL

: Bursar
: Natural or Forced cooling, as per design requirements.

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TECHNICAL SPECIFICATION FOR CONTROL &
INSTRUMENTATION

Protection

16/12/2011
Rev - 0

Inverter over/under voltage (AC & DC)


Static switch position
Maintenance (alt.) power failure
Real time battery status
Converter and inverter temperature
AC line under / over voltage, phase loss
DC link over / under voltage
Battery open

AC input breaker
DC output fuse/breaker
Battery fuse/breaker
Automatic charge control according to the rate and duration of battery
discharge
Rectifier current limit
Reverse battery protection
Inverter short circuit and current limit protection
Static switch power circuit failure
Battery low voltage
Inverter output breaker
Inverter output short circuit, earth fault & overload
Converter and inverter temperature
DC link over / under voltage
There shall be an intelligent battery management system with microprocessor controlled;
temperature compensated battery-charging system with trickle and boost charging. There shall be a
display available for indicating the battery backup time at the present load conditions. Also the
charging of battery after an input power failure shall be according to the rate of battery discharge and
the duration of discharge and the condition / type of battery thereby increasing battery efficiency and
life. A programmable automatic battery-testing feature shall be included. The battery charging system
shall be suitable for the initial battery charge / discharge cycles required during commissioning.
For power wiring inside the panels, only electrolytic grade copper bus bars shall be used. For lower
power and for small lengths, high conductivity, multi strand, PVC insulated, 1100 V grade, flexible
cables with hydraulically crimped lugs at the ends may be used. The cross section details of the bus bar
/ cable are to be furnished in the offer. The copper bus bars shall be sleeved. The bus bars shall be
suitably supported to avoid stress on the terminals / connections. Copper cable between UPS and
Battery bank shall be supplied. Between battery stands, copper cables shall be used for
interconnection.
All cable entry shall be from the bottom of the panel and a removable undrilled gland plate shall be
provided. No components / devices are to be mounted above such gland plates for up to 500 mm. This
clearance is required for termination of power cables. All Power modules and components shall be
accessible from front of panel only, in case rear access being a must, it shall be indicated clearly in the
bid.
The cooling arrangement shall be that the cooling air passes through the heat sinks in a separate duct
to prevent re-circulation of cooling air inside the panel & dust deposition. The cooling air duct shall be
brought up to the top of the panel / cubicle and vented. The hot air vent duct opening at the top of
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TECHNICAL SPECIFICATION FOR CONTROL &
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Rev - 0

the panel shall have a flange type arrangement with a bolted (removable) sheet steel plate / roof, in
order to provide a suitable ducting arrangement above the panel to lead the hot air out side the room
later if required. No components / accessories / electronic cards shall be in the path / vicinity of the
hot air vented from the UPS. The cooling fans of the UPS shall be able to disassembled for checking /
replacing from the front of the panel and can be replaced during the UPS is on and serving the load.
In the parallel and redundant UPS, necessary and sufficient provisions are to be made for working or
attending the faults in any UPS that has failed while the other continue supplying to the load. Suitable
isolations, shrouding and other safety aspects are to be provided.
5.2 UPS POWER DISTRIBUTION BOARDS

1. Distribution Boards shall be floor mounted type with lifting hooks as per the requirement.
The Main UPS distribution boards for the two UPS systems and the sub distribution boards
meant for each plant section which are located at field / MCC rooms shall be of floor
mounted type only
2. The board shall be heavy duty, totally enclosed; dust and vermin proof (IP 54) having
suitable synthetic rubber gasket for doors. Electrical Danger stickers shall be provided on
the front door. Aluminum anodized, engraved nameplates are to be affixed on the front
door.
3. The board shall be fabricated out of 2mm thick CRCA sheet steel, chemically de rusted,
degreased, phosphatised, primer coated and painted with enamel finish as per DIN RAL
7035 outside and white inside.
4. Base channel (50 x 100mm) shall be provided for floor mounted type panel at the bottom
and painted with black enamel.
5. Doors shall be provided for front operation and shall have padlocking arrangement.
6. The incoming Molded case Circuit Breaker / SFU handle shall be within the door and
operation of the same shall be by opening the door. Same is the case for the outgoing
MCBs also. There shall be no cutout on the door.
7. The DP MCBs on outgoing feeders shall be numbered for their identification.
8. All the phase and neutral bus bars and interconnections shall be colour coded & PVC
sleeved. Transparent acrylic insulating sheet shall be provided for shrouding the live parts.
These bus bars shall be suitably supported with 660 V grade epoxy insulators. These bus
bars shall have suitable sized tapped holes for tapping power to the outgoing MCBs.
Suitable size, colour coded, 1.1KV grade PVC insulated, flexible, multi strand, tinned copper
conductor are to be used for wiring between the Bus bar and the MCB and also for the
MCB to the terminals. These wires are to be provided with identifications on both side and
are laid / dressed in PVC wire ways.
9. For neutral connections, separate neutral bus shall be provided and suitably mounted on
epoxy insulators.
10. Two separate terminals for earthing shall be provided on the panels. These earth studs are
connected to a 25x6 mm copper bus bar having pre drilled and tapped holes running at the
bottom of the panel
11. The board shall be supplied with all interconnections between SFU's, Bus bars and MCBs.
The number and rating of DP MCBs are as required and are mounted on DIN rails for easy
removal & fixing. Suitable size (minimum of 4 Sq.mm) screw on type terminals are to be
provided for phase & neutral of each outgoing MCB with numbering.
12. Extended hylam separators between Double pole MCBs shall be provided to avoid
flashovers from one affecting the other.

ANICPL

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TECHNICAL SPECIFICATION FOR CONTROL &
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Rev - 0

13. Boards shall be suitable for entry of all cable from bottom with undrilled, removable gland
plates.
14. Suitable cable glands and lugs for incoming and outgoing cables shall be provided.
15. Component mounting angle/channel shall be suitably chosen and depth adjusted as per
requirement, so that shrouding sheet covers come in the same vertical plane.
16. Sufficient space for proper termination of incoming and outgoing cables shall be provided
inside the board to facilitate ease of erection, maintenance and repairs. Up to a height of
350 mm shall be left free at the bottom of the panel.
17. Power distribution board shall be provided with earthing strip with screw arrangement.
18. The rating of the incoming MCCB / SFU and outgoing DPMCB are to be well coordinated, so
that any short circuit / earth fault on load side are to be isolated by them without affecting
the UPS.
19. The GA, wiring scheme, rating, BOM of such UPS distributions are to be got approved from
the client.

Junction Boxes
1. Junction boxes shall be heavy duty, wall mounted type, totally enclosed, dust and vermin
proof, enclosure class IP- 54 with synthetic rubber gasket.
2. Junction Boxes be fabricated out of 2 mm thickness sheet, chemically de rusted,
degreased, phosphatised, primer coated and painted with shade RAL 7035 Siemens Gray.
The JB shall have front door either hinged if size is more then 10 terminals or bolted
otherwise. The wall mounting bracket shall be made such that, a gap of 30 mm is
maintained between the JB back side and the mounting plane / wall. Two numbers of earth
studs are to be provided for all JB. For JB having 50 terminal or more shall have one 25 x 3
mm copper earth bus with 5mm pre tapped holes for earthing of shield / drain wires of the
cables.
3. Terminals shall be of screw on type, PVC, DIN rail mounted, suitable for 2.5/1.5 sq.mm
wires with numbering. These terminals are to be fixed at a depth and angle that is
convenient for termination and working and are to be kept projected from the JB back
wall.
4. Junction box shall be provided with 1A/2A glass fuses to avoid inrush of current to the PLC
Modules in case of short circuits etc.
5. Shorting links shall be provided for fused terminals and neutral terminals in each JB. Apart
from the above a set of five earthing terminal blocks of 4 Sq.mm size are to be provided for
JB having 50 terminals and above to terminate spare cores of cables.
6. Sufficient space for proper termination of incoming and outgoing cables shall be provided
inside the junction boxes to facilitate ease of erection, maintenance and repairs. Undrilled
plates are to be provided at the bottom of the JB for cable glanding.
7. PVC channels shall be provided inside junction boxes of 25 terminals and above for proper
dressing and termination ease.
8. Quantity of fuses and shorting links may change during detailed engineering.
9. The GA, dimensional drawing of the different JB are to be got approved from the client.
The purchaser shall approve one number of junction box of each size before the
manufacture of the required quantity
10. 1 no. power socket and light arrangement for 100TB Junction Boxes shall be considered.
11. JB with 100 or more than 100 terminals shall have Light & Power socket.
ANICPL

Engineering & Procurement Tender Document

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TECHNICAL SPECIFICATION FOR CONTROL &
INSTRUMENTATION

16/12/2011
Rev - 0

5.3 C & I SYSTEM CABLES:

All data, field bus, Ethernet, I/O data and CCTV cables that are necessary, including redundant cables
as mentioned in the scope of supply. All connectors, terminators, junction boxes that may require for
these cables shall be the part of system. The outer sheath of these cables are to be colour coded as
per international standards for easy identification.
OFC is envisaged for cables from Programmable controller to Remote I/O and for extension of the high
speed Ethernet to MMI packing plant and to the EMS station at the electrical load centre.
6.0

FIELD INSTRUMENTATION

6.1

GENERAL
Those field instruments, transmitters for measuring temperature, pressure, Air / water flow, level
either continuous or point type, vibration, position, speed, zero speed monitoring etc. meant for
the cement mill both for process control / monitoring, machinery / human safety and that are not
supplied along with the main machinery of any plant which are necessary for the safe, efficient
operation of the plant are included in the scope. The indicative specification of those instruments /
transmitters is given below.
For all the field bus instruments / transmitters either supplied by the Supplier or from the main
machinery supplier, the necessary junction boxes, linking device / segment coupler, repeater, Power
supply, field bus JB, Ts, terminators etc and field bus cables are included in the scope of the
Supplier. Necessary software, drivers and interfaces required for the filed bus instruments like FDT,
DTM etc, GSD, EDS, DDL files, device / transmitter specific software for calibration, configuration,
diagnosis, maintenance, function block changes are included in the scope.
DESIGN DATA AND TECHNICAL SPECIFICATION FOR FIELD PROCESS INSTRUMENTS

6.2

6.2.1 GENERAL SPECIFICATIONS

1.
2.

3.

The suitable compact instruments incorporating latest technology with solid-state modular plug-in
construction.
Necessary companion flanges, clamps, mounting brackets, hardware, JB and other accessories to
make the system complete and operational. Any device not included in the specification but
considered necessary for proper erection, mounting and operation of the equipment shall be
deemed to be within the scope of supply under this specification.
Field mounted instruments should be suitable for satisfactory operation under the environmental
working conditions existing in a cement plant and shall necessarily have dust proof sheet metal
enclosure. Care should also be taken to ensure that rats, lizards and other creeping reptiles cannot
enter the instrument enclosure. Additional enclosure, if required, to give better safety should be
included in the scope of supply. Such enclosures shall have a paint shade of DIN RAL 7035. All field
instruments, segment couplers, power supplies, linking devices etc. which by itself are not
confirming to IP65 enclosure, are to be suitably housed in such enclosures without affecting the
performance, function, working, maintenance and access of the instrument / transmitter

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TECHNICAL SPECIFICATION FOR CONTROL &
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4.

5.
6.
7.
8.
9.
10.
11.
12.
13.

14.
15.
16.

17.

18.
19.

