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TECHNICAL

No: HWB/INST/ EHTC/2017

Design, Engineering, software development,

Manufacture, Supply, Factory testing, Pre-dispatch

inspection, Installation, Commissioning, Training,

Performance monitoring of ELECTRO-

HYDRAULIC TURBINE CONTROL SYSTEM

For 30MW TG Set of EK-1800-2 MODEL BHEL

MAKE at Captive power plant, Heavy Water Plant,

Manuguru

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INDEX

SECTION-A (EXISTING SYSTEM DETAILS)

1.0 INTRODUCTION

2.0 EXISTING TURBINE SYSTEM DESCRIPTION

3.0 EXISTING SYSTEM INSTRUMENTATION, CONTROLS & LOGIC

4.0 POWER SUPPLY IN EXISTING SYSTEM

5.0 DETAILS OF CONTROLLERS IN EXISTING SYSTEM

6.0 LOGICS/PROTECTIONS

7.0 EXISTING DCS SYSTEM USED FOR TURBINE TRIP INTERLOCK

SECTION-B (GENERAL REQUIREMENTS)

1.0 SCOPE OF VENDOR

2.0 FACTORY ACCEPTANCE TEST (FAT)

3.0 TRAINING

4.0 REMOVAL OF EXISTING SYSTEM

5.0 SITE ACCEPTANCE TEST (SAT)

6.0 ERECTION & COMMISSIONING

7.0 SERVICE SUPPORT

8.0 MAINTENANCE

9.0 GUARANTEE

10.0 EARTHING REQUIREMENT

11.0 BROAD SCOPE OF SUPPLY

12.0 GENERAL OUTLAY

13.0 VENDOR QUALIFICATION CRITERIA

14.0 SITE CONDITIONS

15.0 DOCUMENTS

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SECTION-C (FUNCTIONAL & TECHNICAL SPECIFICATION)

1.0 INTRODUCTION

2.0 BRIEF FUCNTINOAL SPECIFICATIONS OF NEW GOVERNING

SYSTEM

3.0 EXISTING POWER SUPPLY

4.0 LOCATION OF GOVERNOR PANEL & SKID

5.0 SKID & PIPING

6.0 TECHNICAL FEATURES

7.0 SPARE PARTS & MAINTENANCE EQUIPMENT

8.0 PERFORMANCE REQUIREMNTS

9.0 I/O REQUIREMENT OF SYSTEM

10.0 SPECIFICATIONS OF I/O S & COMUNICATION REQUIREMENTS

OF THE SYSTEM

11.0 I/O INTERFACE TO DCS

12.0 ENVIRONMENT CONDITIONS

13.0 GENERAL TECHCNIAL REQUIREMENT

14.0 CABINETS

15.0 ADVANTAGE OF NEW SYSTEM

16.0 TEST REPORTS

SECTION-D (TERMS & CONDITIONS)

1.0 PRE – BID VENDOR’S VISIT TO THE SITE

2.0 ACCEPTANCE OF TECHNICAL SPECIFICATIONS

3.0 DEVIATION FROM TENDER SPECIFICATIONS

4.0 CIVIL WORK

5.0 KICK – OFF MEETING

6.0 DELIVERY TERMS & PERIOS

7.0 PRICES

8.0 PAYMENT TERMS

9.0 SERVICES TO BE SUPPLIED BY HWPM DURING ERECTION

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SECTION-E (QUALITY ASSURANCE PLAN)

1.0 FAT & SAT DETAILS OF GOVERNOR SYTEM & OTHER

DEVICES

ANNEXURES

ANNEXURE A1—BLOCK DIAGRAM OF SIGNAL INTERFACING

ANNEXURE A2— DIFFERENT TYPE OF SIGNALS REQUIRED

ANNEXURE A3— BILL OF MATERIALS

ANNEXURE B1— P&ID of turbine control system

ANNEXURE B2—DCS SYSTEM ARCHITECTURE

ANNEXURE B3- GOVERNER LOGIC SCHEMEATIC

ANNEXURE B4 – SIMPLIFIED BLOCK DIAGRAM OF EXISTING HYRALIC AND

ELETRO HYDRAULIC SYSTEM

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Section – A (Existing System Details)

1.0 INTRODUCTION

Heavy Water Plant (Manuguru) has a 3X30 Mwe TG Set in its Captive

Power Plant. Steam Turbine-Generator of Captive Power Plant is single cylinder, condensing

and impulse-reaction turbine of type EK-1800 supplied by M/s BHEL. TG is designed for a

normal output of 27 Mwe and is capable of generating 30 Mwe (Max). TG is provided with

HP extraction (controlled) and LP extraction (uncontrolled which is controlled externally) at

32 ata and 8 ata respectively. Extraction steam is used for process requirements to Main Plant.

