orot-rabin power station, units 1, 2, 3 and 4 ... b - specification mm-2701 .pdf · 14.3 system...

THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B"

Engineering Division SPEC.: MM-2701

ISSUE: For Proposal

B - 1

OROT-RABIN POWER STATION, UNITS 1, 2, 3 and 4

SPECIFICATION MM-2701

PLANT CONTROL & MONITORING SYSTEM (PCMS)

ANNEXURE "B"

PROJECT SPECIFICATION

THE ISRAEL ELECTRIC CORPORATION LTD.

Engineering Division



ISSUE: For Proposal

PCMS Annexure B June 2017 B - 2

Annexure "B" Table of Content

1. Purchaser

2. Name of project

3. Location of project

4. Scope of work

4.1 Scope of Engineering and Supply

4.2 Special Equipment, Tools and Instruments

4.3 Contractor Services

4.4 Work by Others (Facilities and Services to be provided by Purchaser)

4.5 Terminal Points and Terminal Connections

4.6 Commissioning and Combustion Tuning

4.7 Guaranteed Performances and Testing

5. Supplements

6. Standards and Codes

7. Quality assurance and quality control

8. Shipment and Handling of Goods and Documentation

9. Safety, Noise, Environment and Loading Requirements

9.1 Safety

9.2 Noise

9.3 Environmental data

9.4 Earthquake Loads

10. Project system security standard specification

11. Technical Documentation

12. Spare and Renewal Parts

13. Existing Power Station Description

13.1 Existing Power Station Description

13.2 Existing main systems included in project's scope

14. Technical Requirements

14.1 General requirements

14.2 Functional requirements

14.3 System architecture

14.4 Reliability, Availability & Maintainability (R.A.M.)

14.5 Redundancy

14.6 PCMS Embedded Cyber Security (PCMS-ECS)

15. Plant Control & Monitoring System Design Requirements

15.1 Combustion Control System

15.2 Burner Management System (BMS)



ISSUE: For Proposal


16. Control System Equipment Requirements

16.1 Accuracy and Resolution

16.2 Process Data Highway

16.3 Input/Output Equipment

16.4 Processing Controllers

16.5 Communication links

16.6 Auxiliary Equipment

16.7 Power Supplies

16.8 Human-Machine Interface

16.9 Application Requirements for Data Processing and Monitoring

17. Electrical Requirements



ISSUE: For Proposal


SPECIFICATION for

Plant Control & Monitoring System (PCMS)

1. PURCHASER: The Israel Electric Corporation Limited.

2. NAME OF SITES: Orot-Rabin Power Station, Units 1, 2, 3 and 4

3. LOCATION OF SITES: Orot-Rabin, Near Hadera

On the Mediterranean Sea Shore.

4. SCOPE OF WORK:

General

The Scope of Work for this specification includes Engineering, Equipment and

Services for a new Plant Control & Monitoring System (PCMS) and modernize

main HMI for Orot-Rabin Power Station for one (1) Unit (as basic scope) and for

three (3) additional Units (optional scope).

The project does not include replacement of field devices and field cables.

It is essential that the new control equipment shall be compatible with the

existing field devices, especially the drive units which are controlled by pulses.

The scope of work shall include, but shall not be limited to the following:

4.1 Scope of Engineering and Supply:

Within the scope of engineering and supply the contractor shall, as applicable,

design, develop, engineer, manufacture, preserve, assemble, tune, shop test,

pack and furnish with export packing the following:

4.1.1 Basic and Optional Scope of Engineering and Supply, subdivided as follows:

4.1.1.1 Basic Scope of Supply for one (1) Unit, of Orot-Rabin Power Station.

The Plant Control & Monitoring System shall include, as a minimum, the

following:

a.1 Complete new System, based on DCS technology, including the

following:



ISSUE: For Proposal


a.1.1 Combustion Control System (CCS) in accordance with existing

Combustion Control System (CCS) function requirements.

a.1.2 Burner Management System and Boiler Protection System (BMS), for

ignition gas, light oil (first elevation only), heavy oil and coal firing to

allow safe, reliable and efficient operation of the Unit.

a.2 New Human Machine Interface (HMI), based on compatible hardware

and software platform include, as a minimum, the following:

a.2.1 Two (2) Operator Workstations, each with four (4) 24" screens, desktop

mounted with touch screen option.

a.2.2 Two (2) Operator Workstations, each with two (2) 55" Large Screens.

a.2.3 Two (2) Shift Engineer Workstation, each with one (1) 24" screen,

desktop mounted.

a.2.4 Three (3) Engineering Workstations, each with one (1) 24" screen.

a.2.5 Reserved.

a.2.6 One (1) pair (for redundant configuration) of servers for data

transmission to DPMS system (provided by others) using OPC.

a.2.7 Three (3) A4 color laser printers.

a.2.8 Back-up devices including a backup server and local software shall be

provided to enable periodic backup of the data and complete image

backup of the workstations.

a.2.9 Data storage server for Historical data for a minimum period of one year

of data.

a.2.10 All the required up-to-date software: programs and applications to

ensure performance of complete integrated system and of its

subsystems according to this specification (including licenses).

The application software shall include the application software (protocol

conversion) for all the communication interfaces and the development of

100 graphic displays.



ISSUE: For Proposal


a.2.10 Emergency panel with Emergency pushbuttons and additional hardwired

Control devices.

a.2.11 All the hardware and software which provide the implementation of

Embedded Cyber Security (ECS) requirements, as stipulated in

paragraph 14.6 and throughout this specification.

a.2.12 All the necessary hardware and software in order to synchronize the

system with an external IRIG-B format signal generated by Plant GPS

clock per subsystem.

a.2.12 Two (2) firewalls to protect the PCMS Operation Network from external

connection.

4.1.1.2 Optional Scope of Supply for up to three (3) additional Units of Orot Rabin

Power Station, to be exercise for each Unit.

The optional Scope of Supply will be similar to the Basic Scope, item 4.1.1.1

above.

4.1.1.3 Contractor's Basic Scope of Design

The detail design for the implementation of the new/retrofitted control systems

shall be performed by the Contractor and shall include, but shall not be limited

to:

a. System configuration design and implementation, based on the logic

provided by Purchaser (IEC) or different manufacturers, to ensure that

all inputs/outputs required by the logic, are engineered into the new

system.

b. Evaluation of the existing equipment to ensure that the new/upgraded

equipment meets the project requirements.

The Contractor shall be also responsible for the Coordination between

the new Combustion control and the existing Turbine control for

maximum stability and Unit response.

c. All hardware design, software development and implementation of the

new Plant Control & Monitoring System.



ISSUE: For Proposal


d. Cable listing of all internal cables for data highways and cables between

control cabinets or other equipment forming part of Contractor's Scope

of Supply.

e. Development of a database for all tags that are required to be

implemented in the Plant Control & Monitoring System, including inputs,

outputs, calculated values, graphic tags, etc.

f. Design and implementation of the graphics for the Operator Interface

(display content, menus, object dynamic behavior, colors, etc.) as

correlated with system database.

g. Establishing procedures and instructions as may be required for the

systematic dismantling of the old equipment.

h. Establishing procedures and instructions as may be required for the

orderly installation of the new equipment.

i. Establishing grounding requirements and providing procedures and

instructions for proper operation of the Equipment.

The Contractor will provide an evaluation of IEC's existing grounding

system as part of the Field Service scope.

j. Establishing an itemized priced list of recommended test and spare

equipment (if necessary) to be used in maintaining, troubleshooting,

calibrating, and repairing of the Control System and associated

hardware provided per this specification.

k. Engineering for all the communication interfaces within the Plant Control

& Monitoring System and for communication interfaces with DPMS

(supplied by others), including hardware characterization, software

development, protocols conversion, HMI, etc.

l. The Contractor will take into consideration that if one Unit is in operation

and the other is in the maintenance mode, the functions for the common

equipment should be in operation continuously.

The Contractor shall organize Design review (DR) meetings for each stage of

design, for each system.

4.1.2 The Equipment for each Unit shall be supplied complete with appurtenances and

accessories as specified herein, to form a complete system which will achieve



ISSUE: For Proposal


and assure safe and reliable operation with best overall performance at all loads

and modes of operation. All components, appurtenances and accessories shall

be of proven design.

4.1.3 Detailed Scope of Supply:

The Plant Control & Monitoring System shall be of DCS type, based on state of

the art technology, incorporating an integrated design.

The System shall include:

a) Processing cabinets, for I/O cards, processing units and

marshalling/termination cabinets for field cables connection.

The Contractor should consider using the existing control and

instrumentation field cables (due to the infrastructure and space

problems), meaning that existing termination cabinets shall be used for

marshalling (if applicable), or that new cabinets shall be designed

according to the existing cables layout, otherwise the Contractor shall

consider using I/O cabinets in Central Electronic room and define

additional space required for the control, communication and computer's

equipment. The solution shall be reflected in the proposal.

The cabinets shall be secured with lock and provided with cooling fans

for heat dissipation.

b) All computers, servers and communication devices shall be located in

Computer Room or Electronic Room and not in the Main Control room.

Therefore, cabinets required to accommodate these computers shall be

supplied.

The Contractor shall also provide all the necessary devices and cables

(such as KVM extenders) connecting computers to their related screens,

keyboards and mice (the distance between them is approx.200m).

c) Every cabinet housing the servers and computers shall have a local

maintenance station enabling local support including a keyboard &

screen.

d) All redundant power supplies, power distribution and power regulating

devices.

e) All the required signal conditioning and interfacing equipment,

transducers, interposing relays, etc.



ISSUE: For Proposal


f) Redundant Data highways and redundant communication interfaces

between highways.

Cabinets for installation of communication equipment (switches, routers,

bridges, etc.) shall be provided.

g) All the required Workstations should provide a complete integrated HMI

(single window to process) according to this specification.

h) Printers, displays, keyboards, mice, data storage and back up devices.

i) All the required software: programs and applications to ensure

performance of complete integrated system and of its subsystems

according to this specification.

Complete programming, including flow-charting, coding, program entry,

debugging and simulation shall be provided.

The System shall be based on the Contractor's last version of equipment

available on the market at the bid date.

j) Development and implementation of 100 process graphic displays per

Unit.

k) All the hardware and software which provide the implementation of

Embedded Cyber Security (ECS) requirements, as stipulated in

paragraph 14.6 and throughout this Specification, for the complete

PCMS.

l) Emergency Panel with all the necessary Emergency Pushbuttons and

other Hardware control devices.

m) All the necessary hardware and software in order to synchronize the

system with an external IRIG-B format signal generated by Plant GPS

clock.

n) All the prefabricated cables interconnecting the components within

Contractor's Scope of Supply.

o) Any special test equipment required for operation and maintenance of

the system (if required).

p) All the necessary hardware and software for communication interfaces

to external systems (external cables will be provided by Purchaser).



ISSUE: For Proposal


q) The System shall include 20% (for each Subsystem) implemented spare

capacity for I/O’s (I/O's termination facilities, I/O modules, power

supplies, internal wiring, etc.).

The Contractor shall include also at least 20% additional spare capacity

for future expansion. Specifically this means spare space to mount I/O

modules and their associated terminal units (the extra spare I/Os and

extra space shall be provided for each type of I/O).

In addition, spare capacity within the Workstations (both Operators' and

Engineers'), Servers to expand the database and application programs.

4.1.4 The Contractor shall be responsible to ensure that the equipment supplied under

this Contract, shall perform the entire scope of functions and assignments

detailed or implied by this specification, individually, as well in combination with

the existing equipment.

The Contractor shall organize Site survey for full understanding of the existing

system's function/interfaces and Design Review (DR) meetings for each stage of

project, for each system.

4.1.5 Components that are herein specified in regard to manufacturer brand and

model or type shall be considered the standard of supply. The Contractor may

make an appropriate substitution, but all substituted Components offered shall

be noted as EXCEPTIONS to this Specification and are subject to review,

comment, and approval by the Purchaser.

Additionally, while everything else being equal and without derogating from

Contractor's responsibilities under the Contract, the Contractor shall endeavor to

include in the scope of design and supply, components and accessories

manufactured in Israel.

4.1.6 Contractor shall provide, in the required format and form and in a timely manner,

all documentation required by this Specification and/or required by applicable

Standards and Codes and/or as specifically detailed in the Documentation

Submission Schedule (DSS), Annexure "J". A consistent nomenclature shall be

used project-wide in naming all component parts within the Scope of Work. This

shall apply to all drawings, Instruction Books, Bill of Materials, special

instructions, etc. Engineering design shall commence immediately after Contract

award. The cost of correcting inconsistent nomenclature shall be borne by the

Contractor.