16/12/2011
Rev - 0

To reduce inventory, as far as possible, standard equipment in standard sizes and ratings should be
offered. The purchaser reserves the right to select the equipment of a particular manufacturer /
type / model and the Supplier shall supply equipment of that particular make/ type / model if so
required.
All openings for ventilation and forced draft etc. shall be suitably protected with screens. When
screens are provided on top of the equipment, means shall be provided to protect them from
falling objects.
The equipment should be designed so as to ensure safety of operating and maintenance personnel.
Aspect of ease of maintenance, testing, calibration and repair should be given due consideration
while designing the equipment.
All equipment offered should be sturdy and continuous duty type. The instruments must retain
their guaranteed accuracy/sensitivity/repeatability/ total probable error under the conditions
existing in cement plant i.e. heat, dust and vibration.
The equipment should be tropicalised and given protective dips to prevent any damage due to
fungus, mildew etc.
The power supply available at the plant site is 415V +10%, 3phase, 50 Hz + 5% and 230 V AC+ 10% .
For other control voltages, adequately rated step down transformers/power supply units shall be
provided by the Supplier.
Standard analogue signal for all measuring circuits shall be 4-20 mA DC(Other than profibus) and
shall be isolated. Pressure & Temperature Transmitters, which are in C&I suppliers scope, shall be
Profibus based.
The output signal (4-20mA DC) for all measuring devices / transmitters shall be galvanically group
isolsation shall be provided isolated from the input signal and from the AC power supply,
ground/earth bus.
The admissible burden (external load) connected to the 4-20 mA DC output of a measuring device
shall be approx. 0-600 Ohms.
Appropriate 4 wire / 2 wire transmitters with galvanically isolated 4-20 mA DC signal for remote
measuring indication will be provided in sub-control systems (e.g. DC drive, AC drive, MCC,
Vibration transmitter, actuator with remote position indication, AC current and power
measurement etc) which are being supplied by other manufacturers.
All control loops shall include fail-safe provisions and shall be stable for all process conditions.
Cyclic stability in general will not be acceptable.
All the tapping points on main machinery shall be provided by the Supplier and at other locations,
such as hoppers, ducts, pipes, inlet/outlet chambers etc., these shall be arranged and made by the
selected Supplier as per drawing / as directed at site.
All steel work shall undergo a process of degreasing, pickling, cold rinsing, phosphating and
passivating. It shall be given two coats of high corrosion resistant primer and finished by
application of synthetic enamel paint of shade 631 of IS:5. The final finished thickness of the paint
film shall not be less than 100 micron.
230V AC to Field Instruments shall be fed from Instrument Power Distribution Boards to be
supplied by the selected Supplier. However, 24V DC to transmitters shall be arranged from power
supply units assembled in I/O panels that are supplied by the Supplier. UPS supply shall be provided
only for powering the electronic circuitry / cards and for I/O interface control voltage of 230 VAC
from MCC control transformer are to be used.
Suitable earthing terminals/ points / studs are to be provided for all instruments as per the
requirements.
To the maximum possible extent only Profibus instruments / transmitters shall be used.

ANICPL

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TECHNICAL SPECIFICATION FOR CONTROL &
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20.

16/12/2011
Rev - 0

While designing and engineering a filed bus system, any segment shall be loaded only up to 60 % of
capacity / number of nodes keeping remaining nodes for future expansion. This spare node shall be
evenly distributed in the plant sections / locations. Spare / free junction boxes / slots are to be
provided for this purpose at site.
In case of non-availability of field bus instrument / transmitter for measuring a particular process /
safety related variable, the same shall be clearly stated in the offer with reason. Such instruments
shall be then with 4 20 mA analog output.
For discrete interface of point contact type instruments like limit switches, proximity switches,
level instruments, pressure switches, flow switches etc. with I/O shall be suitable for 230 V AC VAC
+ 10 % 50 HZ + 6% and all relay outputs shall be rated for 5 A at 250 VAC. All sub control systems if
any shall be in 230 V AC level only.
For all the supplied instruments, transmitters, gas analyzers, RTD, Thermocouple, the test and
calibration report / certificate from the manufacture shall be provided.
All relevant catalogues, complete specification sheets, selection guides, write up, field bus profiles,
tools, and function blocks available; communication protocol etc for the offered instruments /
transmitters shall be furnished in the offer.
The range of the instruments shall be provided during detailed Engg.
The final specifications / configuration / type / model / size / rating / range / dimensions / make for
any of the instrument, sensor, thermocouple/RTD, pressure / temperature transmitter, level
transmitter, Vibration transmitter, proximity switches, zero speed switches, timers, pressure
switches, solenoid valves, PLC, level sensor, safety system etc. are to be approved by DCPA before
procurement and supply.

21.
22.

23.
24.
25.
26.

6.2.2

THE GENERAL SPECIFICATION FOR PRESSURE / DP TRANSMITTERS


These transmitters shall have a basic accuracy of +/- 0.075% of calibrated span or better. The
turndown ratio shall be minimum of 1: 100. These transmitters shall have a stability of at least 5
years. The TPE shall be better than 0.1 %. The wetted parts shall be AISI 316 L SS / Viton / PTFE.
Process temperature up to 120 Deg.C. Process flanges, adaptors, plugs are of AISI 316 L SS. Sensor
fill fluid Silicone oil. Process connections shall be or inch NPT with 3 way manifold. Mounting
vertical & horizontal 2 pipe mounting. The transmitters are of blind type without local meter. The
enclosure shall be minimum of IP65. All transmitters shall be Profibus/HART enabled. The exact
model and type number of the transmitters, field bus & the application profile version shall be
clearly indicated in the offer along with catalog and detailed specification sheet. The reason for
choosing a particular field bus system over the other shall be clearly explained in the offer.

6.2.3

DETAILED TECHNICAL SPECIFICATIONS

01 RESISTANCE TEMPERATURE DETECTOR (RTD)


a) Process RTD: All the RTDs to be with head but with no junction connection at the RTD Head &
with 10 mtrs. Of extentendable Teflon cable for direct connection at local junction box.
PT 100, 3 wire, duplex RTD complete with die cast AL. screwed cap, dust & weather proof - IP 67
head with chain, nickel plated, spring loaded brass terminals and ceramic block. Cable entry
ET. Insulation Ceramic beads filled with MgO powder and epoxy sealed. Leads 3 wire, silver &
PTFE insulation. Inset sheath SS316, 8mm OD, Thermo well SS316, 21mm OD and 3 mm wall

ANICPL

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TECHNICAL SPECIFICATION FOR CONTROL &
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16/12/2011
Rev - 0

thickness. Mounting Adjustable C. S flange of 108 mm dia, 4no 16mm dia hole at 79 mm PCD.
Length below head as per process / plant requirement. Calibration DIN 43760.
b) Bearing RTD: All the RTDs to be with head but with no junction connection at the RTD Head &
with 10 mtrs. Of extentendable Teflon cable with GI Conduit for direct connection at local junction
box.
PT 100, 3 wire, duplex RTD complete with die cast AL. screwed cap, dust & weather proof - IP 65
head with chain, nickel plated, spring loaded brass terminals and ceramic block. Cable entry
ET. Insulation Ceramic beads filled with MgO powder and epoxy sealed. Leads 3 wire, silver &
PTFE insulation. Inset sheath SS316, 8mm OD, Mounting with adjustable SS 316 ferrule fitting.
Length below head as per requirement. Calibration DIN 43760.
Size and type of RTD will be informed during detail engineering. It shall be supplied with necessary
fittings/matching flange and without cable.

ANICPL

a)

Limit of error

: + 0.05% or 1.5 deg.C


temp. Whichever is less.

b)

Max. temp. with stand : 400 deg.C continuous


capacity

c)

Type

: Duplex RTD, 3 wire

d)

Type of element

: Pt 100, 25 SWG

e)

Insulation

: Mineral
insulated,
elements
embedded in highly compacted
magnesium oxide insulation within
a seamless metallic tube.

f)

Protective
overall dia

g)

sheath

of actual

and :

SS 316, overall dia 16 mm (will be


specified during detail engineering)

Mounting

Adjustable leak proof flange of


MS
for mounting suitable
immersion length

h)

Head

Screwed type, dust and vermin


proof, cast aluminium, 1/2 BSP
double compression type cable
glands suitable for armoured cable
and porcelain terminal block.

i)

Accessories

Matching flange mounted on


protection tubing of 50mm dia, 400
mm long MS tubing for insertion in
the process, nuts, bolts etc.

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TECHNICAL SPECIFICATION FOR CONTROL &
INSTRUMENTATION

16/12/2011
Rev - 0

02 LEVEL TRANSMITTERS
For applications without weighing systems and requires continuous level monitoring, like clinker /
gypsum/ slag hoppers and silos / bins of fly ash, cement, slag etc suitable continuous level
monitoring transmitter / instruments are to be employed. The selection of such systems shall be
guided by the type of the material, size of the material, stickiness of the material, moisture content
in the material, possible maximum & minimum temperature, condensation, total & effective height,
minimum / blocking distance, hopper / silo / bin size & shape, location of the instrument verses the
inlet & outlet chutes, interfering structures, scattered echoes, attenuation factors with measuring
range, power supply requirements, field bus interface etc. For such applications suitable type /
model, without moving parts, guided wave radar or non-contact ultrasonic (time of flight)
measurement solutions with interference echo / multiple reflection suppression logics, signal
pattern recognition by fuzzy logic, user friendly, having easy commissioning and setup features . The
exact type, detailed catalog and specification sheet for the proposed measuring solution to be
furnished application wise in the offer.

ANICPL

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TECHNICAL SPECIFICATION FOR CONTROL &


INSTRUMENTATION

Rev - 0

A) DETAILED TECHNICAL SPECIFICATION FOR ULTRASONIC TYPE LEVEL TRANSMITTER


Sl No

Description

ULTRASONIC TYPE
TRANSMITTER

1.1

Measuring Principle

Ultrasonic for hoppers

1.2

Model

Non-contacting ultrasonic level monitor for


bulk solids. Single point, I/P voltage 230
AC, Voltage selector switch

1.3

For Detecting Material

Lime Stones, Clinker (Solids) & Water

1.4

Probe mounting

Flange type

1.5

Ambient temperature
Enclosure

1.6

Relays

4 alarms / control relays, 1 changeover


contact per relay, rated 5A at 250 V AC,
Resistive load

1.7

Measuring range

15 meters

1.8

Resolution

Less than 0.1% of full scale or 2 mm


whichever is greater.

1.9

Sensor Material

Polycarbonate

1.10

Electronic unit

Graphic / Numeric display

1.11

Display type

LCD with plain text display of signal and


alarms

1.12

Keypads

4 keys for data entry, edit andviewing &


Calibrating parameters

1.13

Data protection

Password for authorized editing

1.14

Interface

4-20 mA output

1.15

Calibration

Through keypad Hand Held Terminal

1.16

Memory

EEPROM (Non volatile), No battery required.

1.17

IP Protection

IP-65 / Type 4X / NEMA 4X

1.18

Cables & Accessories

Included

ANICPL

Design

Remarks

LEVEL Model : Supplier to specify

for -20 to 50 Degree Centigrade

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TECHNICAL SPECIFICATION FOR CONTROL &


INSTRUMENTATION

16/12/2011
Rev - 0

B)RADAR TYPE LEVEL TRANSMITTER

Sl No

Description

Design

RADAR
TYPE
TRANSMITTER

LEVEL Model : Supplier to Specify

Measuring Principle

Radar type for Silos Special designed


with interference, echo and multiple
reflections suppression logics for steady,
reliable signal in dusty, fine particles
laden atmosphere inside silos.

1.2

Model

Non contacting radar type level monitor

1.3

Material

Solid material ( Fines & Course both).

1.4

Probe mounting

Flange type

1.5

Probe
Temperature

1.6

Beam angle Focus

Not more than 5 Degree

1.7

Frequency

24 to 25 GHz

1.8

Measuring range

RADAR - 60 meters

1.9

Response Time

Not more than 10 second

1.10

Resolution

less than 0.1% of full scale

1.11

Display type

Alphanumeric LCD for readout & entry.

1.12

Data protection

Password for authorized editing

1.13

Interface

4-20 mA output

1.14

Calibration

Through keypad Hand Held Terminal

1.15

Cables & Accessories

Included with PTFE Dust Cover

1.1

ANICPL

Remarks

Operating -40 Deg C to + 65 Deg C

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TECHNICAL SPECIFICATION FOR CONTROL &


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Rev - 0

c) Level Switch (RF / Capacitance type)


a)

b)

Electronic Controller :
(i)

Power supply

220V AC + 10%, 50 Hz +5%

(ii)

Alarm contact

2 NO + 2 NC contacts rated for 3


Amp. at 220 V AC.

(iii)

Mountingof
Controller

Wall mounting in cast Aluminium


housing

(iv)

Local indication

Green LED for Normal and Red LED


for High level

Sensor Probe
(i)

Exposed material

SS 304

(ii)

Insulation

Teflon (Low Temp.)


Enamel (high temp.)

(iii)

Material Temp.

250 Deg. C (Low Temp)

Vitreous

400 Deg. C (High Temp)


(iv)

Probe Housing

Cast Aluminium
Probe length shall be 1 meter for
small hoppers & 1.5 meters for Silo
and big hoppers.