The TG sets are equipped with Electro Hydraulic Controller and Hydraulic governor.

Hydraulic governor having speed controller and extraction pressure controller is a standby

governor to the Electro Hydraulic Controller. Inlet steam conditions to TG are 101 Kg/cm2

(a) and 480 deg C. Maximum designed steam flow through turbine is 241.5 T/hr. Under these

conditions following are the output values:

a) Generation : 30 Mwe

b) HP steam : 133 T/hr.

c) LP steam : 39 T/hr.

d) Flow to condenser : 69 T/hr.

e) Condenser vacuum : 0.107 ata

The generator is of air cooled type and is equipped with static excitation system with

automatic voltage regulator (AVR). Generation voltage is 11 KV.

In Electro Hydraulic Turbine Control System (EHTC), the electronic methods of measuring

and processing of signals are utilized, which offer the advantages such as faster response time

flexibility, dynamic stability and integration of complicated functional relationship through

multi controllers. The processed electronic signals are introduced in hydraulic circuit through

Electro-Hydraulic converter (EHC).

2.0 EXISTING TURBINE SYSTEM DESCRIPTION

Single cylinder, condensing turbine is provided with 42+1 stages out of which first stage is

single row having blades on it. The first stage is followed by HP and LP blades which are

separated internally with steam glands. Steam flow to HP part and LP parts of the turbine is

regulated by steam control valves for the purpose of controlling the HP steam pressure. HP

part is nozzle controlled and LP part is throttle controlled. HP extraction steam at 32 ata after

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14th stage and LP extraction steam at 8 ata after 27th stage of turbine is taken for process use at

Main Plant. Axial thrust coming on the turbine is taken care of by balancing piston and the

residual thrust by thrust bearing provided at the front side.

2.1 HYDRAULIC GOVERNING SYSTEM DESCRIPTION

2.1.1 CONTROL PHILOSOPHY:-

Basically there are two controls; speed control and extraction pressure control. For the

purpose of extraction pressure control, Single casing turbine has been divided internally with

steam glands into HP part and LP part. In each part of the turbine, steam flow is regulated by

a set of steam control valves (0801 and 0802). The amount of opening of each valve is

controlled by the Hydraulic signal (secondary oil pressure) generated by speed governor and

extraction pressure controller.

Speed governor generates the secondary oil pressure for control valve actuator (Servo

Motors) in such a way that the change in amount of steam flow through HP & LP parts of

turbine is same. This does not affect the steam flow through extraction.

Extraction pressure controller acts in such a way that upon decrease in extraction pressure, HP

control valve opens more and LP control valve moves in close direction. Valve movements

through changes in secondary oil pressure are designed such that the increase in power in HP

part of the turbine is equal to the decrease in power in LP part of turbine, thereby maintaining

constant power for different extraction demand. Similarly upon increase in extraction

pressure, HP control valve moves in close direction and LP control valve moves in open

direction.

Output of speed governor and extraction pressure controller is coordinated in a Hydraulic

amplifier (1830) through simple lever system.

2.1.2 SPEED CONTROL:-

Turbine speed is sensed by a Governor impeller (1111), which is driven at rated speed by

turbine main shaft. Governor impeller is supplied with a small quantity of oil from the main

oil pump. Depending upon the speed of turbine, governor builds up a pressure of 2.5 Kg/Cm2

(g). This oil pressure is called as primary oil pressure.

Primary oil pressure acts on bellow (1112) of speed governor. The force exerted on the

bellow by primary oil pressure is transmitted to the lever through a pin. A compression

spring (also called as speeder spring) is mounted on the top of the lever. Spring is pre-

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compressed by speeder gear motor (1851) or a hand wheel (1113). The spring balances the

primary oil pressure acting on the bellow. The travel of the bellow is transmitted to the lever,

which is pivoted at one end. At its free end the pivoted lever is connected to control sleeves

of follow up piston assemblies of Hydraulic amplifier (1830).

Hydraulic amplifier (1830) consists mainly of 2 sets of control sleeves, follow up piston,

tension spring and a set of lever system for extraction pressure control. Control sleeves and

follow up pistons are provided with control ports. The follow up pistons are held in their

respective control sleeves with the help of tension springs. The overlap of ports between

control sleeve and follow up piston depends upon primary oil pressure, speeder gear position

and tension in the tension springs.

Oil from the trip oil circuit is admitted into the follow up piston through an orifice. The

pressure inside follow up pistons depends on overlap of control ports. This pressure is called

as secondary oil pressure.

