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R0 Date: 26/May/10 ITEM : COAL HANDLING PLANT PROJECT : DESEIN PRIVATE LIMITED CONSULTING ENGINEERS COAL HANDLING SYSTEM FOR 2 x 800 MW UNIT OF SRI DAMODARAM SANJEEVAIAH THERMAL POWER PROJECT AT KRISHNAPATNAM TATA PROJECTS LIMITED, HYDERABAD DOC NO. : TPL-069-0788-I-DOC-053 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED OPERATIONAL AND CONTROL PHILOSPHY FOR COAL HANDLING PLANT TECPRO SYSTEMS LIMITED Issue/Rev.: OPERATIONAL AND CONTROL PHILOSPHY FOR COAL HANDLING PLANT COAL HANDLING SYSTEM FOR 2 x 800 MW UNIT OF SRI DAMODARAM SANJEEVAIAH THERMAL POWER PROJECT AT KRISHNAPATNAM OWNER : ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED OWNER'S CONSULTANT : DESEIN PRIVATE LIMITED CONSULTING ENGINEERS B.O.P. CONTRACTOR : TATA PROJECTS LIMITED, HYDERABAD C.H.P. CONTRACTOR : TECPRO SYSTEMS LIMITED Issue/Rev Date By Chkd. R0 26/May/10 VS KM Signed (Initials) Reason for Issue FOR INFORMATION KRISHNAPATNAM

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ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED

OPERATIONAL AND CONTROL PHILOSPHY FOR COAL HANDLING PLANT

DESEIN PRIVATE LIMITED CONSULTING ENGINEERS

TATA PROJECTS LIMITED, HYDERABAD

COAL HANDLING SYSTEM FOR 2 x 800 MW UNIT OF SRI DAMODARAM SANJEEVAIAH THERMAL POWER PROJECT AT KRISHNAPATNAMIssue/Rev.: R0

TECPRO SYSTEMS LIMITED

DOC NO. : TPL-069-0788-I-DOC-053

Date: 26/May/10

OPERATIONAL AND CONTROL PHILOSPHY FOR COAL HANDLING PLANT

ITEM :

COAL HANDLING PLANT COAL HANDLING SYSTEM FOR 2 x 800 MW UNIT OF SRI DAMODARAM SANJEEVAIAH THERMAL POWER PROJECT AT KRISHNAPATNAM ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED

PROJECT :

OWNER :

OWNER'S CONSULTANT :

DESEIN PRIVATE LIMITED CONSULTING ENGINEERS

B.O.P. CONTRACTOR :

TATA PROJECTS LIMITED, HYDERABAD

C.H.P. CONTRACTOR :

TECPRO SYSTEMS LIMITED

Issue/RevR0

Date26/May/10

Reason for IssueFOR INFORMATION

ByVS

Chkd.KM

Signed (Initials)

Tecpro Systems Ltd.

Document No. By Approved By Date ISSUE/REV

TPL-069-0788-I-DOC-053 VIVEK KM 26/05/10 R0

Project ClientCONSULTANT

COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.

M/s TATA PROJECTS LTD.HYDERABAD. FICTHNER INDIA ENGG.PVT LTD.

OPERATIONAL AND CONTROL PHILOSPHY TABLE OF CONTENTSSECTION No. TITLE PAGE No. 2 8 10 13 19

1 2 3 4 5

SYSTEM DESCRIPTION ELECTRICAL SYSTEM DESCRIPTION INSTRUMENTATION TECHNICAL & OPERATIONAL DETAILS OF PLC OPERATIONAL & CONTROL PHILOSPHY WITH SYSTEM DESCRIPTION ANNUNCIATION SYSTEMS SEQUENTIAL INTERLOCK FOR CONVEYORS & OTHER EQUIPMENTS ELECTRICAL CONDITION FOR DRIVES CONVEYOR START UP & STOP SEQUENCE DUST SUPPRESSION & EXTRACTION SYSTEM

6 7

35 37

8 9 10

41 43 48

Date ISSUE/ Rev.