The switch shall provide immunity for false actuation in the event of
coating and clinging in silo/hopper and also on probe.

D) CONTINUOUS LEVEL LIMIT SWITCHES

a)

Application

Detection of liquid levels

b)

Power supply

220V AC +10%, 50 Hz +5%

c)

Output

One set of potential free


changeover contact per channel
rated for 6 Amp. at 220V AC and 420 mA output linear with Level for
continuous monitoring.
PROBE LENGTH 3-5M ADJESTABLE

d)

ANICPL

Housing

Cast aluminium weather proof or


sheet steel

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TECHNICAL SPECIFICATION FOR CONTROL &


INSTRUMENTATION

e)

Calibrating range

0 to 50 K ohms

f)

Operating temp.

-20 deg C to +60 deg C

g)

Available

A- Max.2
for
operation

single

Rev - 0

point

B- Max.2 for pump logic


C - Max.2 for Control and 1 for
high-level alarm.(TO BE DISCUSS)
h)

Cable entry

1/2"

i)

Special features

Fail safe high/low


programmable

field

Alarm/Normal indication by one red


and one green LED per channel.
Long cable connection permissible
between
probe and evaluation
unit.
Level Switches
For hopper point level sensing, especially for high level monitoring for bag filter/ ESP hoppers, fly ash,
cement silos etc, where fine materials are handled, The level sensing probe shall be suitable for 300
Deg. C and of 2 flange mounting type.
Switch assemblies supplied for net differential switching shall be capable of field adjustments. The
power supply shall be 230 V A.C 50 Hz. The monitor shall have snap action micro switches with
minimum 2 sets of SPDT contacts with provision to select fail-safe mode and adjustable time delay.
The relays shall be rated for 5 A at 250 V AC. The monitor enclosure class is IP65. The cable entry for
eletectrical connections shall be NPT (F). The cable distance between the electronic controller unit
and probe shall be at least 50 meters. The type of the system, level probe and length are according to
the application and location.
3. Smart Pressure/Differential Pressure/Draft Transmitters

ANICPL

a)

Type

2 wire system capacitance type

b)

Accuracy

+0.5% Calibrated span

c)

Repeatability

+ 0.05% of calibrated span

d)

Span & Zero

Continuously adjustable externally,


span turn down ratio of 10

e)

Output

Profibus-PA

f)

Mounting

Pedestal/pipe

g)

Flange & Adapter

Cadmium plated carbon steel

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h)

Bolts

Cadmium plated carbon steel

i)

Paint

Epoxy base

j)

Process connection

1/2" BSP

k)

Items to be provided along with transmitter:

16/12/2011
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- Double compression type brass cable glands for armoured cable.


- Impulse pipeline approximately 30 metres on each leg, 12mm dia
straight couplings for extending standard lengths, end tube fittings etc.
- Mounting bracket/pipe with base plate for pipe mounting
- 3 valve manifold
- Local Indicator LCD type integral with transmitter body
- Dust pots/catchers - 2 nos. with each transmitter

ANICPL

l)

Primary element material shall provide good creep fatigue resistance and
low hysteresis.

m)

Smart transmitter to be provided with communication link with plant


control system facilitating remote re-ranging, calibration and diagnostics.

n)

All transmitters shall be Differential Pressure type which can be


converted to Pressure/Draft type by plugging the ports

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4. Smart Flow Transmitter


a)

Type

2 wire system capacitance type

b)

- Accuracy

+ 0.5% of calibrated span.

- Linearity

Better than 1%

c)

Repeatability

+0.05% of calibrated span

d)

Span & Zero

Continuously adjustable externally,


span turn down ratio of 10

e)

Output

Profibus-PA

f)

Mounting

: Pipe mounted type.

g)

Flange & Adapter

Cadmium plated carbon steel

h)

Bolts

Cadmium plated carbon steel.

i)

Paint

Epoxy base.

j)

Process connection

: 1/2BSP

k)

Special features

: - Built in square root extractor


: - Built in NTP correction module

l)

Items to be provided along with transmitters:


- Double compression type brass cable glands for armoured cables.
- Mounting bracket pipe

- 3-valve manifold.
- Impulse pipeline 30 metres, 12mm on each leg with straight connectors
for extending standard lengths, end tube fittings etc.

- Local Indicator LCD type integral with transmitter body


- Dust pots
m)

ANICPL

Smart transmitter shall be provided with communication link with plant


control system facilitating remote re-ranging, calibration and diagnostics

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5. Converter (KW /mA, A /mA)


a)

Enclosure

: Sheet steel, suitable for outdoor


installation

b)

Power supply

: 220 V +10%, 50 Hz + 5%

c)

Input

: 0-1 A from CT 110V AC from PT

d)

Output

: 4-20 mA DC (linear with input)


galvanically as well as optically
isolated

e)

Overload capacity

: 6 times normal input for 60 secs.

6. R/mA Converter

a)

Type

: R/mA

b)

Supply Voltage

: 220V AC + 10% 50 Hzz

c)

Input

: 1K/5K

d)

Output

: Single, 4-20 mA (Optically and


galvanically isolated)

e)

Load

: 750 Ohms

f)

Accuracy

: + 5% of span

g)

Housing

: Cast Aluminium

a)

Type

: Motorised / Electronic Audio Visual

b)

Range

: 500 meter radius (Audio + Visual)

c)

Power supply

: 220V AC

d)

Mounting

: Field mounted

e)

Protection

: IP55

f)

Tone

: In case of electronic hooter, tone


adjustment shall be possible.

7. Field Hooter

8. Pressure switch

ANICPL

a)

Type

: Diaphragm/Bellows

b)

Repeatability

: 0.5%

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c)

ON/OFF Differential

: Adjustable

d)

Switching

: Snap acting micro switch suitable


for 5 Amps at 220 V AC, change over
contact

e)

Mounting

: Field

f)

Working pressure

: Adjustable over entire


0-10 Kg/cm sq. range. (shall be
suitable to operate at minimum
pressure of 0.5 kg/cm2.)

g)

9.

Accessories

: Nipple and isolation valve, 150/200


mm long impulse tubing for
mounting on process pipe line

Zero Speed Switches


For zero speed detection of rotary airlocks, screw conveyors, belt conveyors, belt starvation detection
- inductive, 2 wire, 230V AC 50 Hz, normally open, 200 400 mA, 20 30 mm sensing distance,
minimum 50 mm dia, flush type, chrome plated brass / steel fully threaded barrel, IP67 proximity
switches with LED indication shall be used. These proximity switches shall be of low off state leakage
current type suitable for directly interfacing to the plant PLC input modules with a cable distance of
500 meters. The proximity switch shall be suitable for 120 Deg.C with integral PTFE / silicon insulated
cable of 2 to 3 m length. Special IP65, sheet steel/ poly carbonate, field mounted junction boxes with
two gland holes and four numbers of screw on terminals of 2.5 sq.mm shall be supplied for all
proximity switches. The targets for zero speed switches are to be made to cover the full sensing face
of the proximity switch. Sensing flag shall be supplied with controller and proximity cables are with
protection conduit shall be considered.
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 enameled, wire
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 input
channels of I/O.

ANICPL

a)

Application

: Under speed/stand still monitoring


of rotating machine/linearly moving
belts

b)

Type

: Non contact type/proximity type

c)

Range

: Covering 5 RPM to 3000 RPM in


multirange

d)

Protection

: IP55 /IP65

e)

Power Supply

: 220V +10%, 50 Hz +5%

f)

Output

: 2 NO+2NC alarm contacts

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g)

In-built features

Rev - 0

: - Range selection switch on front


- LED Indication for power supply
ON
- LED Indication for under-speed
- Adjustable time
control

on

delay

- Adjustable trip point control


h)

Accessories

: Target plate for sensor


mounting arrangement

with

Proximity type sensor M50/M30 to


sense 30MM/20MM distance/probe
with cable (20M length). Cable, end
connector, Female connector for
extension cable shall be supplied
loose with protection conduit.
10. Vibration Transmitter
Application

: For Vibration Pick up of Fans

Type

: 2 pick up in X-Y Axis

Power Supply

: 220V AC + 10%, 50 Hz + 5%

Frequency Range of Transducer

: 1 to 1000 Hz

Measured Variable

: Peak value of vibration displacement

Measuring Range

: 0 20 mm/s Adjustable

Output Signal

: 4-20 mA corresponding to zero & span


2 nos settable potential free lim
contacts to be provided

Accuracy

: 5% of the measured value


2% of full scale

Admissible External load

: > 600 ohms

Enclosure Protection

: IP 65

Items to be provided

: - 10 M interconnecting cable with ea


transducer
- Double Compression type cable glan
for power, Input and signal outp
cables

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- Necessary screws, nuts, washers etc.


Alternatively 2-wire 24 VDC Vibration transmitter (Loop Powered) shall be considered.

11. Pull Cord Switch


Application

: Emergency field stop for belt conveyor


Pan Conveyors

Enclosure Class

: IP 65

Output

: 2 NO + 2 NC potential free contacts


with LED indication.

Cable entry

: Suitable for 2 cables of 4x1.5

Paint Shade

: Epoxy paint in 631 of IS :5

12. Belt Sway Switch


Application

: Belt drift monitoring

Enclosure Class

: IP 65

Output

: 2 NO + 2 NC potential free contacts


with LED indication.

13

Cable entry

: suitable for 2 cables of 4x1.5

Paint Shade

: Epoxy paint in 631 of IS :5

CONTROL DEVICES:
a.

GENERAL REQUIREMENTS
Sensing elements, field devices and instrument items and transmitters which are required
and included as part of the mechanical equipment by the tenderer, have to be clearly
defined. This definition shall include specifications of equipment, quantity, and make.
Instruments required for the machinery safety along with transmitters shall be included as
part of main package.

b.

BASIC DESIGN CRITERIA OF FIELD CONTROL ELEMENTS (SENSORS)


Field control elements included in the tenderer's scope of supply shall conform to the
following general design criteria :
a) Dust proof conforming to NEMA 4/ IP65
b) Water proof conforming to NEMA 4/ IP65

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c) Wiping action on contacts (self cleaning), encapsulated contacts are preferred


d)

Explosion proof where required

e)

Housing preferably made of metal. Covers to be fitted easily, screws to be secured.


Electronic equipment to be suitably protected against radio interference, as required.

f)

Resistant against vibration (contact pressure)

g) Suitable for ambient temperature of - 20 degree to + 70 deg.C


h) All potential free contacts shall be wired up to terminal block
i) Current rating:
Contacts (2 NO + 2 NC)

0.5 amp at 48 V DC (min.)


10 amp at 220 V AC (min.)

Electronic

: - short circuit proof


- protected from inductive voltage spikes
- maximum inverse voltage &over voltage

Analogue

prote

- 4-20 mA, galvanically isolated


(against earth and power supply)
- Local Analog digital display indication

Mountin

By screws, mounting holes to be


Sealed, adequate,mechanicalprotectionto
be included.
The installation shall be done by the Tendered.

k) Connections

- Sensor type field elements to be


Supplied with min 10 meters long
Extension cable.

- All others

Lug type connection

A documentation giving details of all special electrical devices included in the Tendered'
scope of supply (wiring
diagrams, maintenance
manual,
special operating
instructions, etc.) shall be provided.
All types of elements will be subject for approval by the Purchaser/Consultant.
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c.

16/12/2011
Rev - 0

DESCRIPTION OF INDIVIDUAL CONTROL DEVICES AND EQUIPMENT


1 MOTION DETECTORS
Will be a standardised proximity head fitted wherever possible to the final driven element
of the machine.
The Tendered shall provide a hole metric M 6 (min. 20 mm) in the centre of the final
driven shaft of the machine.
The motion detector, controller as well as operating metal protrusion shall form a part of
tenderers scope of supply.
Necessary bracket for installation proximity and controller shall also form a part of
tenderers scope of supply.
2 MAGNETIC SEPARATOR:
Both High and Low excitation provision shall be in Magnetic Separator.
If more than one coil is used all the coils shall be terminated in a suitable box, so that in
case of problem in any coil it can be run with lesser coils.
Current sensing relay shall be reliable one. Temperature sensor shall have duplex channel.
One signal to interlock in local panel and one for CCR indication.
3 METAL DETECTOR:
Panel for Metal detector shall have rack mounted type cards.
All the electronic cards shall be placed and designed properly.
Loose relays shall not be used. The Relays shall be mounted on PCBs with connections
coming to approachable terminals.
Panel shall be designed in such a way that fault finding & maintenance is easier.
Electronic timers with display shall be used.
Search coil shall be supplied along with necessary vibration pads to avoid nuisances
tripping. Search coil to control panel distance shall be minimum 15meters to be
considered.
Sensitivity of metal detector shall be adjustable.
4 PROXIMITY SWITCHES/LIMIT SWITCHES
Will be standardised proximity head type limit switches. The tenderer shall provide special
mountings as may be required for an application.
Application of this type of switch will be to chute gates, belt take-up, tripper
positioning, valve position, clutch position, brake position and similar applications.

