‘SHEET 10F 12 SPECIFICATION FOR PLC SYSTEM Se Re. | 0 ‘ava ; © | 03-08-10 | First sue fr information : JcGupta | AK Bhasin Rajavat fev | bne [Bescon ffeion — [repredby | GiiedBy | pp. 8y | oper Contractor ‘lens Engg. Consultant Gient TRACTEBEL Engineering GPEC ® ENERGY oS Gujarat Paguthan Energy BGR ENERGY SYSTEMS LTD. Corporation Private Limited Contractors ob No OGED-735_| Consultants Pro] No Glznt’s P.0, No;= 5011000819 HEATING SYSTEM, GPEC ENGINEERING DOCUMENT TLE= ‘SPECIFICATION FOR PLC SYSTEM TYPE OF DOCUMENT: SPECIFICATION -INSTRUMENTATION PEC DOCUMENT No? Contractors Doc. No. fev GIX-BGR-OGED-739-IN-SP-401 Scale: None Sheet: Lofla Size: ‘84 (2973210)‘SHEET @ 20F 12 SPECIFICATION FOR PLC SYSTEM. Rev. | 0 1.0 14 444 12 124 13 134 GENERAL SCOPE This specification defines the minimum technical requirements for design, manufacture, assemble, calibration, factory testing, packaging and supply of PLC ‘system within a process package for GPEC- heating system. ‘The provision of this specification shall in no way be considered a limiting clause for relieving vendor from any of his obligations to deliver PLC system within the specified limits and guarantees. Moreover, the system shall be designed and constructed in ‘order to guarantee the maximum operating reliability and the operating flexibility without any effect on the quality and capacity. DEFINATION OF TERMS: ‘The following terms used hereinafter shall have the meaning indicated below: PROJECT GPEC Natural gas supply system. CLIENT Gujarat Paguthan Energy Corporation Put. Ltd, CONTRACTOR : BGR Energy systems Ltd. CONSULTANT : TRACTEBEL Engineering MANUFACTURER / VENDOR ‘Company which could be recipient of a “direct” purchase order for the supply of equipment. ("Vendor’ shall be understood as a synonymous of “SUPPLY” or “SELLER’, which is ‘sometimes used instead.) SHALL indicates a mandatory requirement. REFERENCE DOCUMENTS: For design, manufacturing, inspection, testing, installation of the equipment supplied, reference shall be made to the latest edition, except otherwise noted, of the codes and standards listed in the specification and to all other referenced documents or applicable rules governing on site. Input /Output list GIX/BGRIOGED-739-IN-OT-401 Control Philosophy of Heating System — GIX/BGRIOGED-739-IN-OT-406‘SHEET 30F12 ‘SPECIFICATION FOR PLC SYSTEM Rev. | 0 14 15 15. 18. 16 16. 16. 17 17. 47. INTERNATIONAL CODES AND STANDARDS: ANSIISA S 51.1 Process Instrumentation Terminology IEC 60529 Specification for weather proof enclosure IEC 60079n8:2148 Specifications for Flame proof enclosure IEC 61000 Electromagnetic compatibility for industries process Measurement and control equipments. HAZARDOUS AREA CLASSIFICATION: ‘1 Hazardous area classification: Zone 1. Gas Group IIA / IIB, Temp. Class T3. All instrument components. Equipment and wiring falling in hazardous area shall be selected based on hazardous area classification. Control room will be located in non. hazardous area. Where applicable all electrical equipment shall be certified by CENELEC / ATEX / FACTORY MUTUAL (FM) / EQUIVALENT CODES. 2 The following table indicates the mechanical protection against the atmospheric agents for instruments and enclosures containing instrumentation components, for Indoor and outdoor installation. Ratings Use Pat Panel protection POWER SUPPLY: 1 Microprocessor based PLC control system:230 V AC # 10 %,50Hz + 5 %-UPS power ‘Supply for control system and 230 v ac non-UPS power supply for panel lighting fans. «Power sockets ,panel heaters, thermostat etc. 2 Field Transmitters: 24 V DC loop power through barrierisolator,24 V DC power will bbe derived from 230 V UPS power supply at PLC based control panel. CONTROL PANEL SPECIFICATION ‘1 Dedicated PLC along with processor, power supply, ilo cards, communication cards ‘& panel view shall be provided for control & monitoring of each heater. Control panel shall be common for three (3) heaters. Three (3) PLC’s along with the accessories, shall be accommodated in this control panel. The panel shall be self-standing in dust & vermin proof, floor mounted, sheet steel enclosure. Minimum degree of protection for panel shall be IP41 as per 1S-2147. 