Description

By

ITEM

Operational & Control Philosophy

Page 1 of 48

Tecpro Systems Ltd.

Document No. By Approved By Date ISSUE/REV

TPL-069-0788-I-DOC-053 VIVEK KM 26/05/10 R0

Project ClientCONSULTANT

COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.

M/s TATA PROJECTS LTD.HYDERABAD. FICTHNER INDIA ENGG.PVT LTD.

It is recommended to study this document with reference toi) ii) FLOW DIAGRAM PLANT LAYOUT : TPL-069-0788-M- FD-001. : TPL -069-0788-PLT-001.

1.0

SYSTEM DESCRIPTION

A brief description of the proposed coal handling system is furnished below:The coal handling system comprises the following 1 Crushing 2 Stacking 3 Reclaiming 4 Blending 5 Bunker Feeding System

Conveying into plantCoal will be received at the jetty by ship, unloaded and sent to the plant Crusher house through a cross country conveyor. (By others).

a) Crushing

Coal as received inside the crusher house will be screened, crushed and conveyed. Coal of (-) 300 mm size is received and single stage crushing is envisaged. Two nos. of screens and crushers are considered. Eccentric Disc type Roller screens has been provided in the crusher House to screen out (-) 25 mm coal. (+) 25mm coal will be fed to the crushers where the same will be crushed to (-) 25mm size. Ring granulator type crushers has been provided in the crusher house for crushing the coal. Rated capacity of each screen and crusher will be of 1600 TPH. After crushing, coal will be fed into belt conveyors BCN- 1A/1B which will feed the coal into junction tower JNT-1. From there coal will be diverted, stock piled, blended and fed into the bunkers.Date ISSUE/ Rev. Description By

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Operational & Control Philosophy

Page 2 of 48

Tecpro Systems Ltd.

Document No. By Approved By Date ISSUE/REV

TPL-069-0788-I-DOC-053 VIVEK KM 26/05/10 R0

Project ClientCONSULTANT

COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.

M/s TATA PROJECTS LTD.HYDERABAD. FICTHNER INDIA ENGG.PVT LTD.

b) Stacking Crushed domestic coal received at JNT -1 will be conveyed through BCN-3 conveyor and will be stockpiled through Stacker cum reclaimer (SCR-1). Two (2) nos. of domestic stock piles are envisaged by using SCR-1. Also, a portion of crushed domestic coal received at JNT-1 is conveyed through BCN -2A/2B and fed to JNT-3. In JNT -3, coal is received and conveyed through BCN-4 and stock piled using SCR-2 on the southern side. Crushed imported coal received at JNT-1 is conveyed through BCN -2A/2B and fed to JNT 3. Coal from JNT -3 is received and conveyed through BCN-4 and stock piled using SCR-2 on the Northern side. Two numbers of Stacker cum Reclaimers viz., SCR-1 and SCR-2 mounted on trunk conveyors BCN-3 and BCN-4 respectively have been envisaged. Bucket wheel drives are variable type to adjust the feeding capacity.

c) Reclaiming The reclaim system will be controlled from operator station in the CHS control room. The coal can be reclaimed by bucket wheel system of SCR or an emergency reclaim system. The coal form stock pile will be reclaimed by stacker cum reclaimers (SCR-1 and / or SCR2), and feed to trunk conveyors BCN-3 and /or BCN-4, which will feed coal to bunkers through series of conveyors and traveling trippers.

Whenever the reclaimer is not available, coal will be reclaimed by dozers into the emergency reclaim hopper (ERH). Two sets of emergency reclaim hoppers has been provided out of which one will be for domestic coal and another for imported coal. Below the each of the reclaim hoppers rod gate, rack & pinion gate and vibrating feeders has been provided for feeding coal to the belt conveyors BCN-5&7. Vibrating feeders are driven by variable frequency drives thus adjusting the feed capacity.