4.1.7 Changes in design already approved by the Purchaser are normally unaccepted.

However, should such changes become necessary on an exceptional basis, the



ISSUE: For Proposal


Contractor shall obtain the Purchaser's approval prior to introducing any such

change.

4.2 Special Equipment, Tools and Instruments (if required)

4.2.1 Contractor shall provide all special equipment, tools and instruments required for

safe and secure transport of all components from ex works to final destination,

and for test and maintenance of Equipment provided under this Contract. Said

equipment, tools, and instruments should be in Contractor's Proposal where it

should be clearly stated which are provided on a loan basis and which are

included in the Contract Price.

4.2.2 The Contractor shall furnish all necessary special tools, instruments and/or test

equipment which are required to fulfill the approved test procedure for equipment

tested by Purchaser.

4.2.3 Maintenance equipment and tools provided under this specification shall be new

and of best quality. They shall be shipped to the job site in a suitable separate

box, clearly marked with the name of the equipment they are intended for.

4.3 Contractor Services

The Contractor shall provide the services listed in the following sub-articles as

part of the basic Scope of Work or as Purchaser’s option, at the per diem or

lump sum rates, all as stated in the Summary of Prices and Delivery Schedule,

Annexure “C1”. Field personnel provided by the Contractor shall be capable and

qualified to perform the required duties to the satisfaction of the Purchaser. They

shall be vested with authority to make decisions that could affect the status of

the Equipment and which are binding on the Contractor.

4.3.1 Erection Services:

Contractor shall provide the services of competent advisors to direct and instruct

Purchaser's personnel during erection, including, without limitation, identifying

the equipment, unpacking, intermediate storing, erection sequencing and

erection checking as may be required to assure proper and successful erection

and installation of the Equipment provided under this Specification.

4.3.2 Commissioning and Start-Up Services:

Contractor shall provide the services of competent engineers to calibrate, tune,

commission the Systems and to direct Purchaser's personnel and assure proper,



ISSUE: For Proposal


complete and successful commissioning, starting, placing into service of the

Equipment provided under this Contract with the balance of equipment at the

related power station Unit(s).

4.3.3 Training:

Contractor's personnel shall conduct a thorough training course on site pertaining

to the equipment furnished under this Specification, for Purchaser's personnel

(operation, maintenance and engineering/design teams), covering, without

limitation, correct design, start-up, safe operation at all modes of operation, safe

shutdown and general maintenance. The Contractor shall verify that the trainees

are completely familiar with all phases of such procedures and are capable of

operating and maintaining the equipment successfully.

In addition, Contractor’s personnel shall conduct a thorough training course for

Purchaser’s maintenance personnel with respect to The Plant Control &

Monitoring System Equipment, including hardware and software of control logic

system. The course shall be conducted at the Contractor’s or Subcontractor’s

sites before conducting Equipment Field Performance Test. The Purchaser’s

maintenance personnel, qualified through said training course, shall take part in

Contractor’s or Subcontractor’s factory tests of the Control Equipment.

4.3.4 Acceptance Test

4.3.4.1 Inspection and Testing - General

The Purchaser shall have the right at all reasonable times to inspect and test the

work.

Contractor shall make all necessary arrangements and provide all reasonable

facilities and access for such inspection and testing, either at Contractor's shop

or offices or at the shops or offices of any manufacturer where any part of the

work is being designed, fabricated or manufactured.

The Contractor shall receive the list of anticipated inspections by the Purchaser

and shall give ample notice as to the time and place when each part of the work

will be ready for such inspection. Purchaser may reject any part of the work

found to be defective or not in accordance with the Contract. Such inspection by

the Purchaser shall in no way relieve the Contractor from his obligation to furnish

the work in accordance with the Contract.

In the event the Contractor fails to provide the Purchaser with reasonable



ISSUE: For Proposal


facilities and access for such inspections and if, in the opinion of the Purchaser,

it is necessary to dismantle the equipment for such inspection, then Contractor

shall bear the expense of such dismantling and reassembly.

The Factory Testing shall be performed, according to Annexure “D” - Equipment

Performance Guarantees, for the new equipment and subsystems

within the Contractor's Scope of Supply that can be mounted on factory: e.g.

Combustion Control, Boiler Management System and the related

HMI and communication equipment (data highways, servers, HMI's, etc.).

The Site Field Test shall be performed for the complete system, including new

and existing/upgraded equipment and subsystems.

4.3.4.2 Factory Acceptance Test (FAT) shall be conducted according to Annexure “D” -

Equipment Performance Guarantees.

4.3.4.2.1 Contractor shall perform a complete cyber security test prior to the FAT

according to paragraph 14.6.

4.3.4.2.2 The Contractor shall perform, according to Contractor's Standards, a complete

functional test of the Systems at the factory, to assure that the System

components are properly interconnected and that the control strategy is properly

configured.

The Purchaser shall participate in the FAT.

The Purchaser shall be notified of the test dates in writing at least sixty (60) days

prior to the tests and shall be given a list of the proposed test procedures with

that notification. FAT procedures should be provided for Purchaser (IEC)

approval.

All system subassemblies such as modules, power supplies, workstations, disks,

peripherals, etc. or subassemblies identical in design and construction shall

have undergone tests under ambient temperature conditions as specified herein

without malfunction or degradation of performance.

4.3.4.2.3 The test shall demonstrate that all the specified types of modulating and logic

functions, including unit, function and protection levels, are satisfactorily

accomplished. The demonstrations shall include the operator stations with their

keyboards, and any other equipment as well as all inter-connections within and

between equipment cabinets. Input and output signals of the field equipment not

available during the preliminary test, shall be simulated by the Contractor, using

his equipment (hardware and software).

Each type of drive control loop shall be tested with simulation equipment.



ISSUE: For Proposal


4.3.4.2.4 Contractor's tests shall also include the following:

a. Physical inspection for conformance to drawings and appearance of

equipment;

b. Demonstration of the proper functioning of all the types of hardware by

a thorough exercising of each device, including CPU's and distributed

processors, individually and collectively;

c. Demonstration of a complete system software generation; the system

being tested should be generated from scratch using the resource media

provided;

d. Demonstration of the proper functioning of all the software, including

test cases with normal and exception data;

e. Simulation of alarm(s) and status change conditions;

f. Simulation of a subset of process inputs from convenient test panels or

simulator, which allow individual analog inputs to be varied over the entire

input range via individual setters and individual digital and pulse inputs to be

acquired;

g. Demonstration of input conversions, calibrations and transformations;

h. Simulation of input noise and transient conditions;

i. Deleted;

j. Demonstration of all HMI interface functions in English and Hebrew;

k. Simulation of failure situations and failure of each component that is

redundant (controllers, communication, power supplies, workstation(s), etc.);

l. Demonstration of data base management software of the Engineering

Station, including tests to verify on-line addition/deletion of points and

modifications to various system and application data files;

m. Demonstration of the display generator/editor, log generator/editor and

other software maintenance functions;



ISSUE: For Proposal


n. Demonstration of the Graphic Displays in English and Hebrew;

o. Demonstration of on-line editing, controller programming, testing and

integration;

p. Demonstration that average and peak load system timing requirements

have been met while exercising all vendor-supplied software;

q. Demonstration of the use of on-line and off-line diagnostics and test

programs;

Demonstration of simulated DHW error detection and recovery.

Simulation of all interfaces (links) from other systems.

Simulation of IRIG-B synchronization.

Demonstration that spare capacity and response time requirements have

been met, including execution of a simulated maximum sized application

program;

r. 1. Recovery from AC power source failure, if applicable.

r. 2. Recovery from DC power supply failure.

s. Random inspections to verify the accuracy of hardware and software

documentation;

t. Demonstration of the accuracy of the system performance monitoring

software.

Contractor shall supply detailed test reports including the results of items

above.

4.3.4.2.5 Changes necessary for the system to perform the specified functions shall be

made in a permanent on-line manner and re-tested before completion of the

test activities.

All costs arising from factory simulation tests, including replacement of

damaged materials, shall be borne by Contractor. The Contractor shall submit

a written test report.

4.3.4.2.6 When the Contractor has completed his simulation, the Purchaser reserves

the right to perform a "hands-on" demonstration of all the equipment.

When the Purchaser is satisfied with all the above tests and test report is

signed by both parties, the FAT is considered complete.



ISSUE: For Proposal


4.3.4.2.7 Prior to shipment, all necessary components of the system shall have

experienced power-on-operation of at least thirty (30) days unless otherwise

agreed. The test shall include a two hundred (200) hour continuous run and

provide a report of any failed items during this period. The assembled system

includes I/O circuitry cabinets, communication devices, peripherals such as

printers, digital displays, recorders, screens, etc., workstations of all kinds and

the data highway, with all system software configured, uploaded and running.

4.3.4.2.8 Factory tests shall be scheduled early enough before shipping, to permit

debugging the hardware and/or software problems which may occur during

the tests. Tests shall cover all functions to be performed by the System.

4.3.4.2.9 Upon satisfactory completion of the System tests, the equipment shall be

considered completed and no hardware shall be changed, replaced

substituted or otherwise altered except upon written agreement with the

Purchaser. Under no circumstances may the System hardware be used to

supply parts for tests or substitution in other tests in the Contractor's facilities.

4.3.4.2.10 All procedures during installation, assembling, connecting, loading and testing

during FAT, packing and shipping shall be in accordance with Security of

critical project performed by vendor abroad, supplement 5.1.5.

4.3.4.3 On Site Field Test – Site Acceptance Test (SAT) shall be conducted

according to Annexure “D”.

4.3.4.3.1 The Purchaser will run an extensive field performance test, which shall be

carried out after the complete system has been fully erected, installed,

connected to mounted field equipment and placed in service. The purpose of

this test is to demonstrate compliance of the delivered system with plant

requirements.

Criteria and procedures for Acceptance Testing are to be developed by

Contractor and mutually agreed upon by Purchaser and Contractor.

The successful accomplishment of this field test shall certify the unqualified

acceptance of the delivered system and mark the beginning of the warranty

period.

4.3.4.3.2 The following procedure shall apply:

Submission of a Test Plan



ISSUE: For Proposal


The Contractor shall prepare a detailed plan of the suggested tests to be

carried out on site. The plan shall follow the factory performance test and

shall include:

a. A set of tests to verify that system performance is equal to the

performance during factory tests.

b. A start-up and on-line tuning procedure of all loops.

c. One cycle of plant start-up and shut-down.

d. An uninterrupted running of the entire control system (including as

many plant start-ups and shut-downs as dictated by process

considerations) for a period of 4 weeks. Any interruption of the power

generation due to system failures, shall cause a renewed counting

(repetition) of the 4 weeks period.

e. A set of tests (performance tests) to verify that the guaranteed values

are fulfilled.

4.3.4.3.3 Testing

The Contractor shall provide all special equipment, tools and instruments

needed for the acceptance tests.

The Purchaser will document every single step of the tests performed,

including: date, identification of logic channel, functions and devices tested,

test results, comments and signature.

Unsuccessful tests, factory acceptance test as well as on-site field test, shall

be repeated after the defect (whether in design, hardware, software,

documentation or installation) has been rectified by the Contractor at his own

expense. Contractor shall rectify any defects within a reasonable period not

exceeding 2 weeks. Replacement parts are to be supplied at the expense of

the Contractor.

4.3.4.3.4 Acceptance Document

Upon successful completion of the on-site tests, an acceptance certificate will

be issued by the Purchaser.

Purchaser will issue a qualified acceptance document if 98% or more of the

performed tests were successful, under the provision that the Contractor shall

rectify any outstanding defects within 3 months.



ISSUE: For Proposal


An unqualified acceptance document will be issued if less than 98% but more

than 80% of the tests were successful.

No acceptance document will be issued if less than 80% of the tests were

successful.

4.4 Work by Others (Facilities and Services to be provided by the Purchaser)

In performing its duties the Contractor shall not be required to provide facilities,

services and equipment as detailed below [further details with respect to

Purchaser's undertaking regarding qualifications, quality, quantities and

scheduling should be in accordance with Contractor’s information defined in

scope of design and should be stated in Contractor’s proposal]:

4.4.1 Purchaser's Scope of Supply:

- Cables (Power, instrumentation and control)

- Cable Trays

- Fire detection and protection system.