2 Enclosure shall be fabricated with cold rolled cold annealed (CRCA) sheet minimum thickness 1.5mm and gland plate thickness shall be 3 mm,SHEET @ 40Fi2 ‘SPECIFICATION FOR PLC SYSTEM feney Rev. | 0 1.7.3 Mounting height of equipment / components requiting operation and observation Shall not be lower than 300 mm and higher than 1600 mm. all component shall be so ‘mounted that they are easily accessible for inspection and maintenance. Panel size (tentative) shall be 1200(W) x 800(D) x 2100(H) mm, 1.7.4 Color of panel: RAL 7032 for the panel exterior, semi glassy white for interior and black for the base frame. 1.7.5 The entire surface of panels and accessories, comprising front, rear, sides, etc. shall be treated and painted as follows: 1) All exposed surfaces included structures shall be sand blasted and grinding done until they are smooth and free of sand, rust etc, 2) Chemical treatment / pricing shall be done to remove rust, oil, entrapped impurities and other foreign materials. 3) Ifnecessary, suitable fiter shall be applied to all pits and blemishes on the surface. 4) The front surtace of the panels shall be painted with three coats of sealing primer and surface. The entire surface shall be sanded between coats. Two Coats of finish paint of high-grade lacquer enamel shall be given at shop. 5) All other surfaces including those of accessories shall be painted with two Coats of sealing primer and surface and two coats of lacquer enamel finish paint. 8) A final coat of finish paint of high-grade lacquer enamel shall be given at site after assembly and filling of front panel but joints with suitable filler, to present and continuous pane! surface. DFT of finished coat shall be SOum. 7) The finish of final coat shall be of se loss texture to minimize light 1.8. PANEL SHALL HAVE THE FOLLOWING MINIMUM ACCESSORIES: 1) Door switch 2) Cable gland 3 MCB. 4) 5A power supply socket 5) Panel light 6) Lugs 7) Cooling fan 8) Panel heater with thermostatSOF 12 ‘SPECIFICATION FOR PLC SYSTEM 19 19.1 192 1.93 194 19.5 1.9.6 9) Terminal blocks etc. 10) Acknowledge, reset, Test push button for annunciator. PANEL CONFIGURATION ‘The panel shall be configured for instrumentation scheme as shown in the P&ID. The ‘quantity of indication lamps, push buttons, and selector switches, barriers and signal ‘Multiplier shall be selected according to fulfil the operational requirement of instrument scheme as per P&ID requirements. All the signal from hazardous area shall be routed through suitable isolator / barriers. The isolator / barriers shall be capable of powering the two wire transmitters in the field. Redundant power supply unit (240V AC / 24V DC) power supply shall be Provided in control panel for powering each PLC, panel view monitors, isolator, barrier etc. The following indications / alarm shall be provided as a minimum at LCP including BMS: power on, burner on, bumer off, water bath high temperature alarm, low water bath level, heater trip alarm, low fuel gas pressure alarm, common fault alarm, m: line gas temp high alarm & Gas alarm etc. All 4 to 20 mA analog signals & potential free digital signal shall be available at terminal block of instrument local panel The following control functions shall be available as minimum in panel: Fuel gas pressure-after let-down, fuel gas temperature-after let-down, water bath temperature, gas outlet temperature, fuel gas meter reading, water bath level, gas inlet and outlet pressure etc. PLC shall have the following minimum specification 1) PLC shall have own processor, memory, power supply unit & communication modules, serial interface modules and I/O card complete in all respects. Each card shall perform dedicated functionality w.r:t. analog input, analog output, digital input and digital output functions. 