Date ISSUE/ Rev.

Description

By

ITEM

Operational & Control Philosophy

Page 3 of 48

Tecpro Systems Ltd.

Document No. By Approved By Date ISSUE/REV

TPL-069-0788-I-DOC-053 VIVEK KM 26/05/10 R0

Project ClientCONSULTANT

COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.

M/s TATA PROJECTS LTD.HYDERABAD. FICTHNER INDIA ENGG.PVT LTD.

d) Blending Blending of domestic coal and imported coal will be done by reclaiming coal from the respective stock pile at the required proportion (70:30) and conveyed to the succeeding conveyors where they get mixed and fed in to the bunkers. Domestic (70%) : 1120 T/h (Rated) Imported (30%) : 480 T/h (Rated) The coal can be blended in the following options, i) Direct Feeding domestic coal by 70 % and Reclaiming imported coal by 30 %. ii) Direct Feeding imported coal by 30 % and Reclaiming domestic coal by 70 %. iii) Reclaiming domestic coal by 70 % and Reclaiming imported coal by 30 %.

(i) Direct Feeding Domestic coal by 70 % and Reclaiming Imported coal by 30 %. Option-1 Crushed domestic coal will be sent to JNT-1 through Conveyor BCN 1A/1B. At JNT-1 coal will be divided as 70 % and 30% by the flow divider (FD-1 and or FD-2). 70 % of domestic coal will feed into Trunk conveyor BCN-3 and remaining 30% coal will feed into conveyor BCN-2A/2B. Conveyor BCN-2A/2B will convey the coal to JNT-3 and which will then feed the coal to Trunk conveyor BCN-4.SCR-2 will receive and stock the 30% domestic coal on the southern side Imported coal 30% will be reclaimed by bull dozer which will be fed into the Emergency reclaim hopper ERH-2. Rod gate, rack & pinion gate and vibrating feeders are provided below ERH-2 for feeding into Conveyor BCN 7, which will then convey the same to JNT-4.

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Operational & Control Philosophy

Page 4 of 48

Tecpro Systems Ltd.

Document No. By Approved By Date ISSUE/REV

TPL-069-0788-I-DOC-053 VIVEK KM 26/05/10 R0

Project ClientCONSULTANT

COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.

M/s TATA PROJECTS LTD.HYDERABAD. FICTHNER INDIA ENGG.PVT LTD.

Domestic coal from trunk conveyor BCN 3, Conveyor BCN-6A/6B and Imported coal from Conveyor BCN 7 will be blended in JNT-4. From there blended coal will be fed through series of conveyors for feeding into boiler bunkers.

Option-2 Crushed domestic coal will be sent to JNT-1 through Conveyor BCN 1A/1B. At JNT-1 coal will be divided as 70 % and 30% by the flow divider (FD-1 and or FD-2). 30 % domestic coal will feed into trunk conveyor BCN-3 and remaining 70% coal will feed into Conveyor BCN-2A/2B. Conveyor BCN-2A/2B will convey the coal to JNT-3 and which will then feed the coal to trunk conveyor BCN-4. SCR-1 will then receive and stock the 30% domestic coal either on the southern or northern side. Imported coal 30% will be reclaimed by Bull dozer which will be fed into the Emergency reclaim hopper ERH-2. Rod gate, rack & pinion gate and vibrating feeders are provided below ERH-2 for feeding into Conveyor BCN 7, which will then convey the same to JNT-4. Domestic coal from trunk conveyor BCN 4 and Imported coal from Conveyor BCN 7 will be blended in JNT-4. From there coal will be fed through series of conveyors for feeding into boiler bunkers.