4.4.2 Purchaser's Scope of Design:

- Designating tag numbers for Control cubicles, electrical and control

equipment, junction boxes, cables, drawings, etc.

- Electrical design, including connections to field equipment, junction boxes,

external connections, etc.

- Electrical feeding to Contractor's electrical equipment.

- Electrical Rooms:

- General arrangement drawings.

- Data for civil design.

- Equipment erection and base frames.

- Cable tray system.

- Cable routing.

- Grounding system external to the PCMS

- Electrical installation drawings and documentation.

- Fire stops and fire breaks.

- Lighting and power system.

- Air condition system.

- Fire detection and protection system.

- Basic I/O list

- Graphic displays' drafts

- Control Logic Diagrams (CLD)

4.4.3 Purchaser's Erection Services



ISSUE: For Proposal


Purchaser shall provide all the necessary labor force, general purpose tools and

facilities in order to dismantle, erect and install the Equipment provided under

this Specification, following Contractor’s instructions and according to

Contractor’s procedures and supervision.

4.4.4 Commissioning, Start-up and Performance Test Services

Purchaser shall provide all the necessary labor force, general purpose tools and

facilities in order to perform commissioning and start-up of the Unit and to

perform performance tests following Contractor’s instructions. Contractor shall

take into account that due to the broad scope of the System, several experts

may be required to be in the field simultaneously.

4.5 Terminal Points and Terminal Connections

Contractor shall terminate the Equipment provided under this Specification at the

agreed upon terminal points with the appropriate terminal connections taking into

consideration that:

4.5.1 All electrical and control cabinets shall be terminated at the terminal blocks for

incoming and outgoing cables.

4.6 Commissioning and Combustion Tuning

The commissioning and combustion tuning of the Equipment shall be conducted

in accordance with the provisions set forth in Annexure “D” to the Contract –

Equipment Performance Guarantees.

4.7 Guaranteed Performances and Testing

The performances of the Equipment shall be verified by a site test in accordance

with the provisions set forth in Annexure “D” to the Contract – Equipment

Performance Guarantees.



ISSUE: For Proposal


5. SUPPLEMENTS:

The following supplements are attached hereto and their requirements form an

integral part of this specification - to the extent they are consistent and conform

with the requirements specifically set forth herein. In the event of a variance

between the requirements of the Supplements and the particular requirements

set forth in the Specification, the requirements specifically set forth in the

Specification shall take precedence.

5.1 Purchaser's general documentation, quality assurance, quality control

requirements:

5.1.1 Standard 01-1E Standard Specification for Contractor’s Drawing

and Data Transmittal.

5.1.2 Q-APP-02-PR: Quality requirements from suppliers.

5.1.3 General Security Safeguard Requirements for Control and Data Acquisition

Systems in IEC - Power Stations.

5.1.4 Detailed Security Safeguard Requirements for Control and Data Acquisition

Systems in IEC - Power Stations– Project MM-2701 [Later].

5.1.5 Security of critical project performed by vendor abroad [Later].

5.2 Purchaser's standard electrical requirements and data sheets:

5.2.1 EPD-A.03/04 Control Cubicles – Electrical Wiring Requirements

5.2.2 Deleted.

5.2.3 EPD-A.20/04 Contact Rating of Mechanical, Electromechanical

and Solid State Devices

5.2.4 EPD-A.19/04 Nominal Voltage, Frequency and Phase rotation of

Instruments and Control units

5.2.5 EPD-2/99 Standard requirements for painting and corrosion

protection of electrical equipment.

5.2.6 EPD-B.32/05 PLC/DCS Based Control Systems Control and Operation

of Typical Devices.



ISSUE: For Proposal


5.3 Purchaser's drawings

5.3.1 System configuration Drawings:

MD0/05-I15-N00001-IC, Rev 01

5.3.2 Functional diagrams

5.3.3 Electronic Room general arrangement

5.3.4 Control Room arrangement

5.3.5 Typical logic diagrams (final elements)

6. STANDARDS AND CODES:

6.1 Standards and Codes referenced in this Specification and in the Supplements to

this Specification form an integral part of this Specification - to the extent their

requirements are consistent and conform to the requirements specifically set

forth herein. All such Standards and Codes are to the issue, including all

amendments, supplements, etc., current as of the date of the Contract, unless

indicated otherwise. In the event of a variance between the requirements of the

Standards and Codes and the particular requirements set forth in the

Specification, the requirements specifically set forth in the Specification shall

take precedence.

6.2 The Equipment to be provided under this Specification, including all

appurtenances and accessories, shall be designed, fabricated, inspected,

tested, stamped and preserved to the extent indicated in said referenced

Standards and Codes. Where this Specification does not include such reference,

The Equipment, or any of its components, shall be designed, fabricated,

inspected, tested and preserved, as applicable, to comply with currently

recognized International and/or Contractor's Standards, whichever are tighter

and more restrictive.

6.3 The Contractor may propose Standards and Codes as alternates for, or

additions to those specified herein. A copy of each proposed Standard and

code, if any, shall be submitted (in English) for Purchaser's approval. In case

Purchaser's approval is granted, the Contractor shall remain responsible for the

compatibility of the design and the physical interfaces between the supplied

Equipment and the equipment supplied by others.



ISSUE: For Proposal


6.4 The Purchaser shall assist Contractor in identification of Israeli codes and

standards applicable to the Work. In all cases Contractor shall adhere to and

comply with the requirements of Israeli official standards found to be more

restrictive than those specified herein.

6.5 Subject to the provisions stated above, the equipment shall be designed,

manufactured, erected, tested operated and maintained in accordance with the

standards, regulations, directives and publications of the following agencies and

organizations:

ANSI: American National Standards Institute, Inc.

NEMA: National Electrical Manufacturer's Association.

ABMA: American Boiler Manufacturer's Association.

NFPA: National Fire Protection Association.

ISA: Instrumentation, Systems and Automation Society

IEC: International Electrotechnical Commission.

NEC: National Electrical Code.

IEEE: Institute of Electrical and Electronics Engineers

OSHA: Occupational Safety and Health Administration, as applicable

6.6 Furthermore, without derogating from the technical requirements stipulated in

this specification, the items listed bellow shall be designed in accordance with

the standards specified herein or their equivalents:

6.6.1 Control Logic:

- NFPA 85 - Standard for the prevention of

furnace explosions/implosions in

multiple burner boiler-furnaces.

- NFPA 850 - Recommended practice for fire protection

for electric generating plants.

- NFPA 70 - National Electric Code.

6.6.2. Fire detection and protection:

a. National Fire Protection Association Standards (NFPA) or

b. British Standards (Great Britain) and European standards

c. Local industry standards

7. QUALITY ASSURANCE AND QUALITY CONTROL:



ISSUE: For Proposal


7.1 Without derogating from the provisions of the General Conditions, Contractor's

quality system shall meet the requirements of Purchaser's Standard Q-APP-02-

PR, "Quality Requirements", and of the requirements of the Inspection and Test

Plan, all as further detailed in Annexure "M" to the Contract.

7.2 The Contractor and the main subcontractors shall be certified to ISO-9001-2000

by a certification body qualified to EN-45004 levels A or C or otherwise as may

be acceptable to the Purchaser.

7.3 The Contractor shall submit upon request a copy of its Quality Assurance

Manual including Quality Procedures.

7.4 The choice of main subcontractors shall be subject to Purchaser's approval and

the Contractor shall be responsible for assuring that their quality

assurance/quality control programs, including their organizations, procedures,

personnel qualifications, etc., meet Purchaser’s quality requirements. Contractor

[also Suppliers at the first stage of proposal evaluation] may propose additional

possible sub-suppliers by submitting to the Purchaser a formal request for

approval with sufficient details for evaluation including country of origin for

design and manufacturing, proven experience with respect to equipment of the

same size and functionality, quality assurance, catalogues, functional

parameters and technical data.

8. SHIPMENT AND HANDLING OF GOODS AND DOCUMENTATION

The Contractor shall comply with the requirements for Shipment and Handling of

Equipment set forth in Annexure "R" to the Contract and additionally with the

following supplementary requirements:

8.1 All components or accessories shipped detached for field mounting or field

assembly shall be suitably tagged to allow easy identification. Tags shall be

stamped with cross reference data such as Manufacturer's Name, Contract No.,

Power Station, Unit No., reference drawing and Equipment Designation, and

shall be exceptionally durable and securely tied to items by wire or other

methods approved by Purchaser.

8.2 Major pieces of Equipment shall be supplied with nameplates.

8.3 Unless specially designated, all Equipment and other items shall be packaged

for outdoor storage until erection. Where required by the nature of the

Equipment, the Contractor shall furnish and install necessary covers to protect

the Equipment from sand, rain, hail, wind, dust and salt spray. Equipment shall



ISSUE: For Proposal


be adequately sealed and protected during shipment to prevent corrosion and

entrance of foreign matter. All exposed machined surfaces shall be protected

where required with a suitable antirust compound or covers before shipment, for

shipment and storage until erection.

8.4 Before packing, the equipment shall be cleaned to remove all dirt and waste

material left for fabrication, to the extent that it can be put into service without

further cleaning.

8.5 The top, back and bottom ends of the control cabinets shall be provided with a

temporary enclosure, tightly sealed to prevent entry of foreign matter during

transport and storage at the job site. The entire panel or console shall be

adequately protected to prevent damage to components during handling and

transport.

8.6 The control cabinets and all equipment shall be carefully packaged to ensure

arrival to the plant site undamaged by handling and weather.

9. SAFETY, NOISE, ENVIRONMENT AND LOADING REQUIREMENTS

9.1 Safety

The Equipment supplied under this Specification shall meet the U.S.

"OCCUPATION, SAFETY, AND HAZARD ADMINISTRATION" (OSHA)

requirements.

9.2 Noise

The noise level of the supplied Equipment shall not exceed an A-weighted sound

level of fifty five (55) dB(A) at a distance of one (1) meter from any major

surface.

9.3 Environmental Data

9.3.1 The Control equipment shall be located in air-conditioned rooms. However,

during the periods the air conditioning unit is out-of-service, the ambient

temperature may range from 1C to 50C and the relative humidity of the air may

rise up to 100%.

The equipment shall be designed to operate without limitation under these

conditions, with no reduction of its life expectancy.

Fans will be included in new cabinets where necessary to obtain max. 50C.



ISSUE: For Proposal


9.3.2 All electrical components mounted outdoors shall be provided in an outdoor

weatherproof enclosure, NEMA 4X or IP65 with corrosion protection, and shall

withstand the following conditions:

- Room Ambient temperature: 1 50C. The temperature inside the

cabinets my reach 60C when air-conditioning is out of service.

- Humidity: up to 100%, non condensing.

- EMI: according to MIL-Std. 461B.

- RFI: FFC Class A.

9.4 Earthquake Loads

9.4.1 The seismic design of buildings and structures in Israel is governed by the

provisions of the Israeli Standard 413 “Design Provisions for the Earthquake

Resistance of Structures”.

According to this Standard, the seismicity of the site is expressed by the

expected horizontal ground acceleration coefficient Z.

The expected horizontal ground acceleration coefficient Z expressed as:

Z = ah,max/g.

The maximum expected ground acceleration ah,max has the meaning of peak

horizontal ground acceleration, expressed in m/sec2, with a 90% probability not

to be exceeded over a 50 years period. The gravity acceleration g = 9.81

m/sec2..

The expected horizontal ground acceleration coefficient (Z), per provisions of the

Amendment 2 (2004) to the Israeli Standard 413 is 0.11 for the Orot-Rabin

Power Station.

9.4.2 Seismic environment for electrical equipment

The seismic environment is defined according to IEC Publication 60068-3-3

("Seismic test methods for equipment") for "General seismic class".

1. For the Scope of Work the peak acceleration at the ground level shall be

taken 2 m/sec2.

2. The value of the super-elevation factor (k) shall be:

k=1 for equipment mounted on rigid foundation

k=1.5 for equipment rigidly connected to buildings

k=2 for equipment installed on stiff structure connected rigidly to

building



ISSUE: For Proposal


3. The equipment shall comply with the relevant Qualification Criterion,

according to paragraph 4.3 of IEC Publication 60068-3-3, which fulfils

the required functionality statements.

10. PROJECT SYSTEM SECURITY STANDARD SPECIFICATION

The Contractor shall comply with the general requirements for Project system

security standard specification set forth in Supplement 5.1.3 (General Security

Safeguard Requirements for Control and Data Acquisition Systems in IEC -

Power Stations) and as furtherer detailed in Supplement 5.1.4.