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Limit switches (2 NO + 2 NC) for diverter gates, actuator controlled valves, shut off valves
etc. are part of the tenderers scope of supply.
5 LEVEL DETECTORS/INDICATORS
Types of level detectors vary for individual applications. The tenderer shall
provide
specification, mounting device and typical drawing of preferred level detectors only.
Level detectors for Bucket Elevator Boot, silos, hoppers, process bag filter hoppers, shall
form a part of tenderers scope of supply. Ultrasonic/ RADAR level sensors is preferred for
continuous level monitoring for hoppers and silos.
6 PRESSURE, FLOW AND
PROTECTION

TEMPERATURE

SWITCHES/SENSORS

FOR

MACHINE

Shall be supplied and installed by the tenderer to suit the individual application. Locally
mounted, continuous monitoring devices with an isolated output 4 - 20 mA, 2-wire
technique, external load upto 600 Ohm is required. For applications which require one
set point only, switches with liquid filled (mercury type) or pressure operated contact
systems can be applied. All transmitters shall be provided with locally mounted indicator.
Switches to be adjustable over full range and calibration scale visible with the case closed,
shall be ensured.
The type of switch or sensor shall be subject to approval by the Purchaser.
Flow element wherever required (Venturi, Orifice, piezzo rings ) shall be included in the
scope.
7 TEMPERATURE DETECTORS
Temperature detectors (RTD, Pt 100 3 wire type including junction box) wherever specified
or necessary for protection and monitoring like large process fan bearings, gearboxes etc.
shall be tenderers scope of supply.
8 VIBRATION DETECTORS
Big fans, gear boxes, Mill and any other critical equipment shall be provided with vibration
sensors for X-Y-Z Co-ordinates. The scope of supply of the tenderer include the sensor and
the locally mounted transmitter (with output signal 4-20 mA galvanically isolated).
9 LOAD CELLS
The tenderer shall supply the load cells of hermetically sealed design with field mounted
electronic unit with local indication and circuitry giving 4-20 mA isolated output for remote
display. The load cells shall also be supplied with brackets and expansion assemblies for
other vessel. Copper straps shall be supplied along with to bridge-over each load cell to
protect them from stray welding current.
Special cable required between the load cell junction box and field mounted electronic unit
shall be included by the Tenderer in addition to special cables required between load cells
and junction boxes (Approx. 25 Meters). The load cell system shall be subject to approval
by the Purchaser.

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10 PROCESS INSTRUMENTATION
Unless otherwise specified, the Tenderer shall provide mounting arrangements (brackets,
holes, flanges, etc.) for process control and monitoring sensors specified for temperature,
pressure, flow, position, etc. Location, size and type of arrangements to be subject
to Purchaser approval.
11 VALVES/DAMPERS/GATES AND ACTUATORS
On/off valves shall be included in the supply. Best quality equipment shall be provided.
Valves shall be standardised and be subject to approval of the Purchaser.
End limit and torque limit switches for valves shall be supplied by the tenderer with 2 NO +
2 NC Contacts.
12 CONTROL VALVES AND ACTUATORS
Solutions with variable speed drives (for pumps, critical large fans, etc.) are preferred to
solutions with constant speed drive and control actuators. Where this is not possible,
control valves and actuators and corresponding mechanical linkages shall be included by
the Tenderer. Actuators and valves shall be standardised as much as possible. Motors
shall be preferable of the 3-phase squirrel-cage type. The feedback element shall be
4 - 20 mA, galvanically isolated. Where required the feedback element shall be directly
connected to the shaft. Actuator internal limit and torque switches shall generally be
included. The pot shall be 1 K ohm & transmitter shall be mounted in the actuator. The
position transmitter shall be 2 wire type and shall be suitable for 24 VDC from the plant
control system.
Actuator travel time and flow characteristic shall be adjusted to the specific application.

7.0

SPECIAL INSTRUMENTS

7.1 GENERAL PURPOSE VIEWING CCTV SYSTEM

Application
Collective Surveillance system for monitoring machine operations Expandable Up to 32 nos. camera
For main plant. chutes, hoppers, field activities, gates within the plant sections etc. field of
observations generally being non illuminated.
System envisaged
Multi camera with Two monitors having sequential & manual selecting switcher. Real time and
freeze frame, quad and full screen. Shall accept colour & B/W mixed signal. However if required for
specific areas dedicated monitors shall be employed. Simultaneous background video recording for
any four selected cameras.
No. of camera locations
05 Nos. The system shall be open for expansion.
Camera

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Colour, compact solid state design (CCD) suitable for out door field mounting(24 hours. Viewing)
with necessary protective covers and shades and operating up to 46 Deg. C ambient. Camera shall
be suitable for viewing upto 500mtr . It shall be high resolution day and night vision colour camera.
Signal processing shall be digital ( DSP)
Europe standards of operation including more than 580 TV lines horizontal resolution, approx.
470,000 picture elements or more, pure colour filter, auto back light that adjusts the picture to
prevent the objects from appearing dark due to a strong back light & white compensation, S/N
ratio better than 50 dB, auto gain control , electronic shutter control, etc. These fine tune features
shall be easily set using the On screen menus. The lenses shall be motorised zoom lenses, 1/3 inch
format.
Synchronisation can be done Int/ Ext. switchable. .
Low illumination sensitivity ~ 0.5lux .
CS mounts for lens with remote pan, zoom and tilt controls, with auto/ manual
iris, variable shutter speed. Auto iris lens type shall be auto sensing DC /video
drive.
Standard mount for camera shall be the part of system camera enclosure with
Sun Shield, Thermostatically controlled heater & blower with filter.
230V ,50 Hz, AC operation
All the cameras shall be equipped with surge protection devices.
Monitor

50 Inches TFT LCD monitors

Compatible with camera

230V ,50 Hz., AC operation

Location min 200metres, max 2 Km.

from cam

Digital Video Recorder ( DVR) :


DVR shall have following features:
No. of Channel shall be 12 nos (NEXT SIZE). & 500 GB HDD along with DVDRW. Ethernet port shall
be available with the DVR. It shall be with MPEG4 compression , upto 704 x 480 (NTSC) or 704 x 576
( PAL) recording resolution , upto 400 images per second recording rate ,partition recording.
Channel , resolution , quality & frame rate settings shall be configurable per individual camera.
PIP( Picture in Picture ) for multi screen live & playback video.
Remote client & administration functions ,support for continuous, motion , alarm and scheduled
recording
- Local & Remote PTZ control
- 4 Audio inputs & 1 audio output
Grounding Transformer :
Grounding transformer shall be provided with each camera system.
Accessories

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Control panel for remote operation with camera/ location switching unit, pan zoom &
tilt controls for camera, auto focus, power On/Off control for camera.
All interconnecting armoured coaxial cables/OFC and power cables along with
necessary power supply and connectors.
Camera, lens and monitor ceiling / wall mounts.
Signal boosters / repeaters if required in case camera distance from monitor is so high.
For very large distances / inaccessible areas where routing of cables are difficult
wireless option having suitable wattage with all accessories like antenna, multi channel
Transmitter/Receiver shall be considered and included in scope .

All the CCTV camera signals shall (both audio & video) have a provision for interfacing with the plant
intranet in Ethernet with necessary hardware, software and interfaces for viewing the video
information at user PC screens and at the MMI.

7.2 MILL ELECTRONIS EAR SYSTEM (OPTIONAL)

7.2.1

Electronic Ear
Application

: Cement mill sound level


measurement system

Type

: Folaphone sensor

Power Supply

: 220V AC + 10%, 50 Hz + 5%

Measuring Frequency Range

: 1-5 KHz

Signal level from Microphone to


sensor

: 1-500 mV

Signal I/P from sensor

: 1 mV or more

Output Signal

: 4 wire loop powered 4-20 mA


corresponding to zero & span.
2 nos settable potential free limit
contacts to be provided

Cable from Sensor to transmitter

: Connector with shielded cable 2*


0.75 mm2, max length 15 meter
cable

ANICPL

Admissible External load

: 500 ohms

Enclosure Protection

: IP 65

Stand & accessories

: Pedestal mechanical drawing shall be


provided.

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Test Mode

Rev - 0

: Test mode shall be provided to


Calibrate and test the Electronic
ear in absence of signal from
sound source.

7.3 TELEPHONE EXCHANGE (EPBX)

Telephone exchange is required for the communication inside the plant premises & colony premises.
The system shall be the latest design with all the facilities mentioned below. The system shall have 300
Line ports with extendable up to 500 lines. IP PBX IP card to connect two systems in LAN or Wan or to
use Internet to make calls (VOIP) or use IP phones or Wi-Fi phones. Distributed client server
architecture with the latest concept in computing based on SLIC.Every extension with individual tone
detectors i.e. TRULY 100% NON-Blocking .DTMF Caller ID inbuilt with incoming call printouts, caller
name display, ID based routing etc
8-channel Auto attendant for distribution of calls. Full fledged no answer, Busy, wrong no., holiday,
after office hours messages etc. simultaneous 8 calls can be answered.
All the features shall be through the motherboard and fully programmable. Apart from the above, the
normal features include Call Screening, Boss Secy., Call privacy, Call Forward, Call transfer, call follow
Me, Call Pick up, Speed dialling, Elaborate I/C CALL ringing assignment (Separate day & night),
Individual line AND extension Class, Programming from any extension with password, Night answer, &
toll restriction are available as standard features.
The system should be housed in aluminium cabinet and utilizes polycarbonate stickers for display
along with Modular Structure ,Ready for future expansion & Flexible configurations , Universal Slots Any card can go in any slot.. The design and shape shall be ergonomic and the operations shall be
simple. The system software shall be suitable for upgraded continuously .
The minimum hardware/software shall be as underThe system should provide telephony functions on any underlying data infrastructure.
The system should be scalable to support: any voice/data convergence traffic increases
The system call server must be based on SW easily up datable and manageable
The system must have an availability of 99,999%
The systems should be able to use SIP end points as extensions for the users and SIP trunks to be
interconnected with other IP PBX and to access value added applications like collaboration or Unified
Messaging.
The system should offer the choice between distributed or centralized communication servers and
media gateways without jeopardizing the WAN VOIP links, features level and applications availability.
The system should integrate with TDM equipment and enable any mix between IP or TDM and Wired
or Wireless phones.
The system should be scalable, distributable and modular.
The system should manage CAC (Call Admission Control) mechanisms to optimize the usage of the
bandwidth in the WAN for multi-site configurations.
The system must manage a large range of telephonic services, integrated contact center applications,
collaboration and Unified Messaging applications.
The system must be able to interoperate with other telephone systems and endpoints using the below
standards: QSIG GF , QSIG BC , DPNSS , DSS1 , H323 , SIP.
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The IP PBX system should provide standard APIs compliant with Internet standards like XML, SOAP &
WSDL for CTI, call control and management functions.
The IP PBX system should also provide legacy APIs such as CSTA, TAPI, CSTA.
The IP PBX system should provide call routing points for connecting Contact Center applications.
System Hardware and Software
The IP PBX hardware must have high flexibility in term of capacity, system upgrade and support IP &
TDM without external interfaces
The Call Server should able to support minimum 1500 users in a stand alone configuration
The Call Server should able to handle traffic minimum 300K BHCA
The system must support the following external telephony interface signaling:
E1 CCS PRI (VN3-4-6-7 /ETSI) DASS2
E1 CAS (R2, Q421, MFC Ericsson, Q23, Decadic)
T1 CCS generic
T0 ISDN BRI (VN3-4-6-7 / ETSI)
E&M
Analog Loop Start and Ground Start (with FSK and DTMF CLIP)
The switching must be able to handle Power over Ethernet devices
PRI card shall be considered for 30 P&T Lines interface .
PoE devices must be managed for : Economic efficiency according to device needs and Security to
avoid overload of the system or the device
For bandwidth intensive users, the supplier should be able to supply a switch device to distribute PoE
to supplementary Ethernet devices
The device must be an economic, plug and play device that offers: auto negotiated 10/100/1000 BT
transfer ,port-based and 802.1Q VLAN support ,802,3af remote power
The proposed system should be based on an open software architecture, Linux being the preferred
one.
The architecture based on soft-switches should permit the geographical relocation of the
communication servers through a standard IP network. Media Gateways should be carrying the
interface cards, which should generate their own feeds from a common source
The system's software can be hosted in appliance servers or in blade servers architectures
The system must manage, control and support a range of IP telephone stations for both voice and
telephony applications as well as IP application stations for voice, telephony, and Web services
support.
The proposed system must support native IP communications in direct or "peer-to-peer" with only the
telephone signaling transiting back toward the controlling communications server.
The voice and signaling frames should be marked [tagged] in order to be recognized. The standards of
marking supported will be: Level 2: IEEE 802.1p/Q and Level 3: TOS / Diff Serv
The system should support for voice encoding the following standards: G.711,G.723.1 and G.729A
The proposed communications system must support H.323, SIP, XML technology
The proposed system should integrate an H.323 gatekeeper server, without external equipment, that
offers the following services:
Automatic registration of the H.323 terminal and assignment of a call number by the RAS protocol
Resolution of the address, the terminal H.323 can be identified by its call number or by its IP address
that can be assigned dynamically by a DHCP server.
Establishment of communications in direct mode