Option-3 Crushed domestic coal will be sent to JNT-1 through Conveyor BCN 1A/1B. At JNT-1 coal will be divided as 70 % and 30% by the flow divider. 30 % domestic coal will feed into trunk conveyor BCN-3 and remaining 70% coal will feed into conveyor BCN-2A/2B. Conveyor BCN-2A/2B will convey the coal to JNT-3 and which will feed to trunk conveyor BCN-4. SCR-1 will then receive and stock the 30% domestic coal either on the southern or northern side. Imported coal which will be reclaimed by stacker cum reclaimer of SCR-2, and Domestic coal form Conveyor BCN 4 will be blended in the JNT- 4. From there coal will be fed through series of conveyors for feeding into boiler bunkers.

Date ISSUE/ Rev.

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Operational & Control Philosophy

Page 5 of 48

Tecpro Systems Ltd.

Document No. By Approved By Date ISSUE/REV

TPL-069-0788-I-DOC-053 VIVEK KM 26/05/10 R0

Project ClientCONSULTANT

COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.

M/s TATA PROJECTS LTD.HYDERABAD. FICTHNER INDIA ENGG.PVT LTD.

(ii) Direct Feeding Imported coal by 30 % and Reclaiming domestic coal by 70 %. Crushed imported coal will be sent to JNT-1 through Conveyor BCN 1A/1B. At JNT-1 coal will be divided as 70 % and 30% by the flow divider (FD-1 and or FD-2). 30 % imported coal will feed into trunk conveyor BCN-3 and remaining 70% coal will feed into Conveyor BCN2A/2B. Conveyor

BCN-2A/2B will convey the coal to JNT-3 and which will feed the coal to trunk conveyor BCN-4. SCR-2 will then receive and stock the 70% imported coal on the northern side. SCR-1 will reclaim 70 % coal of domestic coal and feed the same into trunk conveyor BCN-3 which will then feed to JNT-2. Domestic coal reclaimed from SCR-1 and diverted imported coal will get blended in JNT-2. From there blended coal will be feed through series of conveyors for feeding into boiler bunkers.

(iii)Reclaiming domestic coal by 70 % and Reclaiming imported coal by 30%. Option-1 Domestic coal 70% will be reclaimed by SCR-1 and fed into the trunk conveyor BCN-3 which will feed in to JNT-4 through conveyor BCN-6A/6B. Imported coal 30% will be reclaimed by SCR-2 and fed into the trunk conveyor BCN-4 which will feed into JNT-4. At JNT-4 both the coal will get blended and fed into boiler bunkers through series of conveyors.

Option-2 Domestic coal 70% will be reclaimed by SCR-1 and fed into the trunk conveyor BCN-3 which will feed into the JNT-4 through conveyor BCN-6A/6B. Imported coal 30% will be reclaimed by Conveyor BCN 7 and fed into JNT-4. At JNT-4 both the coal will get blended and fed into boiler bunkers through series of conveyors.Date ISSUE/ Rev. Description By

ITEM

Operational & Control Philosophy

Page 6 of 48

Tecpro Systems Ltd.

Document No. By Approved By Date ISSUE/REV

TPL-069-0788-I-DOC-053 VIVEK KM 26/05/10 R0

Project ClientCONSULTANT

COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.

M/s TATA PROJECTS LTD.HYDERABAD. FICTHNER INDIA ENGG.PVT LTD.

Option-3 Domestic coal 70% will be reclaimed by SCR-2 and fed into the trunk conveyor BCN-4 which will feed into the JNT-4. Imported coal 30% will be reclaimed by Conveyor BCN 7 and fed into the JNT-4. At JNT-4 both the coal will be blended and fed into boiler bunkers through series of conveyors.

e) Bunker Feeding System The coal as received in JNT-4 will be fed into steam generator bunkers through a series of belt conveyors BCN-8A/8B, BCN-9A/9B, BCN-10A/10B, BCN-11A/11B and BCN- 12A/12B, and traveling trippers as shown in the flow diagram. Other Auxiliary equipments like belt weigh scales, inline magnetic separator; metal detectors, dust extraction system, dust suppression, sampling system and ventilation system etc., will be provided as per flow diagram.

Date ISSUE/ Rev.