11. TECHNICAL DOCUMENTATION

The Contractor shall provide all documentation required by this Specification and

by applicable Standards and Codes, in the required format, form and submission

schedule, as detailed in Annexure "J" - Documentation Submission Schedule.

12. SPARE AND RENEWAL PARTS

The Contractor shall provide upon purchaser's request as purchaser's option

spare parts at their itemized prices, subject to the applicable terms and

conditions, all as further detailed in Annexure "C1"- Summary of Prices and

Delivery Schedule.



ISSUE: For Proposal


13. EXISTING POWER STATION

13.1 Existing Power Station description

13.1.1 Steam Generator Description

The M.D. “A” Power Station consists out of four (4) drum type steam generators,

Manufactured by Babcock & Wilcox Canada Ltd. Each unit burns pulverized coal

and heavy oil. The steam generator is a radiant tower type generator with natural

circulation.

The maximum continuous capacity of each unit is 2,441,000 lb (1,107,238 kg) of

steam per hour at 2050 psig (144 kg/cm2 gage) and 1005ºF (540ºC).

The units are designed to produce the maximum continuous capacity either by

burning pulverized coal or heavy oil.

At over pressure and 'top heater out" condition the units can produce

continuously 2,556,300 lbs (1,159,538 kg) of steam per hour at 2150 psig (151

kg/cm2 gage) with both superheat and reheat temperatures at 1005ºF (540ºC).

Based on the original design, the superheater and reheater steam temperatures

are controlled at 1005ºF (540°C) by spray attemperation and gas recirculation,

respectively, when heat absorption is greater than required.

At the present, due to operation problems, the Superheater and Reheater steam

temperatures are controlled at 977ºF (525°C) and the flue gas recirculation

control is disabled.

The furnace is 54 feet wide, 32 feet deep and 196 feet from the center line of the

lowest furnace wall headers to the center line of the drum. The furnace water–

cooled surfaces consist of a front wall, two side walls, a rear wall and two

division walls.

13.1.2 Fuel System

The Fuel System includes eight (8) coal feeders, eight (8) coal pulverizers and

twenty four (24) burners. The type of the feeder is gravimetric and was

manufactured by Stock Equipment Co.



ISSUE: For Proposal


The pulverizers are of type EL size 76 manufactured by B&W Canada Ltd., each

with a capacity of 18 tons per hour with coal grindability of 50 HGI and coal

fineness 70/200.

The sealing air for the coal feeders and pulverizers is supplied by two 2) seal air

fans which were manufactured by Sheldon's Manufacturing.

The Primary Air both dries and carries the pulverized coal from the pulverizers

through the coal piping to the burners and furnace. There are three (3) 15¼”

(387 mm) I.D. coal pipes per pulverizer, each pipe is connected to a burner at

the same elevation at the front or the rear wall.

13.1.3 Burners

Each unit is equipped with twenty four (24) circular burners arranged at four

elevations, six at each elevation, three on the front and three on the rear walls.

The burners arranged in two common windboxes: one for the three lower

elevations and one for the most upper elevation. Each coal nozzle with its burner

pipe is located in the center of the burner opening. The throat size is 35” (889

mm) diam. while the secondary air register size is 42” (1067 mm) diam. The

throat is packed with

refractory.

The pulverized coal and hot Primary Air mixture is discharged into the furnace by

the coal nozzle.

The impeller at the end of the coal nozzle deflects the coal out into the whirling

secondary air stream where ignition takes place. Ignition is initiated by high

capacity gas igniter located in the throat in such a way that the lighter frame

extends into the coal stream beyond the end of the coal nozzle.

Each burner is equipped to fire heavy oil by means of B&W steam atomizers

racer type sprayer plate. Total twenty-four (24) oil burners are sized to produce

full load steam flow.

The burners cannot fire simultaneously heavy oil and coal. It is possible to

control the fuel type firing (heavy oil or coal) for each group of burners (each



ISSUE: For Proposal


elevation consists of two (2) groups of burners, one at front wall and one at the

rear wall).

The lower elevation of burners is also equipped to fire light oil with air

atomization for boiler pressure raising and low load carrying up to 20% Of MCR.

The B&W spark ignited gas igniters are rated 10,000,000 BTU/h (2,520,000

kcal/h) each at gas pressure of 4.8 psi (0.34 kg/cm2) above furnace pressure &

igniter cock (100% open) when using propane as ignition gas but can be

adjusted manually to a lesser output as determined by the ignition characteristics

of the coal.

13.1.4 Pulverizer

The Babcock & Wilcox “El Pulverizer” employs the ball-bearing principle of

grinding. The rotating bottom ring is mounted on a shaft driven by spiral bevel

gears, which are housed in the base of the pulverizer and completely separated

from the grinding zone. The non-rotating top ring is held in position by dual-

purpose springs, which furnish the compression for grinding as well as

preventing rotation of the top ring.

Raw coal enters at the top of the pulverizer and toward the grinding zone.

Primary Air, after passing through the throat, carries coal from the grinding zone

to the static classifier, through louvers, where oversized coal is rejected back to

the grinding zone via the tailings discharge seal. Properly sized coal continues to

the burner with the Primary Air.

Foreign material that may enter the pulverizer collects in the pyrites trap and is

removed periodically.

13.1.5 Air and Flue Gas Flow

The Primary Air system consists of two Primary Air Fans (each providing 50 % of

the required capacity), one steam coil air preheater, one Ljungstrom

regenerative air heater and associated ducting.

Primary Air Fans draw the air from the Forced Draft Fan outlets at a ramped

pressure of approximately 9.5 in (241 mm) w.g. maximum static pressure. The



ISSUE: For Proposal


Fans are Sheldon's type 800 with a test block requirement of 393,100 lbs.

(178,310 kg) of air per hour at 125ºF (51.7ºC) and 54.6 in (1387 mm) w.g.

The bulk of the Primary Air passes through the smallest of the three Ljungstrom

regenerative air heaters supplied for the unit.

The air heater is J. Howden & Parsons Model 21V1RP42 with an effective

heating surface of 33,450 sq. ft (3,108 m).

The heated Primary Air is ducted to the pulverizer's windboxes. A fraction of the

air which bypasses the air heater is used for tempering, thus controlling the

Primary Air temperature to each pulverizer as required by the moisture content in

raw coal and thus maintain a constant coal/air mixture temperature at the

pulverizer outlet.

This fraction of air joins the main flow of the Primary Air flow upstream of the

pulverizer air flow measuring device.

The secondary air, which comprises approximately 80% of the total combustion

air when firing coal, is supplied by two axial flow Forced Draft Fans. The Air

From the Fan's outlets flows to the two (2) steam coil air preheaters, two

Ljungstrom air heaters and then to the front and rear burner boxes. Each air

heater has a heating surface of 191,570 sq.ft (17,797 m2).

Flue gas formed in the furnace passes over the superheaters, economizer and

air heater's surfaces transferring heat to the cooler media.

Downstream of the economizer four (4) gas collecting hoods remove a fraction

of the total gas flow for use in gas recirculation while the main bulk of gas flows

to the three Ljungstrom air heaters, then through two precipitators, two Induced

Draft Fans and through the stack.

To facilitate the option of by-passing the P.A. fans for oil firing and provide

impeller cooling air to the oil burners in service when both P.A. fans are not

running, a P.A. fan by-pass duct with a tight shutoff damper is installed.

There are a total of 24 - 6” (152 mm) butterfly valves installed in impeller cooling

air ducts (one for each duct). These dampers are open to supply air to impellers

of oil burners, which are in service.



ISSUE: For Proposal


13.1.6 Spray Attemperators

There are two (2) SH spray type Attemperators on each unit. Each Attemperator

handles steam from one-half of the boiler width and delivers it through

secondary superheater inlet headers and to be distributed on the other one-half

of the boiler width .i.e. the right hand side primary superheater steam goes to the

left hand side secondary superheater and vice versa.

This arrangement has been incorporated to minimize the effect of unbalanced

firing and to insure a uniform final steam temperature across the secondary

superheater outlet header.

RH outlet steam temperature is controlled by using one (1) spray type

Attemperator which is installed in the RH inlet.

13.1.7 Condensate and Feedwater systems

Each unit includes: three condensate water pumps, three Low pressure heaters

and two High pressure heaters, one dearator and one steam driven turbine

feedwater pump and one electrical feedwater pump.



ISSUE: For Proposal


13.2 Existing main systems to be included in the PCMS

13.2.1 Combustion Control System

13.2.1.1 The main control loops are: Load demand; Fuel demand; Air demand; Throttled

Pressure Control; Boiler Demand Limit Regulator (BDLR); Hard- Runbacks;

Feedwater control; Air flow and Furnace pressure control; Drum-level control,

Deaerator level control and Heater drain level control.

Pulverizer provides coal flow, primary air flow and temperature control in

accordance with fuel demand signal. The primary air flow control is fulfilled by

primary air flow damper. The a.m. fuel demand signal is generated by heat

release signal. Primary air control provides primary air fans inlet dampers control

on base of total pulverizers' demand with number of pulverizers in service feed

forward.

Superheat and reheat temperature control provides proper steam temperature by

spray valves.

13.2.1.2 The existing combustion control system comprises of four main parts:

a. The original 'Leeds and Northrup Co.' (L & N) manufactured DEB-300 dated early

1970's. This part is based on electronic cards that process the Inputs and outputs

of the system to and from all the field devices.

These electronic cards also include the main and auxiliary control loops for the air,

water and fuel control.

b. In the 1990's processors based controllers and workstations were added, to

mainly accommodate the requirements for Unit Load Runbacks. These DPU's

(controllers) include the Front End demands for the main control loops.

c. In 2006 the Workstations were upgraded to MAX DNA by Metso (acquired MAX

Controls / Leeds & Northrup). The communication network and workstations are

common to pairs of units (1+2 and 3+4).

d. Field actuators that include drive units by Limitorque 3 phase, L&N one phase,

Jordan one phase, Auma 3 phase, controlled by pulsed power switches.

13.2.1.3 In addition, the Contractor shall be responsible for the integration between the

new Combustion Control System and the existing Turbine control system

(Turbine Boiler Coordinated control).



ISSUE: For Proposal


The Turbine control system was retrofitted during 2000's to Ovation control

system, manufactured by Emerson.

13.2.2 Burner Management System and Boiler Protection System (BMS)

13.2.2.1 The Burner Control / Management System's logic is implemented by the BAILEY

762 equipment dated from the early 1970's. The equipment consists of logic

cabinets, flame scanners, four oil elevation sections and eight separate coal

elevation sections.

The Burner Management System is designed to ensure a safe, orderly startup

and shutdown sequence of the fuel firing equipment and to prevent errors of

omission and commission during execution of these operating sequences.

The System provides safety interlocks to protect against potential emergency

situations in the event of malfunction of fuel firing equipment and associated air

systems. Boiler Lockout Relay (located in the electrical cabinet) acts parallel to

the Burner Management System in order to increase reliability of the

comprehensive system.