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The proposed system should include the gateways required to allow the buyer to acquire H.323 or SIP
devices to interoperate with the traditional telephony devices (digital stations, IP, analog, private or
public lines).
The proposed system should permit the integration of SIP terminals with other terminals. The SIP
modules are : SIP Proxy, Registrar and Gateway
The hardware of the proposed system must be compliant with the European directive: Restriction of
Hazardous Substances in electrical and electronic equipment (RoHS)
The proposed telecommunication system should allow the use of high level XML APIs based on Web
technology standards (XML/SOAP) to ease creation of telephony and call control features for
integrating telephony services into web applications.
SYSTEM MANAGEMENT
The IP PBX system should provide a suit of applications and tools to permanently evaluate and report
the operational health of the system. It should provide the following functions:
Software licensing check
Automatic recognition of plugged sets
User moving
Monitoring of all the events on the system
Capture of performance and level of use of the resources
Register and log all calls and give accounting information
Monitor and register all users, attendants, trunks activity to generate traffic and level of use analysis
The IP PBX system must include the possibility to have remote maintenance access via dial-up having
access to the system for configuring, diagnosis and monitoring. This access must be protected with
security mechanism to prevent unauthorized intrusions.
The system must include a dedicated management server/platform that will be based on the latest
technologies, such as JAVA/JEE. This server should support a minimum of five (5) clients having
different access rights to the applications.
The management platform must provide a single graphical client (Graphical User Interface GUI) as well
as a web based interface.
The Management platform must provide web access allowing the administrator to manage the system
to use any PC with an internet browser
The management platform must use a client-server architecture allowing different administration
clients to be connected to the system
The management platform must perform at least the following tasks:
Configuration and programming of services, users, categories and all system parameters and features.
This module must provide centralized management in local or remote environments of a single system
or a network. The network manager will be able to quickly and easily edit, create or delete any
network object, by the use of import/export functions and multiple operations.
Faults and Alarms management of all the incidents and fail reports generated by the system itself
informing date, hour, severity level and action recommended to take. This module must be able to
centralize the alarms and events of the system, and:
Give colours according the severity level of the alarm
Notify an alarm depending to the severity level sending an e-mail or activating an script performing an
specific action
Register and generate statistics for the alarms and events in the network in a daily scheme

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Accounting of all calls generated by the users including cost, date, hour. Must provide different
options to group the billing of the calls (cost centre, extension number, trunk, user, city/area
associated to dialled numbers). The accounting module must be able to:
-Adapt to the financial organization of the company along the cost centres and the organization levels
-Manage carriers' fees to apply specific costs. Must be able to manage multi-carrier schemes
-Define thresholds for phone usage and Tracking/monitoring this activity, providing a graphical view of
the accounting thresholds per user, cost canter or group
-Generate reports and graphics classified by:
User , Cost Center , Organization Level, Duration , PIN ,Number Dialled ( Destination) , carrier used
Performance and traffic Analysis of the operation of the system. This must include at least the
following information:
-Measurement of response time
-Measurement of the VoIP traffic
-Statistics on the quality of VoIP calls
-Statistics on the line-occupancy ratio for incoming calls
-Reports and graphics on attendant, trunks and users traffic
-Occupancy rates of the different internal and external links
-Average time spent waiting for an attendant
Directory, module to manage the telephone directory. This must be LDAP compatible to be
synchronized with other directory applications, must also allow web access and provide information
on all desktops allowing click to call features to the users.
The management platform must allow the administrator to generate reports and graphics of the
activity per period of time in terms of traffic, accounting and alarms and giving the possibility to
generate statistics of all this analysis. Those reports must be predefined but the option to personalize
the reports must be also available. These reports should be exportable in HTML, pdf, excel and
LDAP(.ldif) formats
All IP PBX management applications ( Fault & alarms, Configuration, Accounting and performance)
should belong to a single platform and a single image for data storage, minimizing operation expenses.
The management platform must include an troubleshooting & diagnosis tool accessible by WEB to be
used by non expert administrators
The management platform should be able to be integrated with enterprise global network
management platforms (like CA Unicenter TNG, HP Openview, or IBM Tivoli) using standard protocol
SNMP.
Telephony Services:
The offered system must support the following services without
external/additional server to support them:
Text mini-message between advanced sets
Reception of absence mini-message from the called user
Calling Line Identification Restriction (CLIR) for local / internal calls
Communication timeout on outgoing call
Barring for internal and external calls
Call Waiting on :
busy set
busy hunting group
busy voice mail
Intrusion on busy set
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Set loudspeaker call:


On no reply
On busy :
Call back to last caller :
local / internal
external
Automatic call back (activate / cancel) on :
no reply
busy set
busy trunk group
Call back request (activate / cancel) on :
no reply
busy set
Call back request notification by :
LED on the user's set
Icon on wireless phones
Voice guide for analog sets
Dial by name with central directory repository
Last number redial
Multiple redial
Abbreviated dialing
Automatic call set-up on unhook
Private call / Personal Identification Number (PIN)
Distinctive ringing for internal and external calls on all types of sets
Call Overflow:
Overflow on either busy or no reply
Overflow on both busy and no reply
Overflow on out of order
Timed call overflow on no reply
Call Pick up:
Individual
On group
No Replied Calls Repertory: Local / internal calling numbers with caller name,
date and time of calls
Enquiry call / enquiry call cancel
Call transfer on :
reply
no reply
busy
Call transfer to :
set
hunting group
attendant
voice mail
Trunk to trunk call transfer
Trunk to trunk timed transfer
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Three Participants Conference


Meet-Me Conference
Announcement / Paging on Loudspeaker
Calling party name identification (CNID)
Direct inward dial (DID)
Direct outward dial (DOD)
Direct inward system access (DISA)
User set creation : user validation of his set created by attendant
User moving : personal plug in / plug out by prefix
Call recording on voice mail
Voice guides indicating/helping users independent of type of set
Outgoing call with business account code (by prefix or suffix)
DTMF / Pulse Transparency
Appointment Reminder
Call Hold
Automatic exclusive hold (in case of enquiry call or call waiting consultation)
Manual exclusive hold (by Hold or line key or by prefix)
Common hold (by Common hold key)
Mutual hold (initial hold by Hold key)
Call Forwarding:
unconditional
on no reply
on busy
on busy or on no reply
on ringing (call deflection)
Forwarding destination :
set
voice mail
hunting group
attendant or attendant group
call centres group
automated attendant
external number
Substitution
Monocline or multiline mode for advanced sets
Multiline key per directory number for advanced sets
Multidirectory number (DN) for advanced sets
Multidirectory numbers (DN) with supervision (indication of state) of :
set
trunk
trunk group (no over ringing)
Manager / Secretary features:
Call Filtering with manager control
Manager/Secretary hot line
Private Line for Manager set
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Absent secretary key


Secret listening of the secretary by the manager
Multiple Managers / Multiple Secretaries
Twinset: Two multiline sets with (same) Directory Number (TDN) and common
voice mail and accounting
Personal password for :
set lock override for DOD
set unlock
substitution and DISA
DND
general minimessaging consultation
programming individual repertory
key programming
follow-me
remote forwarding
private call
consultation of no replied calls repertory
Hunting Groups
Do Not Disturb
Voice Messaging System:
Voice Messaging system must be fully integrated to the call server and should not require external
server to be hosted
Voice Messaging system must be manageable from the system management platform
Answering or answering with date stamp - The system should provide voice mailbox holders the choice
of two functions: answering the messages or answering them with a date stamp
When a call is forwarded to the voice messaging system, the box holder will be able to chose between
two personalized announcements. If the personal announcement has not been recorded, the standard
system announcement will be substituted automatically.
Recording of calls conversation - The holder of a voice mailbox must be able to take advantage of this
service to record internal or external calls. Recorded calls will receive the same service as messages
that have been left by callers.
Forwarding of voice mail messages - The box holder will be able to send a copy of previously received
messages to other boxes (with or without requesting acknowledgement of receipt).
Call by name - To provide universal access, it must be possible to select a voice mailbox by its name by
using the telephone dialing keypad. The caller will be guided in this operation by voice prompts.
Multiple languages - To ensure consistency with the system voice prompts, the proposed system
should be multi-lingual, offering four different languages
The voice messaging system should be centralized or distributed to serve different sites
The notification of messages must be on: LED/icon on the phone ,Voice Guide, Out call to any
telephone number
The voice messaging systems must provide silence detection to avoid recording of blanks at beginning
or end of recording
The System should allow distribution lists for message broadcast
The System must allow the caller reaching a mailbox to choice forwarding destination
The System must provide External Info-Service / Audiotex
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Telephone handset: Suitable for Desktop with caller ID

7.4 P.A. SYSTEM

General
The Public Address System is for communication between main station and various group operating
stations. The equipment shall be of industrial duty suitable for trouble free operation under very dust,
high vibration and high ambient temperature (48 deg.C ) conditions.
The offered system shall be telephone based PA system & shall be interfaced with plant EPBAX
Weatherproof Field Station shall be designed for voice communication in the hostile environment
where reliability, efficiency and safety are of prime importance.
The system shall be suitable for use in harsh and hostile environment characterized by:
- Indoor & outdoor usage
- Presence of dust & water ingress
- Corrosive atmosphere
- Extreme & varying temperature
- Loud ambient noise due to industrial processes
- Pilferage
- Mishandling, rough usage & safety
PA System provides transmission of routine voice messages over loudspeakers, to all or selected areas
of the plant, in a reliable, safe and efficient manner.
On integration of the two, the PABX user gets access to the PA System where by they can announce
over the loudspeakers from their telephones. The telephone user can announce in individual zone OR
in multiple zones OR in all zones.

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SYSTEM SCHEMATICS (INDICATIVE):


The system shall be with following features
Expanding architecture & Custom configurable
Integrated system to meet the requirement of intercom, EPABX, hotline, PA System, Paging / loud
speaking
Multiple page / party communication channels
Point to point or Point to Multi point and Master / Slave configuration
Multi point, multiple control desks for a large integrated plant
Fully Digital PCM/TDM
Transparent Networking
6.2 The operator at the main station shall be in a position to communicate with various group
operating stations and vice-versa. The following features are required:The operator at main station should be able to select and talk to any group operating station both in
private and public mode.
The operator at main station should be able to call a set of group operating stations and hold a
conference, if necessary.
The operator at main station should be able to make announcement to all or any group operating
stations simultaneously.
The operating station should be able to transmit an emergency siren to one or all the group operating
stations.
The operating station should be able to call main station and speak to either in public or private mode.
Various operating station in a group shall be able to talk to each other directly without disturbing the
main station.
6.3 The equipment to be included for the operating stations shall be Pilfer proof station with built-in
microphone, loudspeaker, page &party switches.
6.4 The equipment to be included for main station should be with separate radio cone type
loudspeaker, and telephone handset (micro phone and ear phone).
6.5 The details of PA system and various group operating stations shall be provided during detailed
engineering.
6.6 The offer should include a schematic diagram of the system clearly indicating the cabling details
(type & size).
6.7 The supplier shall submit a dimensional sketch of main station, junction boxes, operating station
and UPS.
6.8 The offer should include relevant technical literature / catalogues and the reference list of
customers to whom similar system has been supplied and commissioned.
6.10 The power supply to the PA system UPS shall be 1 phase, 230 Volt + 6%, 50 Hz + 3%.
6.11 The estimated quantity of cables required for the system shall be quoted with unit rates and
cables as required at site shall be supplied.