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Operational & Control Philosophy

Page 7 of 48

Tecpro Systems Ltd.

Document No. By Approved By Date ISSUE/REV

TPL-069-0788-I-DOC-053 VIVEK KM 26/05/10 R0

Project ClientCONSULTANT

COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.

M/s TATA PROJECTS LTD.HYDERABAD. FICTHNER INDIA ENGG.PVT LTD.

2.

ELECTRICAL SYSTEM DESCRIPTION The electrical power distribution system is provided at 3.3 kV & 415V, 3-phase; and 240V, 1phase, voltage levels to supply power to the drives and other electrical equipments / systems of the CHP (Coal Handling Plant). 3.3 kV power shall be distributed power supply to 3.3 kV motors for Belt Conveyor BCN8A/B, BCN-3, BCN-5, BCN-1A/B, BCN-4, BCN-7, Ring Granulator and Stacker Reclaimer machine Transformer. Three Electrical rooms are envisaged. ER-1 shall be located near to JNT-6 and shall receive power via two(2) no 11/0.433 KV service transformers. ER-2 shall be located near to JNT-4 and shall receive power via two (2) no 11/0.433 KV service transformers. ER-2 has been considered as the control room of the CHP and PLC, back up panel etc shall be housed in ER-2. ER-3 shall be located near to crusher House and shall be fed by two(2) no 11/0.433 KV service transformers.

ER-1 shall feed to the equipments in and around JNT-6 and shall house the following panels/equipments a) Service Transformer. b) PMCC-1. c) Welding Distribution Board. d) Main Lighting Distribution board. e) Power distribution board. f) PLC IO racks. ER-2 shall feed to the equipments in and around of JNT-4(CHP CONTROL ROOM) and shall house the following panels/equipments a) Service transformers. b) PMCC-2 c) Main Lighting Distribution Board d) Welding Distribution Board e) Power distribution Board f) PLC Panels g) UPS.Date ISSUE/ Rev. Description By

ITEM

Operational & Control Philosophy

Page 8 of 48

Tecpro Systems Ltd.

Document No. By Approved By Date ISSUE/REV

TPL-069-0788-I-DOC-053 VIVEK KM 26/05/10 R0

Project ClientCONSULTANT

COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.

M/s TATA PROJECTS LTD.HYDERABAD. FICTHNER INDIA ENGG.PVT LTD.

h) 220 V DC Battery. i) Battery Charger. ER-3 shall feed to the equipments in and around of Crusher House and shall house the following panel/equipments a) Service Transformers b) PMCC-3 c) Main Lighting Distribution Board d) Welding Distribution Board e) Power distribution Board f) PLC IO racks g) UPS.

Date ISSUE/ Rev.

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ITEM

Operational & Control Philosophy

Page 9 of 48

Tecpro Systems Ltd.

Document No. By Approved By Date ISSUE/REV

TPL-069-0788-I-DOC-053 VIVEK KM 26/05/10 R0

Project ClientCONSULTANT

COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.

M/s TATA PROJECTS LTD.HYDERABAD. FICTHNER INDIA ENGG.PVT LTD.

3. INSTRUMENTATIONAll the conveyors will be provided with following instruments / safety protections to ensure safe and trouble free operation a) Pull Cord Switch: All the conveyors will have pull ropes, connected to Pull Cord Switches on both sides. Switches shall be placed at 15M from either side and at intermediate spacing of 30M.In case of any abnormality or emergency, the operating personnel can stop the conveyor immediately by pulling the pull cord. Control room personnel will get corresponding TRIP indication on the PLC. Once operated, the lever of the pull cord switch will latch and the conveyor can not start without manually resetting the operated pull cord switch. Alarm and annunciation shall be generated from Pull cord switch operated in operator station and in Annunciation facia of back up panel. b) Belt Sway Switches: Belt Sway Switches are provided in pairs on both sides of conveyor . Switches shall be placed at 15M from either side and at intermediate spacing of 50M. If the belt runs away from the conveyor centreline by a significant amount, the switch gets acted and trips off the conveyor to prevent any damage to the belt edge. Control Room person will get a corresponding trip indication in the PLC. Service staff then should correct the problems causing the belt misalignment or run out and then only the conveyor should be started again. Alarm and annunciation shall be generated from Belt Sway switch operated in operator station and in Annunciation facia of back up panel. c) Local Control Station Local push button station shall be provided for all the drive motors of the plant. Start/Stop push buttons for unidirectional motors. FWD Start / Stop / REV Start push buttons for bidirectional motors and only start push buttons for Emergency motors.