ISSUE: For Proposal


13.2.3 Existing I/O

13.2.3.1 CCS – Boiler Control I/O

ANALOG + MAX I/O

N I/O TYPE I/O

NUMBERS

VOLTAGE/

CURRENT/

RESISTANSE

RANGE/

TYPE COMMENTS

1 DIGITAL

INPUT 156 V 115 VAC

2 ANALOG

INPUT 100 I 4 - 20 mA

PASSIVE

TRANSMITTERS

3 ANALOG

INPUT 53 mV TYPE E THERMOCOUPLES

4 ANALOG

INPUT 2 Ω

100 Ω PLAT

RTD

5 ANALOG

INPUT 2 Ω

10 Ω Cu

RTD

6 DIGITAL

OUTPUT 212

220 VDC /

115 VAC

RELAY

DRY CONTACT

7 ANALOG

OUTPUT 16 mA 4 - 20 mA

CONTROL

OUTPUTS

8 ANALOG

OUTPUT 6

PULSE

CONTROL

OUTPUTS

9 ANALOG

OUTPUT 58 mV 10 - 50 mV TO DPMS

10 ANALOG

OUTPUT 8 V 0 - 10 V

FEEDER DEMAND

CONTROL OUTPUTS

11 ANALOG

OUTPUT 11 V 0.2 - 1 V TO DPMS

12 ANALOG

OUTPUT 5 V 1 - 5 V TO INDICATORS

13 DRIVE UNIT

INTERFACE 44 V

1 Ø

115 VAC

PULSE

SLIDE (POSITION)

FEEDBACK

0 - 15 VDC

14 DRIVE UNIT

INTERFACE 15 V

3 Ø

220 VAC

PULSE

SLIDE (POSITION)

FEEDBACK

0 - 15 VDC



ISSUE: For Proposal


15 DRIVE UNIT

INTERFACE 16 V

1 Ø

115 VAC

ON/OFF CONTROL

OUTPUT

DIGITAL FEEDBACK

115 VAC

( OPEN/CLOSED

POSITION)

TOTAL 704

13.2.3.2 Burner Control – Burner Management System I/O

BURNER CONTROL I/O

N I/O TYPE I/O

NUMBERS

VOLTAGE/

CURRENT

RANGE/

TYPE COMMENTS

1 DIGITAL

INPUT 650 V 125 VDC FIELD INPUTS

2 DIGITAL

INPUT 200 V 24 VDC

CONTROL ROOM

INTERFACE (PUSH

BUTTONS)

3 ANALOG

INPUT 1 mV TYPE E THERMOCOUPLE

4 DIGITAL

OUTPUT 33

250 VDC /0.5

A

OR

250 VAC/5.0

A

RELAY

DRY CONTACT

5 DIGITAL

OUTPUT 343

115 VAC/7.0

A

RELAY

DRY CONTACT

6 DIGITAL

OUTPUT 240 V

200 mA

(max load)

24 VDC

CONTROL ROOM

INTERFACE (LAMPS)

7 ANALOG

OUTPUT 48 mA 4 - 20 mA

FLAME SENSOR

OUTPUTS

TO DPMS

TOTAL 1515



ISSUE: For Proposal


14. TECHNICAL REQUIREMENTS

14.1 General requirements

All components, appurtenances and accessories shall be of proven design,

verified by Power Plant Operation.

The Plant Control & Monitoring System (PCMS) shall be of DCS type, based on

state of the art technology, incorporating an integrated design, according to the

following:

-Integration, based on the same hardware/software platform for all subsystems.

-Connectivity with existing DPMS using OPC.

-Field instruments will be hardwired to the system via terminal blocks.

-Maximum use of the existing field instruments, drive units, cables and

infrastructure.

-Maximum use of the existing Electronic Room cubicles' arrangement.

Where existing cabinets can be reused without disturbing the field terminations,

the existing equipment will be removed from the cabinet and new I/O panels

installed and wired to the existing field terminal blocks by Purchaser (IEC). In this

case the existing field terminal blocks will be considered as marshalling

terminals,

For other systems Contractor shall provide new I/O cabinets which include

terminal blocks to match the existing terminal points as much as possible.

Terminal blocks with disconnecting capability shall be provided.

-High system's Reliability, Availability and Maintainability.

Basically, the system automation level shall match the existing conditions.

Explicit requirements will be discussed during detailed design.

14.2 Functional requirements

14.2.1 The PCMS shall provide a complete and integrated functional arrangement

using microprocessor based DCS, complete with all devices, to provide efficient

and reliable control of the light oil, heavy oil, coal and ignition gas systems with

respect to their safe start-up and shutdown.

The functional requirements for the PCMS included herein are directed at

establishing the criteria for the power station operation, control and supervision.



ISSUE: For Proposal


However, it is not intended to limit the operation, functions and safeguards to

those either mentioned or implied.

The Contractor is expected to make any additional suggestions or

recommendations that will improve the proposed operational procedures or

method of plant operation and supervision. All the system engineering and

hardware needs to form a fully integrated, complete and operable start-up and

on-line control system shall be supplied whether or not specifically detailed.

The PCMS's functions are:

- Process Control as executed with the existing system with the additional control

function, as listed in this Spec.

- BMS and boiler protection

- Operation and supervision of the controlled systems from the integrated HMI

- Signal conditioning

- Storing and archiving of the PS data and means to present data to the operator

- Control system self-diagnostic and testing

- On-line engineering and maintenance of system software configuration,

including integrated system drawings and documentation.

- Alarm management.

- Alarm annunciation and display.

- Data transfer to the DPMS.

14.3 System architecture

The System shall support a decentralized, hierarchical structure that is capable

of being physically distributed to remote plant locations (if required). The system

shall permit data acquisition and control functions to be performed at various

plant area locations while providing the capability to monitor and control the

distributed functions from a central facility. The system shall be flexible enough

that it can be configured to a wide range of process control applications at the

loop and component level without changes to the hardware.

The System's architecture must maintain as a minimum the following:

a. All requirements as listed in this Specification.

b. Distribution of controllers, I/O's and other processing tasks.



ISSUE: For Proposal


c. Full implementation of the redundancy concept as required by this

Specification.

d. Availability of information to/from third party computerized systems through

the use of standard communications, protocols and data structures.

e. Availability of all information and operation functions in all Workstations.

f. All protection signals involved a trip signal to a major equipment in between

processors shall be hardwired and not via communication.

g. Each subsystem (BMS and Combustion Control) shall be controlled by

separate redundant controllers.

14.4 Reliability, Availability & Maintainability (R.A.M.)

The system shall utilize a combination of redundancy and fault tolerance

techniques to maximize system reliability and availability. Contractor's

responsibilities shall be verified according to Annexure “D” - Equipment

Performance Guarantees.

14.4.1 The system shall be assembled, programmed and configured to survive the

failure of any device or single process sensor, with no degradation in the process

control capability. The fault tolerance attribute will be included on all the DCS

levels as follows:

- Operator Workstations.

- Data Communication System.

- Process Controllers.

- Critical Input/Output Processing.

- Power Supplies.

Failure on any level (I/O channel, processing module, Operator station,

communication) shall not jeopardize other entities on the same level or above, or

prevent them from communicating with each other.

Each single failure shall be clearly reported to the Operator's Station(s).

14.4.2 Failures in the PCMS must not cause the Protective functions to fail.

The protective subsystems must be fail-safe.



ISSUE: For Proposal


14.4.3 A device or System shutdown/failure shall not cause a loss of any data stored

for logs or trends. After restart, any data which might have been affected by

the shutdown/failure shall be so indicated.

14.4.4 The System Structure shall permit the removal, exchanging and installing of

any I/O card, controller, power supply when system is powered and on-line

without disturbance to normal functioning of the rest of the system.

14.4.5 Functions performed by the controller modules during normal operation shall

continue unaffected if the Workstation(s) is/are out of service. The system

shall continue to report alarms if one Workstation is out of service.

14.4.6 Power failure shall always be considered a recoverable system error. On

restoration of power, the System shall safely resume operation, generating a

message which includes the time of the power failure. No new setting of the

internal clock shall be necessary.

14.4.7 The required reliability, availability and safety will be achieved by the

necessary functions distribution and/or by using the redundancy for the

hardware levels according to the corresponding functions.

The self-diagnostic will provide on-line continuous checking of all components

of the system for fault detection. The failure shall be identified by the system

up to the card level.

14.5 Redundancy

14.5.1 The System shall be based on redundancy configuration on the Process

Controller level. A Redundant Controller will receive a constant updating of its

data base.

The failure of a primary Controller shall cause an alarm in the Operator

Station(s). Switchover to a redundant controller shall be automatically and

shall not affect the system functionality and the operator ability to monitor or

control any point. The switchover shall not depend on the availability of the

communication system and shall be bumpless.

Any changes in set-point, output and mode of control, tuning adjustments or

related adjustments shall be transmitted to the back-up Controller

automatically within one cycle of operation. The secondary Controller will

monitor the same I/O channel but will remain passive. The Contractor shall

provide the detailed description of the switchover procedure and switchover

time in case of a primary controller failure.

Any failure of the controller shall be alarmed.



ISSUE: For Proposal


Contractor shall provide the necessary redundant Controller’s and I/O cards

power supplies. The contacts' interrogating voltage shall be provided from

separate power supplies, "ground isolated". An alarm shall be provided by an

I/O card in case of ground fault detection.

14.5.2 I/O Level

The input/output signals integrity will be ensured by using redundancy for

sensors and I/O Processing Cards, as required by specific application.

The System shall support redundancy from sensors through the I/O

processing channels to the controllers.

No single sensor or I/O card failure shall cause a system malfunction.

Necessary diagnostic routines shall be provided to detect a failure and identify

the failed sensor.

The Contractor shall provide continuity checking for all heavy duty relays

output circuits.

The required majority voting routines will be provided on the controller inputs

for the shared input signals and on the controller output for the dedicated

input signals.

14.5.3 Communication Level

The Communication Data Highway(s) shall be fully redundant; the throughput

shall be such, that at the HMI application level, no entity of information

(command, alarm annunciation, monitored value, graphic display, etc) will be

delivered or updated in more than 1 sec from the event occurrence.

The transfer phase will not cause any malfunctioning of any subsystems.

14.5.4 Power Supply Level

14.5.4.1 Two power feeds from separate reliable distribution centers will be provided for

any part of the System that requires AC power (such as interposing relays or

filed equipment). An automatic transfer will be provided by the Contractor, so

that no interruption occurs in the event of a single supply failure.



ISSUE: For Proposal


14.5.4.2 D.C. Power Supplies

Redundant power supplies shall be provided for specified services and shall

have the following characteristics:

a. Redundant power supplies shall be provided with automatic transfer or with

auctioneering connection, so that no interruption occurs in the event of failure of

a single supply.

b. An alarm shall be generated, should any power supply fail.

c. A failure in the DC power supply shall be easily identified and components

shall be designed for easy removal and insertion into the cabinets. This shall

require circuit isolation and monitoring so that if a part of the System becomes

isolated, erroneous control action shall not result.

d. Each power supply shall have sufficient capacity to provide 30% future

expansion.

e. All internally generated ac or dc logic voltages that are operated ungrounded

shall be provided with ground detection alarms and isolation devices.

f. If the power supply to or on any module or printed circuit card should fail or if

any printed circuit card or device is removed from its receptacle, the associated

system and all the dependent systems shall transfer to manual. An isolated

contact output shall be provided upon such a failure.

g. The Contractor shall provide all the necessary equipment required to convert

and distribute power to all the field instruments which require a source of

electrical power. Distribution shall include a dedicated disconnecting and

protecting device for each transducer. Electrical isolation between loops shall be

provided.

14.5.5 The System's architecture shall be configured as a fault tolerant control system,

utilizing a minimum double redundant configuration of microprocessor-based

digital modules for modulating and BMS functions.

All primary control and protection functions shall be performed in identical

redundant Control Processor Modules.

14.5.6 The System shall be capable of maintaining proper control and protection upon

a single hardware or software failure occurs or when a failure occurs in one of



ISSUE: For Proposal


the redundant I/O devices. This responsibility includes receiving, conditioning,

and automatically selecting valid process measurement signal, performing

process control calculation, and issuing corresponding output demands, as well

as maintaining necessary interlocks and alarm function. The System shall be

capable of providing on-line diagnostics, on-line testing, on-line repair, and on-

line changes to control set point and overall operation.

14.5.7 The Contractor shall be responsible to provide all means (software and

hardware) for Embedded Cyber Security (ECS) to protect the complete PCMS

from an unauthorized access, in compliance with paragraph 14.6 requirements.

14.6 PCMS Embedded Cyber Security (PCMS - ECS)

Refer to supplement 5.1.3 and 5.1.4



ISSUE: For Proposal


15. PLANT CONTROL & MONITORING SYSTEM (PCMS) DESIGN

REQUIREMENTS

Each PCMS shall include the following subsystems:

15.1 Combustion Control System (CCS)

15.1.1 The Combustion Control System (CCS) shall operate as an integral part of The

Plant Control & Monitoring System.

15.1.2 The Combustion Control System shall perform, but shall not be limited to, all the

functions of the existing System.

15.1.3 Contractor shall provide new redundant controllers, I/O cards, power supplies,

communication interfaces, etc. in order to implement al the required control

functions.

The equipment shall interface with the existing field devices especially the drive

units.

15.1.4 The existing System includes approximately 3000 points.

15.2 Burner Management System (BMS)

15.2.1 The Burner Management System (BMS) shall operate as an integral part of the

Plant Control & Monitoring System.

The BMS shall be designed to meet the requirements of the existing system and

Purchaser’s (IEC’s) special requirements.

15.2.2 Each BMS shall provide a full control and protection of the related existing boiler

according to the latest edition of NFPA.