Any variation in primary oil pressure due to speed change, or change in speeder gear position

causes the overlaps of port between control sleeves and follows up piston to re-adjust. This

results in either increase or decrease of HP secondary oil pressure and LP secondary oil

pressure. These pressures are transmitted to the HP and LP control valves

actuators/servomotors respectively.

2.1.3 EXTRACTION PRESSURE CONTROL:-

Extraction pressure is sensed by a pressure transmitter (PT-5-45) and provides actual value to

a pressure controller PIC-5-45. Pressure controller, depending on the set pressure and actual

pressure, produces 0.2-1.0 Kg/Cm2 pneumatic signal. This signal is transmitted to a

pneumatic actuator (Positioning device) which in turn positions the tension springs in follow

up pistons through levers. Upon decrease in extraction pressure HP follow up piston spring is

pulled up and LP follow up piston spring is released. This results in increase in HP secondary

oil pressure and decrease in LP secondary oil pressure. Upon increase in extraction pressure,

control action is reversed. These pressures are transmitted to the HP and LP control valves

through servomotor actuators respectively. These HP and LP secondary oil pressures are

generated in Hydraulic amplifier through combined action of speed governor and extraction

pressure controller.

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2.2 Electro-Hydraulic Governing System:

System consists of speed controller, frequency controller and load controller (power

controller). TG is started up and synchronized by means of speed controller and afterwards

there are two alternative modes of operation.

2.2.1 PARALLEL OPERATION:-

In this mode, TG is driven with its output regulated by the power controller. HP Extraction is

pressure controlled at the same time. A constant value control facility permits extraction

pressure control while simultaneously maintaining the constant output issued by the power

controller. In order to assist the steam generator control system, there is also an initial (inlet)

pressure limiting controller which closes the steam valves of the TG immediately after the

initial steam pressure fall below a preset minimum.

2.2.2 ISOLATED OPERATION:-

In this mode, TG-3 is driven by the frequency controller and TG-1 and TG-2 are driven by

speed controller when on EHTC governing. Steps to be taken for TG-3 and TG-1/2 when

plant comes to ISLAND mode and the steps to be taken for synchronization with grid.

3.0 EXISTING SYSTEM INSTRUMETATION, CONTROLS & LOGICS:

3.1 INSTRUMENTATION:

For instrumentation, refer operational flow sheet on governing system

Enclosed. Annexure B1. Simplified interface between existing hydraulic and EHTC system

is as per enclosed Annexure B4

3.2 CONTROLS:

The following controls are provided in EHTC.

3.2.1 SPEED CONTROL:

The actual value of speed is acquired in digital form by a solid state system measured in three

channel system based on Hall Effect principle. A toothed disc driven by the turbine shaft

causes fluctuations in magnetic flux at 3 independent hall probes. The change in flux is

converted into voltage and then converted into speed value. The pulses of the three channels

are monitored continuously. In the event of fault on any channel the control system continues

to work without interruption. The defective channel is switched out electronically and fault

alarm is initiated. The control system continues to function normally even when two of the

three pickups have failed. Failure of a channel is indicated selectively on the front panel of

the evaluation module and the display can be cancelled only when the fault has been rectified.

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After the evaluation circuitry, the frequency is converted into an analog value and fed to the

speed controller. At the same time the actual value of speed is also fed to a limiter stage

which initiates a signal to the remote tripping gear before the trip speed is exceeded. This

signal acts in parallel with the mechanical-Hydraulic over-speed trip.

The speed set point is normally adjusted from the control room by means of RAISE/LOWER

push buttons. The speed will be controlled manually according to startup curve.

In the event of an emergency trip, the speed set point is set automatically to -1% and when

the generator circuit breaker is open, to 100%.

3.2.2 POWER CONTROL:

The actual value of power is obtained with a load transducer, which produces a signal of 4 to

20mA corresponding to 0 to 30 Mwe from the instrument transformer currents and voltages.

Power set point can be set by hand or by load Imp/Exp. Controller.

The power set point can be adjusted manually with the lower/raise push button.

If the TG is to be operated with load Imp/Exp. controller the manual set point should be set

less than actual load with lower push button. The reference from load Imp/Exp. control will

take over set point control as soon as it acquires an instantaneous value greater than manual

set point. The set point is equalized with the time dependent value. The set point is then to

be controlled according to the loading curve by manual operation of LOWER/RAISE push

button.

The output of power controller is set to the output of initial pressure controller and is

prevented from coming into service as soon as initial pressure controller comes into

operation.

3.2.3 FREQUENCY CONTROL:

Auto tracking frequency is recently adjusted to a minimum limit of 49Hz below which

tracking will not be done and in the event of islanding machine tries to keep the frequency at

value just prior to islanding subjected to minimum limit of 49Hz.