Date ISSUE/ Rev.

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Operational & Control Philosophy

Page 10 of 48

Tecpro Systems Ltd.

Document No. By Approved By Date ISSUE/REV

TPL-069-0788-I-DOC-053 VIVEK KM 26/05/10 R0

Project ClientCONSULTANT

COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.

M/s TATA PROJECTS LTD.HYDERABAD. FICTHNER INDIA ENGG.PVT LTD.

d) Zero Speed Switch: Zero Speed Switch is installed on the Bend Pulley of the Conveyor to check for any belt slippage. If the belt speed falls below 85% of the Nominal Speed, the Zero Speed Switch will initiate TRIP command and stop the conveyor to prevent any damage to the belt. Service staff should correct the problem and then only the conveyor should be started. e) Bearing & Winding Temperature Detectors: All the HT Motors shall be provided with 12 Nos. Simplex Winding temperature detector & 2 Nos. Duplex bearing temperature detector to continuously monitor the Winding & Bearing Temperature. Conveyor Trip command will be initiated in case a high Winding & bearing temperature is detected by the RTD to safeguard the bearing.

f) Level Measurement: Ultrasonic type level transmitter with 2 wire type transmitter with 4-20mA output with HART protocol shall be provided for continous level monitoring of Boiler bunkers. These level indicators shall be provided with local LCD indicator and shall provide the continous level of the bunker in the CHP control room. Radar type, top mounted level switch shall also be provided to provide high and low level alarm in the control room.

g) Hooters:Hooters shall be provided one each in all the proposed transfer points & Bunker units. These hooters will alarm the people in the vicinity of the conveyor before starting the conveyor to move away from the conveyor. After the horn, people will have 1-2 min (adjustable) time to leave the conveyor and move to a safe location. The range of hooter shall be 500 m.

Date ISSUE/ Rev.

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Operational & Control Philosophy

Page 11 of 48

Tecpro Systems Ltd.

Document No. By Approved By Date ISSUE/REV

TPL-069-0788-I-DOC-053 VIVEK KM 26/05/10 R0

Project ClientCONSULTANT

COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.

M/s TATA PROJECTS LTD.HYDERABAD. FICTHNER INDIA ENGG.PVT LTD.

h) Space heater:All HT motors/LT motors 30 kw and above will be provided space heaters using 240V AC supply. It is used to protect the motors from moisture when the supply is off.

i) Heavy Duty Limit Switches Heavy duty roller type limit switch shall be provided to indicate the position and to stop the carriage before over travel. These switches shall be provided for Tripper to indicate the position, at remote. Travel limit switches shall be provided at each end of tripper carriage, for limiting the travel drive between two ends of the track. Each of these travel limit switches shall be duplicated with another limit switch. The first one shall be normal limit and the second one for over travel limit. On operation of normal limit switch, drive shall trip & the same shall be annunciated on the Local Control Panel. For some reason, if the machine over travels & operates over travel limit switch, then the control supply of Local Control Panel shall be cut.