15.2.3 Functional Requirements

15.2.3.1 The Burner Management System shall be suitable for burning ignition gas, light

oil (for first elevation only) , heavy oil and coal.

15.2.3.2 The BMS shall include Master Fuel Trip Relay in order to provide the possibility

of the Power Station safe trip.

15.2.3.3 The BMS's operation and equipment described in this Specification has been

included to serve as a guide to the type of system desired but does not

necessarily encompass all design functions.



ISSUE: For Proposal


The Contractor shall be responsible for furnishing a system design that is

complete in all respects.

15.2.3.4 The BMS shall provide alarms to advise the operator of abnormal or dangerous

conditions.

15.2.4 BMS Requirements

15.2.4.1 The System shall provide equipment and program tasks for “dry” BMS tests for

all BMS operations including opening and closing fuel, burner and scavenge

valves advancing and retracting oil guns. These tests shall be feasible during

ordinary start-up and shut-down operations of the BMS, separately for elevations

and for the fuel oil and coal trip valves and relevant equipment.

15.2.4.2 The System shall include extensive self-checking to detect malfunctions of the

equipment and other feasible checks that indicate erroneous operation.

When such checks show a problem from which the System can recover without

intervention by plant personnel, a system error shall be alarmed and operation

shall resume. If checks reveal a non-recoverable error, an orderly transfer to a

back-up, or if a back-up is not available, it shall be alarmed to allow the operator

to shut the System down, if required.

The System shall be provided with the possibility to set solid state output drivers

in a preprogrammed mode on processor failure (predictable Failure Mode),

retaining of last state position by electromechanical means is not acceptable.

15.2.5 In addition, in Power Station there is Boiler Lockout Relay System, based on

electromechanical relays, which implements also Boiler Protection functions.

The existing Boiler Lockout Relay System will be dismantled and its logic shall

be implemented in the new BMS, in order to provide safe operation of the boiler.



ISSUE: For Proposal


16. PLANT CONTROL & MONITORING SYSTEM

EQUIPMENT REQUIREMENTS

16.1 Accuracy and Resolution

16.1.1 Overall accuracy of the System shall be such that the digital output

representation of an analog input signal shall be within 0.10% of the full scale

range of the signal, as measured at the field analog input terminals.

16.1.2 Time-tagging of events shall have one (1) second accuracy.

16.2 Process Data Highway

a. The data highway shall provide both functional and physical System

distribution capability for communication between the major System elements.

b. The data highway shall be redundant. Fail-over to the alternate cable-circuitry

shall be automatic. Any highway failure shall immediately be reported by the

System.

c. The highway shall be designed so that no single component failure will cause

one or both of the redundant highways to become inoperative. This requirement

includes communication cards, line switches, modems and any other related

electronic devices.

d. All communication and processing circuitry shall be effectively immune to the

types of electrostatic and electromagnetic interference that can be expected in

an industrial environment.

Coupling circuits must satisfy the requirement of rejection of noise - Floating

voltage of a device must not be converted to noise on the highway.

e. The highway shall include all the required communication equipment in order

to interconnect all the system elements.

f. The highway protocol shall include sufficient error recovery capability and

message security checks.

g. The communication protocol shall provide automatic adaptation after the

operation of connecting a new node to the data highway or disconnecting the

existing one.

h. Addition or deletion of nodes on line shall not disrupt plant communication.



ISSUE: For Proposal


16.3 Input/Output Equipment

16.3.1 General.

a. The input/output modules shall be microprocessor-based devices.

b. The System shall include analog input modules, capable of reading all

existing and additional analog inputs (such as but not limited to: 4 to 20 mA,

RTD's (3-wire or 4-wire), thermocouple inputs directly. The System shall provide

all the typical analog input linearization, including thermocouples (types, E, J, K,

S and T), RTD's and square root functions. Custom linearization functions shall

be available.

Linearization of thermocouple inputs shall conform to IPTS-68 standard.

Reference junction compensation shall be internal.

The I/O cards for 4-20mA shall be suitable for 2-wires or 4-wires signals.

c. When a controlled variable exceeds transducer limits it shall be declared

unreasonable and alarmed and all affected portion of the System will transfer to

manual.

d. Digital inputs will be scanned and status retained for use in system logic

algorithms. It shall be possible to assign status designations (on-off, tripped-

running, etc.) for each input.

Each digital channel shall be individually/group isolated with a dielectric test

voltage of 500VAC. No galvanic/opto insulation will be provided for standard

4-20 mA I/O cards.

e. The analog to digital conversion will be a least 12 bit.

f. Each input module shall be separately fused, with a fuse status indicator on

the front of the module.

g. Surge protection devices shall be provided for 50 analog and digital signals

connected to outdoor field instruments exposed to lightning strikes.

The surge protection shall include:

-Surge protection power for power supply system

-Surge protection for information technology Data systems 4-20mA

The surge protection devices shall include status indication or alarm for

replacement.



ISSUE: For Proposal


h. All analog input and output field wiring terminations shall be readily

accessible, allowing for easy installation and removal while the System is on-

line. Any associated printed circuit cards can be installed and removed without

disrupting the field wiring and without disturbance of the rest of the system.

i. All input modules shall meet Contractor's standards for surge-withstand test:

no false output shall be taken as a result of the electrical power surge described

in this specification.

j. Digital output modules shall perform "check before execute" routines on each

updating of digital outputs.

16.3.2 Analog Output to I/P Converter or Drive Unit Regulator

The System shall include analog output modules, capable of driving all existing

equipment such as but not limited to: PAT (Pulse outputs).

Controllers shall generate analog position demand signals to final control

elements.

Range: 4 to 20 mA into 0 to 600 Ohm standard or up to 1000 Ohm total loop

resistance.

Accuracy of the output circuitry: better than 0.25%

Security: Upon loss of power, or in case of disconnection between the controller

and the drive unit regulator, the final control element must be held in its last or

safe position and switched to manual mode of control.

16.3.3 Digital Inputs

a. The Digital Inputs will include alarm/status points which may be a dry contact

either normally open or normally closed type, or solid state (optocoupler).

b. The Contractor shall supply the necessary interrogating voltage such as

48VDC, floating with Ground Fault Detection.

c. There shall be no false signals due to contact bounce up to sixteen (16)

milliseconds either on alarm or return to normal.

d. Scan cycle for digital inputs shall not be greater than 125 msec.

e. SER events shall be discriminated within a time resolution of one (1) msec

and recorded in their proper sequence.



ISSUE: For Proposal


f. Binary inputs from process and/or other controls shall be dry contacts.

16.3.4 Analog Inputs

a. The scan cycle for analog inputs shall not be greater than 250 msec, unless

otherwise specified.

b. An alarm dead-band in percent shall be configurable for each of the analog

inputs so that a value returning to normal will not be announced as returned to

normal while it is within this band.

c. All analog inputs in the System shall have their values checked concurrently

and continually for bad or unreasonable conditions.

d. Thermocouples will be of the grounded and/or ungrounded types. Contractor

equipment shall be able to handle them in any combination.

e. Detection of open circuit thermocouples shall be performed. Systems that

cause calibration offsets or suffer from time delays are not permitted.

16.3.5 Control Outputs to Devices

a. The output modules will be used to control the field devices (circuit breaker

closing and tripping coils, starters and solenoid coils, etc.)

b. For the control of the field devices, dry contacts shall be provided.

The contact ratings necessary shall be at least 3 Amperes for 220VDC utilization

categories and 3 Amperes for all AC utilization categories.

Heavy duty type of interposing relays is recommended for this purpose.

c. The output relays shall have long mechanical life and high contact reliability at

the rated current. The dielectric strength shall be defined by Contractor.

The circuits shall have a surge withstand capability equal to that specified in

ANSI C37.90a.

e. All relay auxiliary contacts shall be brought up to the terminals at marshalling

cabinets, for the Purchaser's use.



ISSUE: For Proposal


Binary outputs to the process systems (interlocks) shall be by dry contacts, with

contact rating at least 3 Amperes for 220VDC utilization categories and 3

Amperes for all AC utilization categories

16.4 Processing Controllers

16.4.1 General

As used in this specification, the words "process controller" refers to any device

configured to perform a set of control, data processing and monitoring functions.

a. The loss of power to any controller shall not result in loss of memory such that

manual reconfiguration is necessary when power is restored.

Upon restoration of power, the System will initialize itself to the established

configuration and resume operation without error.

b. All of the functions performed by the controller shall be executed within a

scheduled time which shall not be altered by changes in configuration or by

system loading.

c. Each controller shall update all of its outputs at least every 0.25 seconds

during all conditions of operation.

d. It shall be possible to accomplish tuning, configuring and reconfiguring of

controllers under key-lock control, through the Engineering Station, utilizing a

convenient set of displays specially designed for that purpose and to down-load

the configuration to controller(s) via Data Highway.

e. All algorithms needed to perform the specified functions shall be provided

pre-programmed and in the System's library.

It shall be possible to configure or reconfigure controller solely through the use of

pre-programmed algorithms (functional blocks).

There shall be no limit upon how many times a particular functional block can be

used within the capacity of a controller.

16.4.2 Operational Characteristics

Controller shall:

- Be started up without the assistance of any higher level device such as a

computer.



ISSUE: For Proposal


- Utilize a design architecture enabling multiple reduced performance levels

prior to a device failure.

- Be unaffected by failure of other devices connected to the communication

system.

- Be added to or removed from the communication system at any time without

upsetting the System's communications.

- Have a trend memory to store historical data.

If power is lost to the controller, all associated control loops shall automatically

transfer to manual.

Following a power failure and upon power restoration all loops will remain in

manual until selected for automatic by the operator.

16.4.3 Computational Capability

Controllers slots shall be configurable to provide control algorithms and

strategies as P, PI, PID control with the following functions:

- cascade or ratio;

- multiplication/divisions;

- square root extraction;

- addition/subtraction;

- lead/lag;

- override;

- high or low signal selection;

- high/low process variable alarming;

- logical gates (AND, OR, NAND, NOR, EXOR);

- time delay;

- interlocks;



ISSUE: For Proposal


- linearization of E type thermocouple signal and of 100 ohm Pt RTD, 10 ohm

Cu, etc. signals;

- Compensation for pressure and/or temperature for level and flow

measurements.

In addition to the basic control and logic functions, controllers shall also perform

the following functions as a minimum:

- scanning -Digital inputs, at least 8 times per second

- Analog inputs according to assigned scan rates

- limit checking - alarm limits for analog inputs

- conversion to engineering units

- change detection - calculating rate of change providing protection against

noisy sensors

- status indications can indicate that changes have occurred, instead of being

transmitted repeatedly

- on-time count and status change count for digital inputs

- sensor correction - linearization, square root extraction, etc.

- time tagging events

- reasonability checking - coarse checks to exclude data that is checking

evidently impossible (like out of range).

- counting

- calibration - examples: cold junction temperature for thermocouples, zero

point offset, etc.

- Independent local data base (configuration) to permit all the required tasks.

Provisions to download/upload this information from/to and to the Workstations.



ISSUE: For Proposal


- Transmitting input data in engineering units, alarms and status information to

other devices such as Workstations or other intelligent modules, according to the

requirements or upon request.

- Monitoring of the I/O modules and its own performance.

16.5 Communication links

16.5.1 General

Communication links shall be used for collecting information from the Plant's

auxiliary systems and other computerized systems supplied by others. The

above mentioned links shall use a standard control-proved communication

protocol(s) such as Modbus Plus or equivalent (pending Purchaser’s approval).

Contractor shall provide all gates/interface units required in order to

accommodate those links.

The Contractor shall specify its requirements and experience regarding the

communications type, standard protocols, etc.

The System shall be able to accept and keep the time stamp for each event sent

via communication link(s) from the other systems.

In case that data does not include a time stamp the System shall apply the time

stamp.

16.5.2 OPC Server(s)

a) The System should be provided with OPC DA, EA Servers for data

transmission to DPMS.

b) The System includes an Historian Workstation; the Supplier should provide

OPC HDA for historian Server.

c) All OPC Server(s) should be OPC Foundation Tested.

d) The HMI software package should include Universal OPC Client software

module(s). A clear list of OPC Server types accessible by OPC Client should be

included.