2) PLC scan time shall not exceed 100 msec. 3) ___ Time stamping; history processing, self diagnostic facility shall be available, 4) PLC shall be based on "Open Architecture” concept so that it can be easily interface with other foreign devices, which are also confirming to “Open Architecture”, 5) Aprovision for serial communication RS 232 / RS 485 module shall be available in PLC. (2 Nos. RS232 & 2 Nos. RS485 Ports required as. minimum)‘SHEET 6 OF 12 2. SPECIFICATION FOR PLC SYSTEM. Rev. | 0 8) PLC shall have miniature type mimic display with feather touch push button / touch screen display at the front panel. 1.9.6.1. Logic Functions: ‘The relevant controller shall be able to handle the following functions: 1) Basic functions: OR, AND, NOT EQUAL, SET/RESET. 2) Timer and counter. 3) Operations on words: comparison, shift, move, Boolean, conversion. 4) Time functions. 5) String functions. 6) PID controls etc. 1.96.2 Digital inputs: ‘Typical specification of digital input modules to be supplied is as given below: 1) Input type 2 Min.16 channel, Vott free contacts (2 wire isolated) 2) Contact wetting 2.4m perinput at 24V DC 3) Resistance recognized: Not exceeding 1 Kilo ohms as a closed contact 4) Resistance recognized: Not exceeding 50 Kilo ohms as a open contact 5) Isolation using opto coupler 6) Debounced circuity : 10m/sec, 7) Indicators + Loop & state LED's for each DI point 8) Voltage withstand 1.5 KV RMS capability 8) NOING contacts: mixing of NOINC contacts shall be possible in The same card. 1.96.3 Digital outputs Typical specification of digital output modules to be supplied is as given bel Output type : Min. 8 channel relay contacts 1) Indicators LED indication for each DO point‘SPECIFICATION FOR PLC SYSTEM ‘SHEET 70F12 Rev. | 0 2) Relay type 3) Contact arrangement 4) Contact rating 5) Isolation 6) Security 1.9.6.4 Analog inputs miniature power relay 11NO + 1NC relay contacts configuration to be Provided up to the RTU terminal block Potential free contact rating of output interposing relay for each DO point (contact rating 48 V DC, 2A; 230V AC, 5A) (vendor to Provide interposing relays for each digital output point.) 2KV RMS contacts to logic ‘output contacts shall be monitored via opto- isolators, shall be short circuit proof and Protected by suitable mechanism like fuse with ‘Suitable visual fuse blown indication provide ‘Typical specification of analog input modules to be supplied is as given below 1) 2) 3) 4) 5) 8) 2) 8) 9) Input type Ranges Multiplexer ADC type Series mode rejection ‘Common mode rejection: Roll over error ‘Temperature coefficient Accuracy 1.9.6.5 Analog outputs Min. 04 isolated, current inputs 04~-20 mA vendor standard, 12 bit binary (exclusive of sign bit) greater than 30 db at 50 Hz greater than 100 db at 50 Hz 1 bit 0.005% per degree CSHEET BOFI2 ‘SPECIFICATION FOR PLC SYSTEM. Rev. ‘Typical specification of analog output modules to be supplied is as given below 1) 2) 3) 4) 5) 6) 7 8) 9) Output type DAC type DAC span Output range Isolation Loading Differential linearity ‘Temperature coefficient Accuracy 10)Receptivity 1.966 Panel view Min. 4 completely isolated current (4-20mA) 12 bit binary (exclusive of sign bit) 10V or SV 4-20 mA DC each output shall be isolated from logic and the others to 500V 1K ohm for current outputs % LSB. 0.01 % FSD per degree C £02 of range ‘set-point value to be held by AO card til updated by new set-point. Man-machine interface (miniature type color touch screen display) shall be Provided to PLC for local parameters’ display and graphical view of process in detail Touch screen display shall have following standard feature as minimum but Not limited to: } 2) 3) 4) 5) 8) 0) Type Operating voltage Display size Display type Display color Display resolution Operating mode compact touch screen display 2av Dc ‘minimum 5* STN/TFT color 320 x 240 min, touch‘SHEET | pee SPECIFICATION FOR PLC SYSTEM sore freey Rev. | 0 8) Interface : RS 232/485 / Ethernet. 8) Program memory + flash / RAM of 256 KB Min. 10) U0 device printer 11)Degree of protection: IP65 for outdoor and IP41 for control room. application. 1967 Galvanically isolated barriers with signal & monitoring of system shall be provided as per requirement and it shall be compatible for SCADA (feature). 