The actual frequency is acquired by a frequency transducer. It converts frequency of 45 to 55

Hz into 4 to 20 mA. The frequency set point can be adjusted from control room. A

connection for an automatic synchronizing device is provided to synchronize the plant to the

grid.

In parallel operation, the frequency influence is set to zero automatically in a stepless way.

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3.2.4 INITIAL PRESSURE CONTROL:

The initial pressure controller is used as a limiter in order to restrict the turbine output, when

the min. initial steam pressure is reached and to assist the steam generator control system.

The initial pressure controller can only be switched on during parallel operation and switched

off for isolated operation. Switching off by hand is possible in isolated operation.

The output of the initial pressure controller is limited to a min. value such that at this min.

pressure, the turbine is able to supply the station service load. At present the inlet pressure

control is available only for TG – 2.

3.2.5 EXTRACTION PRESSURE CONTROL:

Extraction pressure set point can be adjusted steplessly from the control room by means of

LOWER/RAISE push buttons. Extraction controllers can be over ridden by means of

extraction pressure limiters. The pressure limiter becomes inoperative when extraction

pressure limiter is set to 0%.

3.2.6 CONSTANT VALVE CONTROL:

The constant valve control facility has the following functions:

1) To maintain the preset power constant during extraction pressure control action.

2) To maintain the extraction pressure constant during change in valve position affected

by the speed, frequency or power controllers.

The details of existing logic of EHTC system is enclosed in Annexure B3 for vendor’s

reference.

3.3 Following controls are provided by Hydraulic governing system.

3.3.1 SPEED CONTROL: Refer 2.1.2

3.3.2 EXTRACTION PRESSURE CONTROL: Refer 2.1.3

4.0 POWER SUPPLY IN THE EXISTING SYSTEM

4.1 415V Supply:

Supply is used for speeder gear and starting device. In absence of 415V supply, operation of

above is not possible.

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4.2 Control Supply:

±24V DC from existing unit board-1

220V DC for trip solenoid valve.

4.3 Loss of control supply:

1. Will not affect TG governing system.

2. Turbine will not trip as tripping relay and trip solenoid will not have supply.

3. All electrical protections will not be effective.

4. Hand tripping from MCR is also not possible.

Power supply feeders which will be made available to supplier are as follows .

a) UPS supply: 110 V Single phase, 50 Hz.

b) DC supply: - +/- 24V DC

Further distribution from these feeders to any other voltage required for the system shall be

done with help of redundant power supply units and via redundant power supply bus and the

responsibility of this will be in the scope of vendor. Diode o ring module shall also be used

along with the redundant power supplies.

a) All power supplies in the system shall be provided with 100% redundancy.

b) Information of failure and standby take over shall be annunciated on Operator station of

DCS.

c) All equipment, relays, contactors etc., used in the cubicle shall be suitable for the above

auxiliary supply. The auxiliary relays used in the governing equipment shall be of plug in type

and shall have LED indicator, flag indicator and Push button.

4.4 SERVOMOTOR:

The servomotors are hydraulic double cylinders with the double-ended piston rods,

manufactured to test cylinder standards.

There are also leakage oil extraction chambers and the piston rod is heavily chromium plated.

These design features and precision manufacture by specialist companies ensure long service,

low wear and freedom from restriction.

4.5 OPERATION AND FAULT ANNUNCIATION:

Since the turbine is driven from the control room the operators must be provided with

displays at the principal operating and fault conditions, which are, displayed selectively on the

front panels of the individual modules. The signals are output through drivers, which can

power a lamp of 1.9W at 24V.

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4.6 OPERATING MODE SIGNALS:

In the control room:

-Speed controller active: The speed controller is running the turbine.

-Over speed reference release. The signal is displayed when the enable over speed set point

switch in the module BB051 S11 is operated.

-Trip release: Indicates that the electric over speed protection has triggered an emergency

stop.

-Initial pressure controller active: The initial pressure controller is running the turbine.

-Power controller active: Power controller is active due to logic 2 satisfied.

-Initial pressure controller ON: Indicates that the initial pressure controller has been switched

on manually.

-Initial pressure controller OFF: Indicates that the initial pressure controller is switched OFF.

TSE test: Indicates that test programme is run.

Frequency controller active: Indicates that frequency controller influence is acting on the

Load controller.

-Extraction pressure controller active: Indicates that influence of extraction pressure

controller on the constant value circuitry and hence on the valves active.

-Extraction pressure limit active: Indicates that extraction pressure limitation limits the

extraction pressure controller output.

EHTC Fault: This indicates that electronic governor is faulty.

NRV-1 OPEN: This indicates that non return valve-1 is open.

NRV-1 CLOSE: This indicates that non return valve-1 is close.

NRV-2 OPEN: This indicates that non return valve-2 is open

NRV-2 CLOSE: This indicates that non return valve-2 is close.