16.6 Auxiliary Equipment



ISSUE: For Proposal


16.6.1 Printers

The Contractor shall provide:

- Three (3) A4 color laser printers per Unit.

a. The printers shall have graphic printout capability.

b. The system shall have the possibility to make a screen copy printout from any

of the Workstations.

c. All data to be printed shall be available in all the Operator Workstations. The

operator/engineer shall be able to configure for every Workstation the type of

data to be printed.

d. Off-line state of a printer or any printer trouble shall not cause a loss of data to

be printed.

e. Printer status and trouble information shall be part of the system status

information on the Operator Workstations.

f. The printers shall be by manufactured by a well-known company.

16.6.2 Back-up Devices

Back-up means for Operator and Engineering stations shall be provided. The

capacity shall be adequate to the disks size. User-friendly back-up/restore

utilities including all software and hardware shall be included.

16.7 Power Supplies

16.7.1 General Description

The Contractor shall provide whatever DC power supplies and/or step-down

transformers that are required to operate the system.

The Contractor shall supply the data of the exact power demand from each

supply both on normal operation and during start-up (inrush currents).

Two power feeds from separate reliable distribution centers will be provided for

any part of the System that requires AC power (such as interposing relays or

filed equipment). An automatic transfer will be provided by the Contractor, so

that no interruption occurs in the event of a single supply failure.



ISSUE: For Proposal


16.7.2 D.C. Power Supplies

Redundant power supplies shall be provided for specified services and shall

have the following characteristics:

a. Redundant power supplies shall be provided with automatic transfer or with

auctioneering connection, so that no interruption occurs in the event of failure of

a single supply.

b. An alarm shall be generated, should any power supply fail.

c. A failure in the DC power supply shall be easily identified and components

shall be designed for easy removal and insertion into the cabinets. This shall

require circuit isolation and monitoring so that if a part of the System becomes

isolated, erroneous control action shall not result.

d. Each power supply shall have sufficient capacity to provide 30% future

expansion.

e. All internally generated ac or dc logic voltages that are operated ungrounded

shall be provided with ground detection alarms and isolation devices.

f. If the power supply to or on any module or printed circuit card should fail or if

any printed circuit card or device is removed from its receptacle, the associated

system and all the dependent systems shall transfer to manual. An isolated

contact output shall be provided upon such a failure.

g. The Contractor shall provide all the necessary equipment required to convert

and distribute power to all the field instruments which require a source of

electrical power. Distribution shall include a dedicated disconnecting and

protecting device for each transducer. Electrical isolation between loops shall be

provided.

16.7.3 Interrogation Voltage

a. All field dry contacts will be interrogated with 110VDC.

b. Power supplies for the interrogation voltage shall be ungrounded.

Short circuit detecting will be provided for analog inputs



ISSUE: For Proposal


Each group of maximum 32 input circuits shall be detected for ground on the

interrogation voltage lines (both sides of the contact) by a separate ground

detecting circuit.

These detectors shall provide an alarm in case ground is detected. A ground

detection indication shall be provided to indicate in which group of inputs a

ground has occurred.

There will be no need for ground detection push buttons for disconnecting of

groups.

A diagnostics display shall be included in the System which will show the status

of the power supplies.

16.7.4 Supply of Power to the drive units, control valves and the field devices shall be a

dual source power with an automatic transfer switch (ATS) which will transfer to

the alternative power source in case of a power failure. The transfer shall be

done so that no interruption occurs in the event of failure of a single supply.

16.7.5 Loss of Power

Loss of power supply to the System, or loss of power within the System, shall

cause affected portions of the System to transfer to manual and an alarm will be

initiated. When power is restored, all controls shall stay in manual until reinstated

to automatic by the Operator. The loss of power to any drive unit shall be

indicated through alarm contacts furnished by Contractor.

The System shall operate normally under the following tolerances:

1. Input voltage 102 to 132 VAC or 204 to 264 VAC.

2. Maximum power interruption of 0.5 cycles.

When the above tolerances are exceeded, the System will transfer to the

manual mode and the demand signal to the final control element will not change.

Upon return to normal voltage, the System will remain in manual until the

operator will return it to the automatic.

The final drive unit shall remain in position upon loss of drive unit motive power

and/or loss of power to the controller, transmitter and other logic elements

associated with the drive unit or upon loss or interruption of the controller output

signal.



ISSUE: For Proposal


Upon restoration of motive or control power, the drive unit shall become

available for operation without changing its position even if it has been moved by

operating the local hand-wheel. Automatic remote releasing is required.

Manual control of each drive unit or converter shall be possible as long as its

specific motive power is available. Manual control shall be independent of the

logic power source or any drained voltage.

The circuit interrupting devices that are employed to provide isolation shall be

monitored so that erroneous control action does not result from a loss of power

to any part of the System.

16.8 Human-Machine Interface (HMI)

The Purchaser shall provide the conceptual design of Main Control Room

architecture, which shall be based on the advanced ergonomic practice and shall

contain the following:

- Operator Consoles

- Large Screen Displays

- Electrical Operator Console

- Shift Supervisory Console

All the computers shall be provided for 115VAC and 220VAC power supply.

A limited amount of Emergency hardware control devices shall be mounted on

Operator Console.

16.8.1 HMI Implementation and Arrangement

16.8.1.1 Operator Console

The Contractor shall provide the Operator Console according to items 4.1.1.1.1,

a.3 .

The Operator Workstations will be provided with "parallel" redundancy, i.e. any

piece of software (e.g. console database, graphic displays, reports, trends, etc.)

will be installed in each one of the Workstations.

From each Workstation it will be possible to operate and supervise the entire

unit, including electrical systems and auxiliary systems.

The common systems data for HMI use have to be available in both Units.

The Workstation shall accommodate a minimum of:



ISSUE: For Proposal


- 1,000 graphic displays (pop-up is not considered a graphic display)

- 50,000 tags

- 2,000 trends

The hardware platform of an Operator Workstation (OWS) will be based upon

the most advanced and reliable technology available on the market at delivery

date of the first unit.

The Operator Workstations will be connected to the data highway, thus

accessing all the available real time process data.

In addition, for a parallel overview of the entire process four (4) Large Screens

per Unit shall be provided. This screen shall display any of the operator

workstation displays or several of them at the same time.

The Operator Workstations will be provided with keyboards and mice.

16.8.1.2 Engineering Workstation(s)

16.8.1.2.1 The Engineering Workstation is a device meant for on-line configuration, control

tuning, and system debugging and documentation management.

16.8.1.2.2 The EWS shall also include all of the operators' workstations functions.

16.8.1.2.3 The EWS shall have raid disks architecture.

16.8.1.2.4 Software

The EWS shall be provided with all software packages required in order to

perform the following functions, as minimum:

- All operators' functions

- System's configuration

- Controller programming

- Control tuning

- System debugging

- System database management (based on relational database)

- On line system documentation (drawings)

- Graphic displays editing

- History retrieval

- Backup utilities

16.8.1.2.5 The engineer shall be able to display on the screen and/or print the following



ISSUE: For Proposal


additional summaries. These shall enable the engineer to review the up-to-date

documentation of the System more quickly than by reference to external hard

copy.

a. Summaries of all analog inputs, digital inputs, outputs, calculated variables

and booleans, including processing specifications, using a flexible query

scheme.

b. Summary of inputs, outputs, calculated variables belonging to a certain

device.

c. Summary of all points used by performance calculation programs.

d. Summary of points per serial data link, computer interface or remote I/O

cabinet, if applicable.

e. Summary of points per graphic display/per log.

f. Summary of displays/logs per point.

16.8.1.2.6 The Engineering Workstations' software shall enable forcing data inputs/outputs.

16.9 Application Requirements for Data Processing and Monitoring

16.9.1 Alarm Management

Each operator and engineer display shall have an area reserved to display all

active alarms. Alarms shall be classified as follows:

- Grouping of alarms will be available for associating characteristics like

different alarm sound, filtering, etc.

- Communication alarms.

- System alarms (down to the card level).

- Process alarms shall be assignable to every process variable in the database.

Points that shall be alarmed include: analogs, digitals, group digitals and

devices.

- There will be capability of selecting different sounds of alarms.

Deadbands shall also be available to define how far the points must return inside



ISSUE: For Proposal


the limit in order to be considered returned from the alarm condition. Digitals and

devices shall have standard normal/abnormal operating states.

An alarm priority shall be assignable to every variable, or the alarm can be

suppressed (or inhibited) It shall be possible to filter out alarms on displays and

logging devices by priority. The different priorities shall have different color

association.

16.9.2 Logging

16.9.2.1 General

All logs shall be programmed, or configured so that in an easy manner the

engineer will be able to edit the printing format of any log. A full-screen report

generator shall be provided.

16.9.2.2 Logs to be provided by the System:

16.9.2.2.1 Period Logs

This report is generated at a user-specified interval.

16.9.2.2.2 Event Logs

This report is generated when a user-specified condition is met.

16.9.2.2.3 Trip Logs

This report is generated when a user-specified trip condition is met. A trip report

will be printed at the end of the maximum post-trip (40 minutes). This report shall

be capable of reporting the Historical Events (0.1 second) data.

-Trigger condition: - User specified, up to 20 digital point value conditions. For

meaningful reports, these conditions should be the same as the conditions

specified for the Historical Event file.

-Other data used: - Live point values and attributes, lab data files and other

user file data.

-Manual request: - Can be generated by manual Operator workstation

request. The reference time given by the user will be interpreted as the time of

trip.



ISSUE: For Proposal


16.9.2.2.4 One Time Only Logs

This report is generated upon manual request only.

16.9.3 Operator Interface

16.9.3.1 General

The Human Machine Interface (HMI) shall provide an interface to the process

and support monitoring and control through dynamic displays.

HMI shall not execute control algorithms. Loss of HMI or data highway shall not

cause loss of process control.

16.9.3.2 Data Presentation

a. The control displays (samples as provided by contractor), including dynamic

graphics, will be completely built and operative on the screen in 1 (one) second

or less. All displayed data shall be updated in no more than 1 (one) second.

b. Any operator initiated control action, whether requested by the keyboard,

mouse, etc., shall be executed within one second or less. Confirmation that the

operator action has been executed shall be displayed on the screens within 2

(two) seconds or less. Execution and confirmation to an operator action shall not

be slowed due to high System activity, such as an alarm avalanche during a

process upset.

c. The quality of the process data and calculations shall always be indicated

whenever the data is displayed, or logged, or used in other calculations,

including high level programming language statements.

The system shall be able to determine that data is good, bad or substituted.

These terms mean:

Bad - data beyond the reading range of the System or resulted from calculations

with bad data;

Substituted - data value that is manually or automatically substituted.

16.9.3.3 Operator Displays



ISSUE: For Proposal


16.9.3.3.1 The Operator Displays shall be implemented based on EPD-B.32, PLC/DCS

Based Control Systems Control and Operation of Typical Devices (Supplement

5.2.6).

16.9.3.3.2 The intent behind the design of the main HMI is to provide the operator with a

"single window" to the process.

The operator station shall support the following types of displays:

a. Dynamic graphic and control displays

b. Trends

c. Start-up/shut down sequence displays

d. Alarm lists

e. Menus

f. System status

g. Summaries.

h. Alarm history

i. Trend history.

The Contractor shall provide the necessary number for each type of displays, as

required by Systems' functions. The displays shall permit full process

supervision as well as operation of all the corresponding systems.

It shall be possible to compose different types of displays on the same screen,

as required by the System(s) functions (e.g. graphics/trends/controls).

16.9.3.3.3 Graphic Displays

a. Any selected Workstation shall be able to display graphic pictorials of plant

equipment. The Contractor shall fully define and document the graphic

editor/viewer software.

b. Contractor shall be able to embed in the graphic displays, Purchaser-defined

symbols (dynamic or not).

c. Real-time updating shall be provided for the data values, symbols and display

elements when on display. Dynamic graphic symbol updating includes changing

symbols and/or colors, based on a logic defined either by Purchaser or

Contractor.

d. The system shall have the capability of displaying a minimum of one hundred

(100) dynamic analog values or contact status words and a minimum of two

hundred (200) dynamic symbols or any combination thereof on any display.



ISSUE: For Proposal


e. Graphic displays shall provide the necessary means to operate the

corresponding equipment (modulating or binary) by using pop-up screens or

equal.

f. A display definition created for one operator workstation shall be usable,

without any reprogramming or editing, on any other type of workstation which is

in Contractor's Scope of Supply.

g. The System shall include the flexibility in selection of color, thickness, size of

lines and fonts, as in Windows environment.

h) The System shall include the possibility to lower a display to task line and the

navigation between displays, without limitation, as in Windows environment.

i) The System shall include the possibility to select each window and to copy it

as an object on a Microsoft Office application.

j) The System shall include the possibility of navigation between displays,

without limitation, including dragging feature of each window.

k) The System shall include the possibility to mark on the display the element

status: out of service, limited, etc.

l) The System shall include the possibility to open graphic displays by system

name, using a rapid menu.

l) The System shall include the possibility to simply build graphs from the

process displays.