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7.5

ENVIRONMENT INSTRUMENTS

7.6

OPACITY MONITOR

7.6.1

DUST DENSITY MONITOR


a) Measuring
Principle

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: The optical measurement system measures


dust concentration by corelating energy loss of
light
along optical path across stacks of Bag house/
Electro static Precipitators. The quantity of dust
Contained in the irradiated gas is proportional to
Absorbance of light.
The instrument operates according to the TimeDivision- Multiplex (TDM) technique, which allows
the measuring and reference light paths to be
clearly differentiated.

b)Set - Up

: On one side of the stack, the optical


system consists
of light source and receiver, on the other, the
reflector.
Both sides are aligned precisely to one another with their
alignment fixtures.
The light from the source lamp is focused by a lens
and transmitted through the chopper wheel.
Shaped into a
beam it emerges into the exhaust
Stack through the beam splitter (semi-transparent mirror)
and objective lens.
The reflector returns the light back
through the exhaust
stack where it passes through objective lens to beam splitter,
which in turn deflects it through
the receivers
condenser lens on to the receiver.
The chopper wheel and the timing wheel are on a common
axis. Rotation of the disc generates modulated light at 1.2 Khz,
which eliminates the effects of ambient light that can occur in
the exhaust stack.
The timing wheel is shaped so that with
each quarter
revolution it either opens the light path through the exhaust
stack or interrupts the light path, reflecting the source light.
The timing wheel has opposite slots at two different radii. Two
photo electric sensors set on either side of these radii,
alternately switch the receiver signal to measured valve
memory or to reference valve memory.

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In the evaluator, the reference-value is compared to the set


point of highly constant reference-value source and is
automatically adjusted if it fluctuates.
To detect zero point drift or a sensitivity change in the monitor
a zero point reflector and check filter automatically swing into
the light path once an hour.

c) Accessories

The check filter is a screen filter that produces a specific light


attenuation. The zero - point reflector interrupts the light path
on the stack side in front of the objective lens so that
contamination of optical surfaces is also checked.

01 Fail Safe Shutter mounted on both sides between the flange and sender/Receiver unit or
reflector.
If the air purging unit fails, the flange opening to the exhaust stack closes.
02 Weather hoods fibre glass reinforced plastic that protects the monitor and air purging
blower from exposure to the weather.
03 Air purging unit
d) Technical Data
Supply Voltage

: 220 V AC + 10%, 50 Hz + 3 %

Source Lamp

: Incandescent approximately 10 W
Average life approximately 20000 hrs.

Measured variable

: Dust quantity per volume (mg/Nm3)


Range shall be adjustable at site
through multiple selectable ranges

Measured value output

: 4-20 mA DC isolated into load


resistance of 600 Ohms

Relay outputs

: System error and limiting valve


Suitable for 220 V AC switching

Enclosure type

: IP 64

Ambient temp.

: 46 deg. C

Opacity monitor shall have data acquisition system with facility to access data from remote.
All opacity monitors shall be on network for centralised data acquisition system.

7.7

AMBIENT AIR QUALITY SYSTEM

TECHNICAL
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The device to be compact, completely integrated multigas measurement device, including sampling
system, built in temperature control unit, zero air system and data acquisition. The metal housing is
isolated and weather protected.
Capable of measuring: O3, CO, SO2, H2S, NOx, VOC (BTEX), PM10/2.5, Meteorological data, Indoor air
quality.
Integral Zero air supply for internal sensors calibration.
Built in Computer (data storage 5 years +).
Remote diagnostic
Intrusion alert SMS.
Email message in case of any problem.
LAN, WLAN, Internet connectivity (GSM / GPRS).

Enclosure:
The device contains modules for up to seven measurement parameters: CO, NO/NO2/NO X , O 3 , SO 2 , H 2 S,
VOC and PM10 or PM2.5. The unit is upgradable with any module.
The device has a build in air-condition for operation for ambient temperature. The flow of cooled air
within the system has to be defined by mechanical installations.
The analytical modules for the gases are mounted on drawers for easy maintenance and repair. A separate
door edgeways for separate maintenance access is standard. This door is used for access at inlet filter
exchange, operation via direct computer connection and calibration.
General:
The internal modules use reference methodology for CO, NO X , and SO 2.
The sensors modules are made by an established manufacturer to ensure trouble free operation. Heated
parts of the modules are insulated for low power consumption.
The Zero air supply is controlled for each analyzer module separately. There is space on each module for
optional available span gas supplies.
A choice of different meteorological sensors may be connected to the base unit.
Module features and specifications
SO2

Measuring principle: pulsed UV-Fluorescence.


uses pulsed UV fluorescence methodology for long life time of the UV lamp
UV-filtering with mirrors instead of filters avoid frequent UV-filter change
H 2 S-Expansion available.

TECHNICAL SPECIFICATION FOR SO2:

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Measuring Range

dynamic, up to 10 ppm

Zero Noise

0.25 ppb RMS

Lower Detectable Limit:

0.5 ppb

Zero Drift (24 hour):

< 1 ppb

Span Drift (24 hour):

+/-1% of reading > 100 ppb

Reponse Time :

< 90 seconds

Precision:

1% of reading or 1 ppb (whichever is greater)

Linearity:

+/-1% of maximum > 100 ppb

Sample Flow Rate:

500 ml/min

Rev - 0

NOX/NO/NO2
Measuring principle: Chemiluminescence.
a) Special reaction cell sample injection for drift minimization
b) Auto zero valve for zero drift minimization
c) Sample hold loop to avoid NO2-artefacts
d) Single chamber design for cost and maintenance reduction
TECHNICAL SPECIFICATIOS FOR NO/NO2/NOx:
Measuring Range

dynamic, up to 20 ppm

Zero Noise

0.2 ppb RMS

Lower Detectable Limit:

0.4 ppb

Zero Drift (24 hour):

< 0.4 ppb

Span Drift (24 hour):

+/-1% of reading > 100 ppb

Response Time :

< 60 seconds

Precision:

1% of reading or 1 ppb (whichever is greater) @<500ppb

Linearity:

+/-1% of reading > 100 ppb

Sample Flow Rate:

1000 ml/min

TECHNICAL SPECIFICATION
a) Measuring principle: Continuous and simultaneous particulate collection couples with beta ray
attenuation.
b) heated probe and humidity measurement to avoid artefacts due to humidity
c) Aerodynamic particle separation with size selective sampling head for measurements

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Measuring Range

dynamic, up to 10mg/m3

Zero Noise

< 0.001 mg/m

Lower Detectable Limit:

< 0.001 mg/m3

Zero Drift (24 hour):

< 1% /10deg.c automatic zero correction

Span Drift (24 hour):

+/-1% of reading > 100 ppb

Cycle time

User selectable between 30 minutes to 24 hours.

Accuracy

2% of F.S.

Air Flow Rate:

1 m3/h measured across an internal subsonic orifice; user selectable


from 0 to 20 LPM

Sample Flow Rate:

0.6 liters/min.

Technical Specification of MMS:


Integrated meteorological sensor for the parameters wind speed, wind direction, barometric pressure,
temperature, relative humidity, liquid precipitation.

Wind Speed Sensor:


1.
2.
3.
4.
5.

Principle
Range
Accuracy
Threshold
Operating temperature

Ultrasonic
0 - 60 m/sec.
+/- 3% of full scale
0.3 m / Sec.
0- 50 C.

Wind Direction Sensor:


1.
2.
3.
4.

Principle
Range
Accuracy
Operating temperature

Ultrasonic
0-360
+/- 3
0- 50 C.

Ambient temperature Sensor:


1.
2.
3.
4.

Principle
Range
Accuracy
Radiation Shield

RTD (Platinum) Resistance proportional to temperature.


0 - 50C
+/- 3 C
Non aspirated Radiation Shield.

Relative Humidity (RH) Sensor:


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TECHNICAL SPECIFICATION FOR CONTROL &


INSTRUMENTATION

1.
2.
3.
4.
5.
6.

Principle
Range
Accuracy
Sensitivity
Operating temperature
Radiation Shield

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Thin Film Capacitive type Sensor


0-100 % RH.
3% for range 10% to 90%.
0.2% RH.
0- 50 C.
Non aspirated Radiation Shield.

Liquid Precipitation (Rainfall) Sensor:


1.
2.
3.
4.
5.

Collecting Area
Range
Resolution
Accuracy
Operating temperature

60 cm
0..200 mm / hr
0.01 mm
5%
0- 50 C.

Metrological Mast:
One Meteorological Mast of telescopic type and of specified height to be placed on an existing system
(Enclosure) so that height of the Meteorological Sensors from the ground level (GL) is 10 meters. The mast
is required for mounting metrological sensors. Necessary hangers and holders along with electrical
grounding set shall be provided for installation of the sensors. Material of construction of mast & sensors
must be resistance to atmospheric corrosion.
Data Management System:
The system contains a built in Data Processing System. This is based on LINUX for high reliability.
It features full Internet connectivity either via air through GPRS/UMTS/EDGE/WLAN (depending on
configuration and availability) or fixed line connection using ADSL/SDSL/DSL or cable modem.
Any other Inter- or Intranet using TCP/IP-protocol can be used, too.
The Datalogger has an internal storage capacity for five years of continuous operation (three averages, one
minute being the shortest).
It has built in temperature sensors to protect the hard disc from booting at too low temperatures.
Watchdog functionality ensures safe and reliable operation.
Connection capability of additional external gas, particulate and /or meteorological sensors are provided.
Data from these sensors are integrated in the internal data base.
For this purpose the following software protocols are supported: AK, Bayern/Hessen (Gesytec), Thermo
Instrument, T-API, Gill wind sonic, Mierij, Vaisala)

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7.8

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ENVIRONMENTAL DISPLAY BOARD


LED TYPE
Colour

Brand ,size

Working
voltage

Wave
length

Brightness
500mcd650mcd

1.9v-2.1v

Red

Epistar 9mil

620nm630nm

Green

Epistar12mil

520nm525nm

2000mcd2200mcd

3.0v-3.4v

Blue

Epistar12mil

465nm470nm

450mcd550mcd

3.0v-3.4v

MODULE
1
2
3
4

Module size
Pixel in one Module
Scan method
Pixel structure

160mm x160mm
16dots x 16dots
1/4 scan
1R1G1B

SCREEN
1

Pixel density

10000dots/m2

2
3
4
5
6

Brightness Luminance
Visible Distance
Hor. Viewing angle
Vert. viewing angle
Refresh Rate

6000 cd/m2
>10m
H:110
V:55
400 Hz

Max. Power Consumption

Certificates

750W/
CE,ROHS,ISO90012008

Temperature Range

Storage
35-85
Working
20~45

10
11

Software
Operating Humidity

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Storage Humidity
Smoothness

10~99%
0.3mm

14

Life Time

100,000 hrs(11
years)

15

Working Voltage

220/110 VAC, 50/60


Hz

16

Video format

Support AVI, MOV,


MPG, DAT, VOB.etc

17

Gray Scale/colour lever

18

Control Method

4096 degree
Synchronous with
computer

19

maintenance

Back maintain

20

Data transmits

Cat 5 network
cable, maximum
100meters

21

Above 100 meters

22

PC system

12
13

8.0

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Using optic fibre


transmission
Windows
98,Windows
2000,Windows
XP,etc

INSTRUMENT LAB TESTING EQUIPMENTS:


A calibration /measuring instruments along with necessary hardware, master instruments and
software for routine calibration, testing and troubleshooting of field instruments shall be supplied.
Master Calibrators necessary for calibrating / testing of pressure (DP, Gauge) temperature, (T.C, RTD),
level, sourcing & sensing of mV, V, mA, ohm and suitable / compatible for the supplied instruments.
Necessary hardware, DMM, probe, interfacing cards, cables, probes, power supply, battery charger,
segment couplers, terminators etc. are to be supplied. A lap top PC shall be provided with windows
based software for carrying out the calibration, testing, reporting, analyzing, recording & archiving the
reports. The calibration / testing report format shall be user configurable. The master calibrators
supplied shall have calibration certificates from the manufacturer / from third party traceable to
national / international standards.