5.0 DETAILS OF CONTROLLERS IN EXISTING SYSTEM:

1. Speed:

Nominal Speed : 3000rpm

Actual Speed : 0-3600rpm =0…7.2V

Set Point : 0-3450rpm = 0…6.9V

2. Load:

Nominal load : 30MW

Actual value : 0….35MW = 0….-10V

Set point : 0….30MW = 0….+10V

INDIACATIONS:

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Load reference : 0…35MW 4…20mA

Load reference time delayed : 0…35MW 4…20mA

Load actual : 0…35MW 4…20mA

3. Frequency:

Actual value : 45Hz……55Hz = 0…10V

Set Point : 45Hz……55Hz = 0…10V

INDICATIONS:

Actual frequency : 45Hz……55Hz = 4….20mA

Frequency reference : 45Hz……55Hz = 4….20mA

Frequency influence : 0-100% = 4….20mA

Frequency controller : -100%….0…..+100% = 4…20mA output

PRESSURE : 0…..100% = 4….20mA

4. Inlet Pressure:

Nominal value : 100 Kg/cm2

Actual value : 0….140 Kg/cm2 = 0….-10V

Set point : 0….140 Kg/cm2 = 0….-10V

INDICATION:

Actual inlet pressure : 0….140 Kg/cm2 = 4…..20mA

Inlet pressure reference : 0….140 Kg/cm2 = 4…..20mA

5. Extraction Pressure:

Nominal value : 33.5 kg/cm2

Actual value : 0….60 kg/cm2 = 0….-10V

Set point : 0….60 kg/cm2 = 0….+10V

INDICATION:

Actual extraction pressure : 0….60 kg/cm2 = 4….20mA

Extraction pressure reference : 0….60 kg/cm2 = 4….20mA

Extraction pressure limitation : 0….100% = 4…20mA

6. Admission:

Actual value :-4……0…..+4V = 0……-10V = 0….100%

7. Lube oil pressure : 0…4 kg/cm2 = 4….20mA

Trip oil pressure : 0…16 kg/cm2 = 4….20mA

Governor oil pressure : 0…16 kg/cm2 = 4….20mA

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H.P. Sec oil pressure : 0…6 kg/cm2 = 4….20mA

L.P. Sec oil pressure : 0…6 kg/cm2 = 4….20mA

Oil above piston : 0…16 kg/cm2 = 4….20mA

Oil below piston : 0…16 kg/cm2 = 4….20mA

6.0 LOGICS/PROTECTIONS:

Turbine Protections

1. Lube oil header pressure very low : 0.7 kg/cm2 (g)

2. TG over speed : 3300 rpm

3. Condenser vacuum very low : 0.7 ata (228 mmHg)

4. TG shaft vibrations high-high : 110μ

5. TG bearing metal temp. high-high : 115oC

6. Control oil pressure very low : 4.5 kg/cm2 (g)

7. Trip oil pressure very low : 2.0 kg/cm2 (g)

8. Axial displacement high-high : ± 0.8 mm

9. TG inlet steam temp. very low : 430oC

10. Controlled extraction pr. low-low : Only for annunciation

11. Controlled extraction pr. High-high : 40 kg/cm2 (g)

NOTE: Electrical and Mechanical trip settings are at the same level for Lube Oil Header

pressure low- low, condenser vacuum low- low, Axial displacement high-high,

controlled extraction pressure high-high whereas for over speed, electrical trip

setting is 3240 rpm and mechanical trip setting is 3300 rpm.

The System is having field instruments available in working condition with the present

system.

7.0 TURBINE INTERLOCKS AND PROTECTIONS in DISTRIBUTED CONTROL

SYSTEM (DCS):

Turbine related parameters and protections are implemented in the DCS system. The brief

description of the DCS system is given below

EXISTING DCS SYSTEM USED FOR TURBINE INTERLOCKS

Units 1, 2 and 3 DCS system is with latest MICROVERSE3200E DDCS supplied by M/s

MAPL, Pune. Note that one unit is described here and the other unit is exactly similar. Total

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system is based on Intelligent I/O Modules with latest processors with Ethernet connectivity.

Each Unit DDCS is divided into five systems as follows.

1) Burner Management System (BMS)

2) Novatune System (NT)

3) Master Piece System (MP)

4) TGIP (Turbine Generator Interlocks and Protections)

5) Sequence Event Recorder.

Refer the sheets in Annexure-B2 for System Architecture of all these systems.

Field I/Os are connected to IO Modules directly at first level.

Redundancy is maintained at all levels. Failure of IO Module changes over to Standby IO

Module without any interruption to process. In case of closed loop controls, triple

redundancy is achieved using Eurotherm make T640 Multi loop controller as third controller.