j). VIBRATION MONITORING AND ANALYSIS SYSTEMVibration monitoring and analysis system (VMAS) shall provide condition monitoring and analysis of the bearings of HT Motors on continous on line basis. Vibration sensors shall be provided for both DE and NDE side of all HT motors and respective driven equipments. Vibration monitoring system shall consists of Velocity type vibration sensor. These sensors shall be mounted in both X and Y axis at 90 deg to each other. VMAS shall be microprocessor based system (PC based) and shall be interfaced with CHP PLC through redundant communication link. 4-20 mA output to PLC shall be considered to indicate the vibration level in the HMI. The Vibration analysis system shall determine the exact nature of the fault like misalignment, shaft crack, dynamic unbalancing etc. The analysis system shall perform the following analysis a) Bode plot b) Time wave form c) Orbit analysis d) Shaft centre line e) Cascade plotDate ISSUE/ Rev. Description By Operational & Control Philosophy

ITEM

Page 12 of 48

Tecpro Systems Ltd.

Document No. By Approved By Date ISSUE/REV

TPL-069-0788-I-DOC-053 VIVEK KM 26/05/10 R0

Project ClientCONSULTANT

COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.

M/s TATA PROJECTS LTD.HYDERABAD. FICTHNER INDIA ENGG.PVT LTD. f) g) h) i) j) Water fall Bar graph Current values Spectrum Alarms- amplitude and spectral

Vibration analysis system shall be provided with one(1) no 21 TFT, VDU, keyboard/mouse, Vibration analysis software, Bulk data storage etc.

4. TECHNICAL DETAILS & OPERATIONAL DETAILS OF PLC:The control & Instrumentation shall be through microprocessor based PLC system for the entire Coal handling plant covering the total functional requirement of sequence control, interlock & protection, monitoring, alarm, data logging. The CHP PLC shall be hot redundant and will have 100% redundancy features in CPU, power supply , communication and network interface. However, Inputs modules shall be non redundant and Output modules shall be redundant only for critical drives. Information peripherals at the output hierarchy i.e. TFT, printer etc. will be connected within main processor. Redundant UPS system will be incorporated for smooth functioning in CHP control room. The PLC system shall be an integrated control and data acquisition system for providing control & monitoring of coal handling plant equipment from a Main CHP Control Room Building (ER-2) located near JNT-4.The control Room operator shall be provided with color graphic displays of the Coal handling plant and with sufficient details to allow proper control & monitoring of the plant functions. The PLC system consists of PLC panel, operating station (OS), Engineering station (ES) & alarm annunciation. ER-2 shall house the redundant PLC. Remote IO panels shall be provided in ER-1 & 3 for the equipments located near to the respective control rooms. Stacker cum reclaimer machine shall be provided with separated independent redundant PLC system. Stacker cum Reclaimer machine PLC shall be housed in Electrical House on the machine. One (1) no independent redundant bi-directional OPC link with Ethernet based TCP- I/P protocol in envisaged for interfacing with main plant DCS. Two (2) nos VDU/KB based operator station(OS) andDate ISSUE/ Rev. Description By

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Operational & Control Philosophy

Page 13 of 48

Tecpro Systems Ltd.

Document No. By Approved By Date ISSUE/REV

TPL-069-0788-I-DOC-053 VIVEK KM 26/05/10 R0

Project ClientCONSULTANT

COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.

M/s TATA PROJECTS LTD.HYDERABAD. FICTHNER INDIA ENGG.PVT LTD.

one (1) nos engineering work station each with single VDU and single keyboard/optical mouse/trackball has been envisaged. Engineering and Operator station shall constitute of 21 TFT monitor with optical mouse/ track ball/. Resolution shall be 1280 X 1024 pixels. Main memory capacity shall be 8 MB with 160 GB hard disk and shakll have DVD/CD RW drive.One nos. Large Video Screen (LVS) with complete accessories suitable for operation and monitoring of plant equipment/system is also envisaged.

The PLC shall be time synchronized from Master Clock System. PLC Port connectivity provision for GPS link from Master Clock (Time Protocol / NTP / IRIGB NTP / any other standard protocol). System shall be with redundant configuration Spare philosophy for PLC

1. Spare I/O Channels: All types of I/O modules shall be provided with 10 % spare channels. Spare channels shall be wired and shall be distributed among the Control processors.2. 10% hot spare I/O modules (installed) shall be provided.