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4 DIGIT DIGITAL MULTIMETER


S.N
1

DESCRIPTION
MAKE
DC Voltage
RANGE
AC Voltage
RANGE
DC Current
RANGE
AC Current
RANGE
Resistance
RANGE

8
9
10

Capacitance
RANGE
Frequency
RANGE
Diode
Continuity
Mode

11

Additional Features

12

Max.

13
14

voltage
between
any
terminal
and
earth ground
Surge protection
Standard Delivery

SPECIFICATION
As per vendor List
600.0milli Volt
10microVolt

to 1000 V, Accuracy:0.05 %,resolution of

600.0 milli Volt to 1000V;


rms),resolution of 0.1mv

Accuracy:0.7

(true

600.0 micro Amp to 10A; Accuracy:0.2 %,resolution of


0.1microamp
600.0 microamp to 10A; Accuracy:1.0 % (true rms),
resolution of 0.1microa
600.0 ohm to 50.00 Mohm; Accuracy:0.2 %, resolution of 0.1
ohm
10.00nanoF to 9,999microF; Accuracy:1.0 %
199.99 Hz To 199.99Khz; Accuracy:0.005 %
Test Voltage 3.V Approx., Max.Test Current .6milliamp
Throughhold:200 Ohm or less.
4 digit mode
Built in thermometer conveniently allows to take
temperature readings without having to carry a separate
instrument. Unique Low pass Filter Function for Accurate
Voltage & Frequency Measurements on VFDS(Adjustable
Motor Drive)

1000v
8kv
Carrying case(c25),Test leads,Certificate etc.

Specifications of Universal Calibrator:


easy-to-use field calibrator. Use the measure and source functions to test and calibrate for process
parameter.
Small, streamlined shape
Rugged, reliable design stands up to field use
Easy to read measure/source screen to view input and output simultaneously
ANICPL

Engineering & Procurement Tender Document

Page # 86

Project : Nagpur Grinding Unit

16/12/2011

TECHNICAL SPECIFICATION FOR CONTROL &


INSTRUMENTATION

Rev - 0

Measure volts, mA, RTDs, thermocouples, frequency, and ohms to test sensors and transmitters
Source/simulate volts, mA, thermocouples, RTDs, frequency, and ohms to calibrate transmitters
Perform fast linearity tests with auto step and auto ramp features
Power transmitters during test using loop supply with simultaneous mA measurement
Backlight for work in poor light
Circuitry Protection against wrong polarity during measurements
Long battery life
Function ( Measure
or Source)
Voltage

Range
0 to100mV
0
to
10V
( source)
0
to
30V
( Measure)

Resolution
0.01mV
0.01V
0.01V

DC mA

0 to 24

0.001mA

mV(
TC
Terminals)

-10mV to 75mV

0.01mV

Resistance

15 Ohm to 3000
Ohm

0.01 Ohm

Frequency

1 to 1000 Hz
1 to 10KHz

1.0 Hz
0.1 KHz

24V DC

N.A.

0 to 1200 Deg C

0.1 Deg C

0 to 400 Deg C

0.1 Deg C

Loop Supply
Thermocoup
le measuring
RTD
measuring

Accuracy
0.02%
Reading
LSD

Remarks

of
Max.
2
1mA

Load,

0.02%
of
Max.
Load
Reading + 2
,1000 Ohm
LSD
0.025 of Range
+1 LSD
0.5 Ohm
+/- 0.05%
+/- 0.25%
10%
0.7 Deg C or
better
0.3 Deg C or
better

Standard Accessories : Basic Instruments, Battery with AC (Mains) adapter, Test Leads, Instruction
Manuals, Calibration certificate

ANICPL

Engineering & Procurement Tender Document

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Project : Nagpur Grinding Unit


TECHNICAL SPECIFICATION FOR CONTROL &
INSTRUMENTATION

16/12/2011
Rev - 0

Specifications for Analog AC Clamp Meter


1.1.
DESCRIPTION

SPECIFICATION

1.2.

01) AC Current

1.3.

03) DC Voltage

MAX: 600 Amps


MIN: 6 AMPS
MAX: 600 V
MIN: 150 V
MAX: 60 V

04) Resistance

2 KOhms

05) Frequency Response

50/60 Hz

02) AC Voltage

06) Warranty

ANICPL

1.4.
1.5.
1.6.

1 year

Engineering & Procurement Tender Document

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Project : Nagpur Grinding Unit


TECHNICAL SPECIFICATION FOR CONTROL &
INSTRUMENTATION

16/12/2011
Rev - 0

LABORATORY COLOUR DIGITAL OSCILLOSCOPE


S.N
TECHNICAL SPECIFICATIONS
Make :- As per vendor List
1

100 MHz Bandwidth

1 Giga Sample Rates

2 Channels

Full VGA Color LCD

25 Automatic Measurements

8-Bit Vertical Resolution

FFT Standard

Automatic Waveform Measurements

Voltage DC, Voltage ac RMS

10

Frequency

11

Positive Width

12

Negative Width

13

Rise-time

14

Fall-time

15

Positive Duty Cycle

16

Negative Duty Cycle

17

Positive Overshoot

18

Negative Overshoot

19

V Pwm ac

20

Low, Max, Min, P-P Amplitude

21

Mean

22

Cycle Mean

23

RMS

24

Cycle RMS

25

Vpwm ac+ dc

26

Connect &View: Advanced Automatic Triggering that recognizes signal patterns.

27

Automatic Capture and Reply of 100 Previous Screens

28

View Software for Further analysis

29

Built with Optical IR Port, USB ports

30

Optional PAC 91 to connect directly to Printer


Standard ACCESSORIES like set of probes, probe adopter & carrying case etc to be
supplied

31

ANICPL

Engineering & Procurement Tender Document

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TECHNICAL SPECIFICATION FOR CONTROL &
INSTRUMENTATION

16/12/2011
Rev - 0

DC REGULATED POWER SUPPLY


S.N
1
2

DESCRIPTION
Make
Output (Dual)
Current Capacity

3
4
5

Display
Power Supply
Features

Standard Delivery

SPECIFICATION
APLAB
0-36V DC
5Amps
Voltage resolution- 1mv at 0 to 3.999v
Voltage resolution- 10mv at 4 to 36v
Current resolution- 1mA
LCD display with backlit
230V AC, 50Hz.
Adjustable voltage and constant voltage output
Adjustable current and constant current output
Protection for over or lower voltage & lower current
Basic Instrument, Main Power cable, Test leads,
Instruction manual

SINGLE PHASE VARIAC


S.N

1
2
3
4
5

ANICPL

DESCRIPTION
Make
Input
Power
Supply
Output voltage
Output Current
Type
Standard Delivery

SPECIFICATION
As per vendor List
230V AC, 50Hz single phase
0 to 260V AC
8A
Portable
Basic Instrument, Main Power cable, Test leads,
Instruction manual

Engineering & Procurement Tender Document

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TECHNICAL SPECIFICATION FOR CONTROL &


INSTRUMENTATION

16/12/2011
Rev - 0

PORTABLE PRESSURE PNEUMATIC CALIBRATOR


S.N

DESCRIPTION
Make

Range

2
3
4
5

Accuracy
Resolution
Display
mA input
Selectable
inputs

SPECIFICATION
As per vendor List
-0.8(vacuum) to 2 kg
-0.8(vacuum) to 20 kg

pressure

Integral Hand Pump

Features

Standard Accessories

, +/- 0.1%FS+1Digit
Minimum 5 digits
2 line, 16 characters LCD
0-25Ma
Kg/cmSq, Bar, Psi, mBar, mmHg, inHg,
ftHg, cmH2O, mH2O, etc.
Provided
with
pressure/vacuum
changeover switch, fine adjustment
vernier & release valve.
Microprocessor
based,
Battery
operated.
Basic Instruments, Battery with AC
(Mains) adapter, Test Leads, Instruction
Manuals, Calibration certificate

PORTABLE SPEED MONITOR


S.N

DESCRIPTION

SPECIFICATION

Make

As per vendor List

Rpm range

Photo: 5 to 99999/Contact:0. 5 to199999

ft/min

0.2 to 6560

m/min

0.5 to 1999.9

Basic accuracy
Max
rpm
resolution

+/- 0.5 rdg

5
6

ANICPL

Standard Delivery

0.1rpm
Basic Instrument, Batteries
Reflective
tape,
Carrying
Conformance
Certificate

Engineering & Procurement Tender Document

bag,

manual,

Page # 91

Project : Nagpur Grinding Unit

16/12/2011

TECHNICAL SPECIFICATION FOR CONTROL &


INSTRUMENTATION

Rev - 0

LT MEGGER
S.N
1
2
3
4
5
6
7
8
9

DESCRIPTION

SPECIFICATION

Make
Insulation
voltage
Insulation
voltage
(basic
accuracy)
Ac
voltage
(accuracy)
Low resistance
O/P short circuit
current
Ohmmeter
accuracy
Overload
protection
Continuity
Beeper

As per vendor List

Standard Delivery

250V/500V/1000V/2000v
2
/
20/
200M
ohm,<1000M
(3%rdg+5d),>1000M ohm (5%rdg+5d)

ohm

600 V, (0.8%rdg+3d)
200 ohm, 1%rdg
1.5mA, 0.3 to 0.5mA
20/200 ohm (auto), (1%rdg+2d)
2200V<1min
<100ohm
Basic Instrument, Test Leads, Instruction manual,
Carry bag

DIGITAL AC/DC CLAMP METER

DESCRIPTION
Make
Type
01) AC Current
02) DC Current
03) AC Voltage
04) DC Voltage
05) Resistance
06) Frequency
07) Inrush Current
08) Battery Life
09) Sleep function
10) Standard Accessories
ANICPL

SPECIFICATION
As per vendor List
3 & digit
1000 Amps
Accuracy: 2%
1000 Amps
Accuracy: 2%
600 Volts
Accuracy: 1%
600 Volts
Accuracy: 1%
6000 ohms
Accuracy: 1.5%
400 Hz
Accuracy: .5%
100 milli second (useful to capture motor starting
current) etc or initial starting current
150 Hrs
Auto Shut off
To be supplied with the instruments

Engineering & Procurement Tender Document

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Project : Nagpur Grinding Unit


TECHNICAL SPECIFICATION FOR CONTROL &
INSTRUMENTATION

16/12/2011
Rev - 0

PORTABLE TEMPERATURE MONITOR


S.N
1
2
3
4
5
6
5
6
7

ANICPL

DESCRIPTION
Make
Channel/Function
Temperature
Range
Probe
Temperature
Type
of
Thermocouples
Display
Read Out

SPECIFICATION
As per vendor List
1 Channel

Hold Button
Supply
Supplied
Accessories

Hold Key
Batteries
One Bead Probe Thermocouple, 3AA Batteries
(1000 Hrs Life), instruction Manual etc.

K' Type:'-200 to 1370C


With Standard Probe (-40Deg to 260) Deg
K', 'J', 'E', 'T'.
LCD Display
In C. F or Kelvin (K)

Engineering & Procurement Tender Document

Page # 93

Project : Nagpur Grinding Unit


TECHNICAL SPECIFICATION FOR CONTROL &
INSTRUMENTATION

9.0
9.1

16/12/2011
Rev - 0

ERECTION HARD WARES


SPECIFICATION FOR CABLE TRAYS
The specifications are mentioned hereunder for design, manufacture, testing at works, supply of
various size of cable trays as per scope of supply.

9.1.1

STANDARDS

BS-729-1971 or Equivalent IEC for hot dip galvanizing.