Controller outputs changeover between IO Module and T640 is through Relays whereas

inputs are connected in series / parallel as required. All analog I/Os are provided with MTL

make Isolators. Wherever number of controllers requires same Analog Input, Dual Output

Isolators are used. Fault diagnostics are available to user and can be used in logics also to

meet special needs. There is no direct communication link between IO Modules and T640

SLCs for data exchange. At second level, two PC based CPUs (Communication Processors)

are available under each project as Redundant which polls each IO Module in system

sequentially over 10MBPS Ethernet TCP/IP through Network Switch. Also CPU

communicates to T640 SLCs through RS485 communication interface with Modbus RTU

communication protocol. Data exchange between IO Modules and T640 SLCs is achieved

through these links for tracking of control mode and Output. Events and Alarms are recorded

with time resolution of 100mSec at CPU. All CPUs are connected to Operator Stations on

Data High way (100MBPS Ethernet TCP/IP). At third level each Operator Stations /

Engineering Station polls each CPU in unit and updates dynamic data on HMI pages at

refresh rate better than 1second. Operator Stations / Engineering Stations works on On-spec

under windows environment provides Dynamic Data Exchange capability to MS Office and

all other software packages that support DDE. It can be used to generate reports, input off-

line data, and output ONSPEC data to other user application software, etc.

Audio alarms are configured in system to alert Operator on critical alarms. User friendly On

spec Command Language programs are available for special features and supervisory

functions like disk free space monitoring in all system PCs, Object display of tags, Record of

trips occurred on various trip interlocks, PM checks reminders etc..

Sequence Event Recorder (256 DIs) is present in system to record critical parameters (digital)

with time stamping resolution of 1mSec.

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8 channels High Speed Analog Input recorder is available in system with 100mSec sample

time. Data is logged on to hard disk, so that historical trends can be generated for analysis at

any time.

Five Information Stations are provided in Office Area. These work exactly like Operator

Stations for Units with Operator commands disabled.

The controls for following equipment related to TGs are implemented in the TGIP DCS system

a) ON/OFF valves

b) All pumps and auto start interlocks (AOP1,AOP2,DCJOP,ACJOP,EOP)

c) All Fans

d) Control valves to maintain vacuum, LP extraction pressure etc

e) Turbovisory instruments such as axial displacement, vibrations and temperature indications

f) Turbine interlocks and protections to trip the turbine in case of abnormality in the machine

and process parameters

g) Turbine trip First out feature

The System is having field instruments available in working condition with the present system. The

requirement of the specific field instruments if any to be assessed by the bidder and to be provided

accordingly as the job is retrofit in nature.

Section – B (General Requirements)

1.0 Scope Of Vendor

The vendor shall be responsible for providing all materials, equipment accessories and

services, to meet the requirements of functional completeness of the EHTC system as per the

technical specs. Vendor has to carry out the entire scope of work covered under this

specification within the quoted price and without any further commercial implication to the

purchaser.

In the event of any conflict between the requirement of any two clauses or documents forming

a part of this specification the more stringent requirements shall apply unless otherwise

confirmed by the purchaser in writing. The decision of the purchaser will be final and binding

in all such cases. The bidders are informed to visit the site for assessment of the total job and

understanding of the system for bidding.

The major scope of work is given below. The scope of the vendor shall include, but not be

limited to the following:

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a. Design, Engineering, manufacture, software development and supply of

microprocessor based electronic governing system comprising of governor panel, I-H

converter, hydraulic skid, speed pickup probes and all other accessories required for

the operation of this unit in parallel with other TG sets in the plant and in parallel with

hydraulic governor.

b. Inspection, testing (FAT), packing, forwarding, transport to site, loading and

unloading at site, inspection at site (SAT) of the complete microprocessor based

electronic governing system along with all the accessories.

c. Modification of existing mechanical hydraulic governor including the hydraulic

system piping, existing control circuit, existing hydraulic linkages like servomotors,

I/H Convertors, modification for inserting speed pick up probes and addition of

necessary components for installation and working of the Electric to Hydraulic

converter unit.

d. In case of the failure of digital governor, it should be preferably possible to

changeover the TG operation to hydraulic governor system online without

interruption .The modus of changeover shall be mentioned by the bidder.

e. The existing hydraulic governor will be in service with suitable modifications till the

digital governor performance is established. After the performance of the governor is

established, the existing hydraulic system shall be kept as standby to the original

governor.

f. Owner will provide only the space for installation and the Power supply location. The

field wiring connections provisions are to be made by the vendors in the proposed

cubicles along with existing field wiring. The required additional cables ( as brought

out ion BOM), if any, are to be supplied and laid by the supplier.

g. Supply of and laying Interconnecting cables, power cables, earthing strips.

h. The existing earthing system available at HWP (M) shall be utilized; however,

interconnection of earthing system and required accessories shall be in vendor’s

scope.

i. Removal of the existing units, installation of the new units and required arrangements

for shifting the units to the stores.

j. Deputation of required manpower (Technicians/Helpers) for erection and

commissioning of system at site. Tentatively 5 – 6 personnel (Technicians/Helpers)

shall be required for installation & commissioning during shutdown. However if more

manpower is required, the same shall be supplied without any extra cost to HWB.

k. The bidder shall also be responsible till the unit synchronization and loading to full

load, after testing at different loads and operating conditions.