3.10% spare slots for I/O modules distributed among the control processors.UNINTERRUPTED POWER SUPPLY(UPS)

Redundant UPS shall be provided in ER-2 (CHP control room) & ER-3(near crusher house).The system shall be provided with redundant UPS power supply. The power supply provision shall be such that on failure of one power supply the other power supply shall cater to the requirement of the equipment so as never to hinder the functioning of the system in any manner due to power supply failure. 4.1) LARGE SCREEN VIDEO DISPLAY SYSTEM (LVS)

The overall screen size shall be 84 Diagonal to be used as an integrated, single large screen and also to have picture in picture facility. The Large Screen System shall have the functionality to pre configure and save various display layouts to be accessed at any given point of time with a simple mouse click.Date ISSUE/ Rev. Description By

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Operational & Control Philosophy

Page 14 of 48

Tecpro Systems Ltd.

Document No. By Approved By Date ISSUE/REV

TPL-069-0788-I-DOC-053 VIVEK KM 26/05/10 R0

Project ClientCONSULTANT

COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.

M/s TATA PROJECTS LTD.HYDERABAD. FICTHNER INDIA ENGG.PVT LTD.

This LVS shall be used as an OWS with its own dedicated electronics.

The Large Screen Graphics Wall for each unit in Control Room will primarily be used for : a) Display of important data, graphics coming from the PC, Workstation, Video, SCADA etc. To provide real time clear luminous view to share information to operators and visitors. The Large Screen Graphics Wall shall be installed in the Control Room. The overall screen size shall be 84 diagnol to be used as an integrated, single large screen and also to have picture in picture facility. The overall resolution of the graphics wall shall be min 2560mmX2048mm pixels.It should be possible to have the whole screen of the Large Screen Graphics Wall should behave as a single logical screen or in multiple nos of screens (min 4 nos) and the control of the same should be from a dedicated Graphical Control Unit (Controller) having a Keyboard & mouse. The complete system shall be interfaced on 10/100 MBPS LAN. The Large Screen System should have the functionality to pre configure and save various display layouts to be accessed at any given point of time with a simple mouse click. The system should be possible to show the mirror images of operator workstations in freely resizable and repositionable windows. The system should be configured such that any of the operators sitting on the same Ethernet should be able to work on the Large Screen sitting at his own position with his local keyboard & mouse. The offered system should be able to work in 24/7 days environment and is of industrial nature.

b)

c) d)

d)

e) f)

g) h)

. i)

Date ISSUE/ Rev.

Description

By

ITEM

Operational & Control Philosophy

Page 15 of 48

Tecpro Systems Ltd.

Document No. By Approved By Date ISSUE/REV

TPL-069-0788-I-DOC-053 VIVEK KM 26/05/10 R0

Project ClientCONSULTANT

COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.

M/s TATA PROJECTS LTD.HYDERABAD. FICTHNER INDIA ENGG.PVT LTD.

The Rear Projection Module shall have specifications:1.

the

following

The Graphics Wall should be made up of 3 nos. of rear projection modules placed in a single row. The rear projection modules must be based on Single Chip DLP Rear Projection technology. Each of the Rear Projection Module shall h a v e a resolution of 2560 x 2048 pixels and offer 3.7 million colours. Each Rear Projection module should be equipped with a long life, low power redundant UHP lamp. The average lamp life shall be 6,000 hrs (for 110 Watt UHP Lamp). The system should have an in-built lamp redundancy for the availability of the system in the event of a sudden failure of the lamp. The brightness uniformity shall be >95%. The contrast shall be equal to better than 600:1. The luminance on each rear projection module shall be min. 250 cd/m2 (typical) using single lamp. The system should have an in-built optical dimmer to match the brightness of the various projection modules automatically to get a fully uniform display wall. The screen to be used shall be double element-stitched screen. The seam between adjacent screens shall be