IS: 2629 or equivalent IEC for cable tray fabricated.
IS-2633 or Equivalent IEC for quality of the coating.
9.1.2

TECHNICAL SPECIFICATIONS:

PERFORATED TYPE CABLE TRAYS


These trays shall be U shaped made with M.S. Channels, with center perforation and two side edges.
The edges shall be perforated one or un-perforated and tray shall be fabricated with 2.0 mm thick
galvanized sheet steel. The standard length of the cable tray shall be 3.0 meter. The width of the
center perforated portion shall be as per requirement mentioned in the data sheet. The height of the
edge of cable tray shall be from 25 mm to 100 mm depending upon size of the tray. The specifications
of the cable tray are for open type cable trays but on requirement supplier are supposed to supply
fabricated un-perforated channels covers also. The cover shall be fabricated with 20 SWG sheet steel.
The width of cover shall be 5 mm more, than the width of the cable tray. The height of edges of cover
shall be 25 mm. However, higher height shall also be supplied on specific demand. Length of cable tray
cover shall be similar to cable tray i.e. 3.0meter.
The center width between runners shall be as per purchase requirement. Rungs shall be made of with
U shaped channels, having 25 mm to 75mm height without slots / perforation but bottom of the cable
tray shall be slotted/perforated.
The hot dipped galvanized steel perforated cable trays having rectangular U channel on both side
called runner shall be designed for a uniform load of at least 400N per 1000 mm ladder length for 200
mm wide tray. The trays shall be fabricated in a length of 3.00 meter.
The perforated cable trays shall be manufactured from good commercial, high grade strength sheet
steel having minimum thickness of 2.0 mm, 2.5 mm and 3.00 mm. It shall be hot dip galvanized
according to BS-729-1971 or equivalent IEC standard suitable for indoor/outdoor use having high
humidity (about RH-90%) and air pollution. The zinc coating thickness shall works out by applying a
610 gm of zinc per square meter surface with an approximate thickness of 80 micron (min) and 100
micron an average.
The zinc coating shall be smooth, clean and uniform thickness and free from defects like ash and dross
inclusions, bare patches, black spots, pimples, lumpiness, rust stains, blisters etc. The galvanizing shall
not adversely affect on the mechanical properties of the coated material. The quality of the coating
will be established by tests as per IS-2633.

ANICPL

Engineering & Procurement Tender Document

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Project : Nagpur Grinding Unit

TECHNICAL SPECIFICATION FOR CONTROL &


INSTRUMENTATION

16/12/2011
Rev - 0

All manufacturing process including punching, cutting, bending and welding of perforated cable trays
shall be completed and burrs shall be removed before the application of galvanization process is
applied. Zinc conforming to at least Grade Zn-98 as specified in IS-209-1966 shall be used for the
purpose of galvanizing.
The joints of two trays shall be butt construction and shall be made with the help of coupler plates by
nuts and bolts. The coupler plate and nuts and bolts shall also be properly hot dip galvanized, where
the bends of the trays are required at site the same shall be supplied by the supplier as per
requirement. The spacing of rungs (centre to centre) shall be as per technical data sheet.
While adopting the modules at site if cutting of any length is required the same shall be cut at site and
joined by nuts and bolts with the help of coupler plates.
Tests to be carried out:
Following tests to be performed and necessary test certificates shall be provided.
Raw material Test
Physical and Chemical analysis Test
Galvanization Test
Destructive test for Galvanization for Mass and Uniformity
Accessories:
Coupler plates
Fixtures
Bolts, Nuts and Washers
(Quantity as required / necessary shall be supplied)
Special Notes:
i) Trays shall be free of any Burrs / Sharp Edges .No Recycled / Wastage Material shall be used
for Fabrication of Cable trays
ii) Vendor to submit Material specification details for approval
SPECIFICATIONS OF INSTRUMENT TUBE FITTINGS

9.2

The specification covers the requirement for the design ,material , inspection & testing of Instrument
Tube Fittings which includes the following types Stainless Steel Compression Fitting ( For SS Tubes)
Brass Compression Fittings( For Copper Tube)
Following standards ( latest editions at the time of supply) shall be followed:
ANSI /ASME American National Standards Institute / American Society of Mechanical Engineers
B 1.20.1
B16.11

Pipe Threads General Purpose ( Inch)


Forged Steel Fittings Socket Welding & Threaded

BS-4368
IS-319

CS & SS Compression Couplings for Tubes


Specifications for free cutting Brass Bars, Rods & Sections

ISA- RP 42.1 Nomenclature for Instrument Tube Fittings


ANICPL

Engineering & Procurement Tender Document

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Project : Nagpur Grinding Unit


TECHNICAL SPECIFICATION FOR CONTROL &
INSTRUMENTATION

16/12/2011
Rev - 0

Design & Construction:


A. Stainless Tube Fittings:
1. Nomenclature of all Instrument Tube Fittings shall be as per ISA RP42.1
2. Fittings shall be of flare less Double compression type having four piece construction
consisting of two ferrules , nut & body suitable for use on tubes of specified material
3. All parts of tube fittings shall be of SS 316 ,unless specified otherwise.
4. Hardness of the ferrules shall be in the range of HRB 85-90 so as to ensure a hardness
difference of the order 5 to 10 between tube & fittings for better sealing.
5. Nuts & Ferrules of a particular size shall be interchangeable for each type.
6. Spanner hold shall be metric.
7. Threaded ends of fittings shall be NPT as ASSI B 1.20.1
8. Specific Techniques like silver plating shall be used over threading in order to avoid
jamming & galling.
9. Ferrule finish & Fitting finish shall be such that there is no abrasion / galling when the
nut is tightened.
B. Copper Tube Fittings:
1. Nomenclature of all Instrument Tube Fittings shall be as per ISA RP42.1
2. Fittings shall be of flare less compression type having three piece construction
consisting of ferrules , nut & body suitable for use on copper tubes conforming to
ASTM B68 / B68M, hardness not exceeding HRB 50.
3. All parts of tube fittings shall be from brass as per IS319 bar stock & nickel plated .
4. For better grip , vendor shall maintain the Hardness between the tube & ferrule and
indicate the same along with the offer.
5. Spanner hold shall be metric.
6. Threaded ends of fittings shall be NPT as ASSI B 1.20.1
9.3 SPECIFICATIONS OF CABLE GLANDS:

Cable Glands shall be double compression type. This glands shall be suitable for using worst climatic
conditions, weather proof IP 66 as per IS13947. Gland consist of check nut, gland body, neoprene
inner ring, armour clamping cone, armour clamping ring, amour clamping nut, neoprene outer ring,
skid washer, outer seal nut. All metal parts shall be made of brass accurately machined for ease of
assembly.
The Sizes of Cable glands shall decided during detailed engineering which will be as per the Control
Cable sizes procured by Purchaser.

10.0

ENGINEERING ACTIVITIES
The engineering activities which shall be carried out by the supplier shall be as follows:

ANICPL

Engineering & Procurement Tender Document

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TECHNICAL SPECIFICATION FOR CONTROL &
INSTRUMENTATION

Sn.

Activity

P&I diagram

2
3
4
5
6

ANICPL

16/12/2011
Rev - 0

Remarks

Drawings as received from machinery supplier shall


be furnished.
Schedule of Instruments
Drawings as received from machinery supplier shall
be furnished.
Interfacing of sub-control Drawings as received from machinery supplier shall
systems supplied with be furnished.
mechanical equipment
Process flow sheet for Drawings as received from machinery supplier shall
preparation of mimic be furnished.
pages
Cabling concept showing
broad
cable
interconnection.
Estimation of requirement
of type and sizes of
instrumentation, data and
control cables.
Cable
schedule
and Cable schedule and termination details shall
termination details for covered control and instrumentation cables
complete process control connecting plant control system with the HT and LT
and
instrumentation switchboards, motor control centre, thyristor /
including power supply inverter panels, sub-control systems, IPDB and
cables for instruments, various other electrical panels employed for plant
field bus cables, sensor operation.
cables and bill of quantity. The document shall also enlist control and
instrumentation cables emanating from the
electrical panels described above upto the
drives/field
devices/push
button
stations/
mechanisms/field instruments / sensors
Instrument
wiring
diagrams
showing
hooking-up
details
between field mounted
instruments, JBs, IPDBs
and control panels.
General
arrangement
drawing of control desk,
processor panel, I/O
panels, UPS distribution
boards,
JBs,
IPDBs,
instrument panels etc.

Engineering & Procurement Tender Document

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Project : Nagpur Grinding Unit


TECHNICAL SPECIFICATION FOR CONTROL &
INSTRUMENTATION

10

11

12

13

14

15

ANICPL

16/12/2011
Rev - 0

Schematic wiring and


terminal diagrams of
processor panels and I/O
panels.
I/O
assignment
list
showing panel, rack and
channel identification for
various
group
level
processors integrating the
requirement for :
-MCCs (based on feeder
lists
- HT Motors.
- Instruments as per list
of instrument
- Sub-control systems
Detailed
Block
interlocking
diagrams
(BID) / Process function
diagrams.
Requirement of field
junction
boxes/power
distribution boards for
instruments/ Field bus
components .
Instrument
installation
drgs, showing mounting
details connection details
for impulse pipeline with
manifold,
mounting
details of accessories
Control room layouts
showing
equipment
orientation and cable
opening etc.

Engineering & Procurement Tender Document

Page # 98

Project : Nagpur Grinding Unit


TECHNICAL SPECIFICATION FOR CONTROL &
INSTRUMENTATION

16/12/2011
Rev - 0

16

Instrument index sheets

17

Cable routing drgs. for


Control
and
Instrumentation Cables
Field Instrument location Drgs. as received from main machinery suppliers
drgs.
(Marked
in shall be issued to Supplier for execution
Mechanical GAs)
Earthing design with
calculations
for
PCs,
Control
Desk
/
instruments/ UPS or any
other equipment

18
19

ANICPL

Supplier shall give the following information in


tabular form:
- Instrument tag no.
- Instrument flow sheet
drg.no.
- Instrument description
- Service involved such as indication/
recording/controlling etc.
- Instrument location
- Name of manufacturer
- Model no. & type
- Instrument specifica-tion sheet no.
- Instrument piping detail drawing no.
- Electrical schematic drg.no.
- Cable schedule drg.no.

Engineering & Procurement Tender Document

Page # 99

Project : Nagpur Grinding Unit

TECHNICAL SPECIFICATION FOR CONTROL &


INSTRUMENTATION

20

Software development
for controller, MMI, MIS
Shall be done at site by
the selected Supplier
involving the purchasers
engineers

21

Bill of quantity of erection


hardware for complete
automation system

16/12/2011
Rev - 0

Selected Supplier while preparing the software shall


take care of the following :
-Programme for drive controls such as DOL /RDOL /
Damper / DC / HT/ Variable speed drives etc.
-Programme for starting/stopping sequence
for
sequential control, fault monitoring of drives,
local/remote operations.
-Plant programme for measured value processing/close loop control with contact and
analogue output.
-Interactive graphic programme for final control
elements
-Event & Alarm lists
-Data base for analogue parameters
-Controller Block schemes
-Description of standard functions.
-Trending and loop status display.
-Colour mimic graphics
-Management Reporting System, data logging, etc.
-Software development for sub-control
system supplied by main machinery

Note: No engineering and documentation services can be off loaded by Supplier after award of
contract without seeking approval from Purchaser.
10.1

TRAINING OF PLANT PERSONNEL


The Supplier shall provide the following training to the plant personnel for trouble free operation and
maintenance of the equipment.

10.1.1 AT MANUFACTURER'S WORKS/DESIGN OFFICE

01
02
03

Acquaintance with the inner details of system being supplied.


Acquaintance with the hardware and software used.
Programming, incorporating changes in the programme, optimisation of control loop

etc.
04
System and component fault finding.
05
Minor repairing of the defective equipment/components at site.
06 Erection and commissioning procedures.
07 Preventive maintenance of the equipment supplied.
10.1.2 ON JOB TRAINING AT PLANT SITE

1. Plant personnel will be associated actively with software development erection and
commissioning.

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Project : Nagpur Grinding Unit


TECHNICAL SPECIFICATION FOR CONTROL &
INSTRUMENTATION

16/12/2011
Rev - 0

2. All the pre-commissioning and commissioning tests and the set values will be made available to the
plant personnel.
3. All the commissioning problems will be discussed and explained to the plant personnel.
10.1.3 TRAINING SCHEDULE

The training at the Manufacturer's Works/design office / OEMs works shall be arranged for four
engineers in two batches.
The training schedule shall be worked out in consultation with the purchaser's representative that the
personnel are mobilised for training at the appropriate stage of manufacturing and design.

ANICPL

Engineering & Procurement Tender Document

Page # 101