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l. The scope of supply should mainly consist of the above but not limited to the above.

It should be understood that the job is of retrofit in nature; hence the vendor should

take care of all the requirements from field to control room, so that the existing EHTC

is totally replaced with the new system. It should have all the technical inputs and

modes of operation in existing system.

m. After the successful installation & commissioning of the system, the supplier should

station their technical representative for a period of 10 days to give the confidence to

O&M staff of HWP (M) and monitoring the system performance at their cost.

n. The governor & related equipment shall conform in all respects to high standards of

engineering, design, workmanship and latest revisions of relevant standards and shall

be capable of performing in continuous commercial operation up to the supplier's

guarantee in a manner acceptable to the purchaser, who will interpret the meanings of

drawings and specification and shall have the power to reject any work or material

which, in his judgment, is not in accordance there with.

o. The equipment offered shall be complete with all components necessary for their

effective and trouble free Operation.

p. For all the supplies made by bidders, Erection & Commissioning shall be in

supplier’s scope.

q. Performance testing, providing of operation and maintenance manuals, documents

and training of client’s personals

r. Any other points not spelt out required for the system completion is in the scope of

the supplier.

s. System shall be guaranteed for 2 years after the successful commissioning.

t. FACTORY ACCEPTANCE TEST (FAT) of the complete microprocessor based

electronic governing system along with all the accessories, SITE ACCEPTANCE

TEST (SAT) of the complete microprocessor based electronic governing system

along with all the accessories.

u. SOR/BOM (Ann- A3) gives to the extent possible the quantity and type of

component & the required model. However whatever functionalities mentioned in the

technical specifications have to be achieved and for this any additional component

required or job to be done, the supplier shall carry out the same without any cost

implication to HWB. The BOM to be supplied shall consist of, but not limited to,

these items.

v. The cross – ferruling & referencing at the existing Junctions Boxes used for

the supplied system shall have to be corrected by the supplier as per the new

system.

19

w. General guidelines to be followed for new system:

• Preferably all the existing I/Os in the running plant logic to be considered for

engineering and spare I/O’s also to be considered for future.

• The required additional cables if any in addition to the existing cables are to

be arranged by vendor as per the requirement(Ann _ A1 & A2).

• The functioning of the existing EHTC system to be taken care in the new

system, as it is of retrofit in nature.

• Three Speed sensors probes (as in the existing system) with preferably in

median selection configuration in the governor controller and 2oo3 (2 out of

3) logic for over speed protection to be provided. In case only 2 speed probes

are used as inputs to governor controller, supplier to provide a separate over

speed protection system which will use three probes for protection in 2oo3

logic mode. In the three probes used for over speed protection, two probes

already used for control in governor can also be used.

• The bidders are informed to visit the site for assessment of the total job and

understanding of the system for bidding.

• The control will be on digital electronic governor. In case of problem with the

unit it should be preferably possible to changeover to hydraulic systems

without interruption and preferably revert back to EHTC after its

rectification online without any interruption .

• The I/Os should be galvanically isolated preferably opto-isolation, so that any

fault is limited to the particular Input channel only. The job is basically

retrofit in nature, and the suppliers can visit the site before quoting, for

understanding the nature and volume of jobs clearly and the study of the total

system aspects and quote accordingly. It is prudent for the vendors to visit the

site for understanding the system before bidding.

• The existing servomotors are planned to be used with the new system. The

supplier has to take note of the same. In case of any deviations the same are

to be specified in the bids. The response time of the system is to be in the

order of milliseconds to suit the existing TG control system.

• The existing field instruments (except those mentioned in BOM Ann-A3)

can be used in the new system as they are in working condition.( Any specific

instruments required for the system operation to be quoted by the supplier in

their bid.

• It should be possible to incorporate the control features of frequency and

Import/Export control in the system for plant requirements

20

• The existing power supply available at site are mentioned in specifications.

Further distribution from these feeders to any other voltage required for the

system shall be done with help of redundant power supply units and via

redundant power supply bus and the responsibility of this will be in the scope

of vendor. Diode o ring module shall also be used along with the redundant

power supplies.