1968 All field signals related to control & monitoring of system shall be sent to SCADA /DCS on Ethemet TCP / IP. For this purpose necessary provision (hardware & software configuration) shall be available in PLC, 1.9.7 ‘Some panel components information is as below: 1.9.74 tem : LED 1) Function + status display 2) Mounting + Flush mounted 1.972 tem 2 signal multiplier & barrier 1) Function + torepeat signal to PLC 2) Type + Galvanically isolated 3) Signal 1 analogue & digital 4) Input 2 4-20mA 5) Output : 4-20mA 6) output drive capability 0-600 ohm ~ 7) No. of channels + two isolated output (minimum) 8) Accuracy + 0.25% of full scale 9) isolated voltage : S00VDC 19.73 Item + Push Button (with Execute / Cancel provision) 1) Type + Stay put100F 12 SPECIFICATION FOR PLC SYSTEM SHEET Rev. | 0 19.74 19.15 2) Standards 3) Shock Resistance 4) Bleetric Shock Protection 5) Mechanical life Item 1) Type 2) Input 3) Output 4) Current rating » regulation ©) Load regulation 1) Stability 8) Transient recovery period 9) Auto tracking of the output 10) Indication 1) Fuse 12) Output monitoring 13) Protection 14) Ripple and noise Item 1) Type 2) Mounting TEC 947-4-1, VDE 0660 CSA C22, ULS08 Solid State redundant As per IEC 86-227 As per IEC 536 1 million operations Power supply 24 VDC Solid state redundant 230 VAC 50 Hz 24vDe As required 0.05% 0.05% 0.2% under constant load < 100 micro seconds <1% error LED for SUPPLY ON To be provide on AC & DC lines Socket to be provided with adjustment facility Short circuit and over load, potential free contact Required for health signal of power supply 1 mV (rms) or less Solid state Flush panet‘SHEET 2 SPECIFICATION FOR PLC SYSTEM. a a 2 1 peer Rev. | 0 3) Enclosure + General Purpose IP 41 4) Power Supply + 230 VAC 50 Hz 5) Window Size 50 mm X 60 mm. 19.16 19.7.7 19.78 19.79 197.10 197.11 197.12 197.13 6) No.of Windows + 24 Nos. (Minimum) ‘Note: Trip signal & important alarm shall be displayed in Alarm annunciator. Panel Wiring All wiring shall confirm to API-RP-550 Part 1 Section 7& 12. Different signal level cable ‘Shall be routed with separation distances as recommended by API-RP-S50 Section 7. All wiring inside racks, cabinets and back of the panels shall be housed in covered, non- inflammable plastic raceways arranged to permit easy accessibility to various instruments For maintenance, adjustment, repair and removal. ‘Al wiring in the raceways shall be properly clamped. Total wiring cross-section area shall, Not exceed 50% ofthe raceway cross-section area, Rubber / plastic grommets shall be Used for wire entry into individual instruments and entry / exit of wires raceways, Separate wiring raceways shall be used for power supply wiring. DC and low level signal Wiring and intrinsically safe wiring. Parallel runs of AC and DC wiring closer than 300 mm shall be avoided. Wire termination shall be done using self-insulating crimping lugs. No more than two wires shall be terminated on one side of single terminal. Such a practice Shall be avoided as far as possible. The use of short-link for looping shall be avoided. Terminal housing shall be strictly sized with considerations for accessibility and mainten- ine ance. Following points shall be considered: fe nanesy (S vexpor % je DOS: crag) J Description Distance between terminal strip and side of the cabinet parallel to the strip up to 50 terminalsSHEET @ 12 0F12 SPECIFICATION FOR PLC SYSTEM T = | |. Ree | ° Distance between terminal stip and top & bottom of the cabinet] Min 75 mm Distance between two adjacent terminal strip Min 100 mm ‘Addition distance for each additional 25 terminals Min 25 mm Distance between cable gland plate and the bottom of the stip ‘Min 300 mam 19.7.4 all terminals strip shall be mounted on suitable anodized metallic or plastics standoff. 1.9715 No splicing is allowed in between wires / cable straight run. 1.97.16 Terminal stip shall be arranged group wise for incoming and outgoing cable separately. 1.97.17 Cabinets and rack layout shall be made considering proper accessibility and maintenance. 1.97.18 Entire panel wiring shall be cross-ferruled. 1.97.19 All the instruments, switches, relays, timer as required shall be in the bidder’s scope to Complete operational scheme.