16.9.3.3.4 Analog Control Display

The Pop-up/Faceplate displays shall be included for the Modulating control

functions.

The process information provided by the display shall be individually weighted

deviations between the process variables and their set points or target values.

Loops in manual control shall be indicated. High and low operator action limits

shall be provided for each control loop to alert the operator to an impending

process alarm. High and low process alarms shall be shown for each loop when

tripped.



ISSUE: For Proposal


The control display shall include the detailed information for the corresponding

loop, such as:

- Control Station(s) Faceplate(s)

- Analog points in digital or bargraph form

- Digital point status

- Permissives and control interlocks status

- Logic diagrams displays including the possibility to show the fulfilled/non fulfilled

data, using color change.

- Real time trends for process variable, control output, set-point and any

corresponding analog points.

Start-up window displays shall include all the required information, such as: start

permissive, trip cause, etc.

16.9.3.3.5 Operators' Control Displays

The operator shall be able to manipulate set-point, output, ratio, bias and control

modes through the tuning display. For digital points, the operator shall be able to

issue commands to the start/stop and open/close two state equipment. Through

use of a password the operator shall be permitted or restricted from:

- Changing tuning constants

- Changing process variable zero and span value

- Changing alarm limits

- Changing configuration of any of the loop and gate parameters (control

algorithm, signal type and input source, as well as interlocks and delays).

16.9.3.3.6 Trending

The trend displays shall provide continuous on-line representation of up to eight

(8) variables. The variables shall be scaled in engineering units. As a minimum,

the last 24 hours of trend data shall be available for each trend point.



ISSUE: For Proposal


The sampling period (e.g. 1 second, 15 seconds, 1 minute) and type of trend

(e.g. sample, mean, minimum, maximum and summation) shall be configurable.

The possibility to build multi-trend displays (based on the existing display by

selection + CNTR) and multi scale function for multi trend displays, as in PI shall

be provided.

The user shall be able to configure on-line temporary trends of any point in the

System. These trends shall be updated at least every two (2) seconds to show

real time data. As a minimum the last two (2) hours of data for the temporary

trend points shall be available for recall and viewing.

The zero and span scales shall be capable of being individually scaled,

expanded or zoomed for clarity and more detailed viewing. The trend display

shall be capable of being panned from the current time back to available

historical trend time. Trending data must be capable of on line storage with no

external devices.

The trend display shall include the current values of the trend variables, as well

as the corresponding past values as the time pointer is moved through the time

scale.

The operator shall be able to set the grid roll-down speed and the interval

between time lines.

The following information shall be displayed on the screen for each of the

trending variables, in the color of the respective trace:

a. Tag name.

b. Tag description.

c. Current value (numeric).

d. Zero and full scale value.

e. Engineering units.

f. Point quality.

16.9.3.3.7 Historical Trends

a. It shall be possible, following a unit trip, to display analog trends of events that

occurred, for selected variables.

b. Through the use of historical data storage and retrieval functions described in

this Specification, historical trends shall be available to the engineer upon

demand, to be displayed on a screen, with different time scales.



ISSUE: For Proposal


16.9.3.3.8 Control displays

The device sequential control displays shall support the following operator

functions:

- Manual device control

- Auto-manual selection (where required)

- Electrical lockout of circuit breakers and starters operation (for device

maintenance purposes).

- Monitoring (via feedback from controlled devices) of device status (close/open

or start/stop).

- Monitoring of control circuits integrity (disable function).

- Monitoring of abnormal operating conditions and acknowledgement.

- Monitoring of permissive/trip conditions.

- Monitoring or motors/feeders current and throttling valves travel position.

- Synchronizing selection/monitoring (where applicable).

- Sequential control (groups control) selection and actuation, including

possibility and guidance for the manual sequence operation.

- Sequential control monitoring/criteria indication, including status of each step

and necessary feedback signals.

- The device control through HMI shall be multilevel security code protected

against accidental operation.

16.9.3.3.9 Summaries

The operator shall be able to display on the screen and/or print the following, but

not limited to, summaries:

- Summary of all actual operating limit alarms.



ISSUE: For Proposal


- Summary of last shift acknowledges alarms.

- Summary of last shift "return-to-normal" alarms.

- Summary of all bad quality points.

- Summary of all points with substituted values.

- Summary of all inhibited points.

- Summary of status of all peripheral devices.

- Summary of status of all workstations, intelligent modules and highways and

disk usage.

- Summary of all defined system points, according to the plant system

identification codes.

- Summary of assigned trend points.

- Summary of all points belonging to each log on a per log basis.

- Summary of the existing logs and their status.

- Summaries of active graphic control/binary/sequential displays, according to

displays type.

16.9.3.3.10 On-screen Menus

The on-screen menus shall provide the following:

a. Simple, consistent, straight-forward procedures to obtain process

data/operate corresponding equipment.

b. Simplify operation in communicating with the System and eliminate the need

to use reference handbooks.

c. Shorten the time it takes to obtain information by displaying response

messages, error messages and various summaries on Screens rather than

causing a delay until the information is printed.

d. Reduce operator error when making various functional changes to the



ISSUE: For Proposal


System, by adequate help like color highlighting data allowable to change and

menu choices instead of key-ins.

e. Reduce the time of the engineers in making programming changes by

enabling functional changes to be made interactively through the screen in other

than programming language.

f. If the operator makes a keystroke entry error, the response message will

define the specific type of error made, in conversational language and not only

as coded error number or program statement.

g. An operator key-in error shall not cause a system error, either fatal or non-

fatal.

16.9.3.3.11 System Status Displays

The Workstations shall be capable of displaying a status display in a hierarchical

layout. A System status display shall provide an overview of the operational

status of the nodes on the communication network. The display shall be

accessed by a keystroke without the need for key-locks.

From the System display, any node status may be selected and displays of the

status of each module. The module display shall provide the status of a

particular module, the I/O processing modules and the I/O points.

16.9.4 Function Security

Methods shall be provided for limiting access to functions depending upon the

Workstation software module. Individual functions will be enabled or disabled.

Security will be defined as part of the Workstation configuration.

An error message will be displayed when there is an attempt to access a

protected function.

Those functions, the control of which is restricted to an engineer, shall be under

password control. A preliminary list of those functions is as follows:

a. Taking a point out of scan.

b. Rejection of any log.

c. Changing any information in the database of any variable or the configuration

in the intelligent modules.

d. Changes in logs (adding or deleting points, changing trigger conditions, etc.)



ISSUE: For Proposal


or graphic displays.

e. Communication network configuration.

Other functions to be under password control shall be determined by the

Purchaser during the System design, if needed.

The System shall also have the capability to allow the engineer to add or remove

functions to/from the restriction. Contractor shall supply complete instructions on

how this is to be done in field.



ISSUE: For Proposal


17. ELECTRICAL REQUIREMENTS

17.1 General

The requirements detailed under this paragraph apply to all Electrical Auxiliary

Equipment (cubicles, switches, breakers, lamps, relays etc., cables, terminal

blocks, etc.) supplied under this Contract.

17.2 Power Supplies

17.2.1 The Purchaser shall provide the main and auxiliary power supply network.

17.2.1.1 The following electrical power may be provided by Purchaser to The Plant

Control & Monitoring System cabinets:

a. 380 VAC + 5%, - 5%, 3Ph, 50 Hz

b. Uninterruptible power 120VAC, 50 Hz, single phase.

c. 220VDC + 10%, -15% floating, from the station batteries.

d. Single phase convenience power 230VAC, 50Hz.

e. The power feed to the drive units is 208V, 3Ph, 50Hz.

17.2.1.2 The following main and auxiliary power supply network shall be provided by

Purchaser for the Electrical Auxiliary Equipment:

a. 6.9kV +5%, 3Ph, 50Hz (for motors above 250 HP)

b. 380 VAC + 5%, - 5%, 3Ph, 50 Hz

c. Single phase control power 230VAC, 50Hz.

d. Single phase convenience power 230VAC, 50Hz.

e. Uninterruptible Power Supply (UPS), single phase 120VAC, 50Hz.

f. 220VDC + 10%, -15% floating.

17.3 Control Enclosures

17.3.1 Enclosures Requirements

The Control enclosures shall conform to the following standards, as

supplemented herein:

EPD-A.03/04: Control Cubicles Wiring Requirements.

EPD-2/99: Standard requirements for painting and corrosion

protection of electrical equipment.

In addition the following requirements shall be met:

a. Separate Termination/Marshalling cabinets shall be furnished in order to



ISSUE: For Proposal


permit use of the existing cables. All existing and new field cables will be

connected to the a.m. cabinets. No electronic equipment shall be mounted in

the termination area.

b. Separate 230V, 50Hz single phase supply shall be provide by Purchaser for

convenience outlets. This supply shall be separate and distinct from the control

voltage supply.

c. Each cabinet shall be provided with temperature and open door detectors for

alarm.

17.3.2 Wiring

Internal wiring shall be made with wires of halogen-free insulation type and shall

be made according to EPD-A.03/04 requirements.

7.4 Cables & Wiring

17.4.1 Prefabricated Cables

a. Cables will be according to the equipment list. Their types will be subject to

Purchaser’s (IEC’s) approval. The cables will be flame retardant. Cables shall

meet IEEE-383-1974 Flame test requirements or equivalent VDE 0472 Flame

test.

Voltage rating is 600V, according to NEMA-IPCEA, or 500V according to VDE.

b. Cable connectors will be keyed, to prevent improper connection in the field.

The Contractor shall supply all the special tool(s) required for installing the plug-

in connectors.

c. Plug connectors shall include a locking feature to avoid accidental

disconnection.

d. The Contractor shall supply all the special tool(s) required for installing the plug-

in connectors.

e. Plug connectors and cables on both ends shall be tagged with identifying

numbers, according to Purchaser’s cable identification numbers.

f. The individual pre-fabricated cables shall not be cut until final cutting

length information is received from Purchaser.



ISSUE: For Proposal


g. A quantity of about 20% spare plugs and receptacles for each type of connector

shall be provided as part of basic scope of supply.

h. Monitor and control circuits, in which connectors are used, shall also include

provisions for connection

17.5 Control and Distribution Enclosures and Panels

17.5.1 The Control enclosures shall conform with the applicable standards detailed in

article 5.2 above (5.2.1 and 5.2.5).

In addition the following requirements shall be met:

17.5.2 The cabinet design shall be modular, with the logic equipment laid out in clearly

identified functional groups.

17.5.3 Permanent type nameplates and identification drawings shall be provided in the

cabinet to clearly identify and locate individual function devices. Nameplates

shall include a functional system of each device as well as a location number.

17.5.4 Adequate space for mounting fire protection detectors on top cover shall be

provided within each cabinet. On the top cover a removable plate for this

purpose shall be provided with the following dimensions: 250/250mm.

17.5.5 220V, 50Hz, single phase supply shall be provided by the Purchaser for panel

lighting and convenience outlets. This supply shall be separate and distinct from

the control voltage supply.

17.5.6 The Internal wiring shall conform to the applicable standards detailed in article

5.2.1 above.

17.5.7 The Control equipment shall meet the environmental conditions and related

requirements as detailed in article 9.3.1 above.

17.5.8 All electrical components mounted outdoors shall be provided in an outdoor

weatherproof enclosure, NEMA 4X or IP65 with corrosion protection, shall meet

the environmental conditions and related requirements as detailed in article 9.3.2

above.

Contractor shall design the equipment and advise the Purchaser of the

appropriate installation procedures, necessary to prevent any adverse effect on

the System due to RFI and EMI noise produced by the noisy environment of the



ISSUE: For Proposal


plant, which includes motors, contactors and high voltage switchgear, as well as

other external disturbing electro-magnetic fields, like radio transmission devices

or communication equipment, including cellular phones.

The Contractor shall take the necessary steps to minimize the effects of lightning

strikes on circuits which contain elements located outside the main plant

building. This should include proper grounding recommendations, the use of

surge arrestors, optical isolators, isolating transformers or any other means

which will provide suitable protection.

- F I N A L -

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