• The complete work inclusive of installation & commissioning work to be

carried out by the supplier. The charges for the same are to be quoted

separately.( Refer BOM)

• The technical specifications are given to the possible extent, the gaps if any to

be taken care by the supplier during their visit to site and any additional

requirements to meet the working of the system is in the scope of the

supplier.

2.0 Factory Acceptance Test (FAT)

HWP (M)/HWB will conduct factory acceptance test FAT at vendors’ works. Proposed QAP

to be followed is given in the SECTION – E. The purpose of checking is to determine and

ensure that the system is built and configured to the user’s specification and satisfaction.

FAT will be conducted with all the components or subsystems or units connected together

and loading of all application software packages required fulfilling the user’s functional

requirement indicated & implied in the technical specification.

The FAT procedures given in Section-E are the minimum to be carried out. After the award

of work, Supplier shall submit the final FAT procedure based on this document and that shall

be binding upon both Purchaser and Vendor. Vendors shall offer the system for FAT only

after the system is completely internally tested by them and report submitted to meet total

functional requirement. The vendor shall submit the test results and all the relevant

documents one week in advance before the customer is called for tests.

The dispatch clearance shall be given only after all the discrepancies/ anomalies have been

resolved at vendor’s works. Three (3) sets of certified test reports shall be submitted for

approval prior to dispatch of the equipment. The equipment shall be dispatched only when all

the required tests have been carried out and test reports have been approved by the purchaser.

3.0 Training

The training shall cover complete education of various aspects required for the successful

operation and maintenance of the system. The details of HWP (M) personnel to be trained in

an integrated manner on the system are given as below:

21

3.1 At Plant Site before installation & commissioning:

a. 12 instrument Engineers/ Supervisors in 2 batches (6 in each batch). Duration of

training shall not be less than 4 days, covering the total system being supplied in

integrated manner.

b. 5 operation engineers/Supervisors in 1 batch. Duration of training shall not be less

than 3 days, covering the total system operation.

c. 3 Mechanical/Electrical Engineers/Supervisors in 1 batch. Duration of training shall

not be less than 2 days.

d. Training Manual with all the technical details, shall be supplied in both soft form and

hard copies for all trainees and shall be comprehensive. Maintenance and

Troubleshooting also shall be covered elaborately in the same.

3.2 On the job training to be imparted at site during the installation and commissioning for the

plant personnel both operation and maintenance.

4.0 Removal Of The Existing System:

The supplier shall remove the existing system during the shutdown of the plant. And this

activity will be an integral part of the installation scope of the vendor.

5.0 Site Acceptance Test (SAT)

After material reach at site, Installation, commissioning of the system, rolling, loading of

turbines by new governor at different loads and testing various methods of operation shall be

carried out. Before final commissioning of the governing system, all installation checks shall

be carried as approved in the inspection and testing document. Commissioning checks shall

be carried out as approved in the procedure after award of contract.

The SAT procedures given in Section-E are the minimum to be carried out. After the award

of work, Supplier shall submit the final SAT procedure based on this document and that shall

be binding upon both Purchaser and Vendor. . Any other things missed out required for the

system satisfactory performance will be added in situ. This has to be taken as a note by the

bidders.

6.0 Erection & Commissioning

6.1 The erection, installation and commissioning is in the suppliers scope. All the works

from dismantling of the existing system, replacing with new system along with pipes,

local panel and other accessories is in the supplier’s scope.

6.2 The installation and commissioning activities in control room for the different equipment

is in supplier scope.

22

6.3 The supplier also is responsible for transportation of removed materials and handing

over to stores and clearance of site for regular operation and maintenance.

6.4 The performance monitoring will be done as indicated in Section C 5.0.

6.5 The required manpower and arrangements for the above are to be made by the supplier.

6.6 The bidder shall carry out required housekeeping in the areas of their work.

6.7 The jobs not spelt out but required for the completion of installation and commissioning

is deemed to be in the scope of supplier.

6.8 The bidder shall quote for the total job on item wise of different components. The taxes,

duties, charges etc. if any, are to be indicated separately for the job.

7.0 Service Support

7.1 Vendors’ technical representative should be available at HWPM site for a period of 10

days after completion of acceptance and commissioning of the total system for guidance

to the operation and maintenance staff and performance monitoring.

7.2 Vendor shall guarantee the freedom from obsolescence for the supplied system for at

least 10 years after final acceptance of the system, and give the necessary support for

spares and services. The necessary letter from the OEM shall be furnished by the

supplier, regarding technical support & spares acceptance up to minimum period of

10years after the acceptance of the system.

8.0 Post supply inspection by any outside agency in respect of supplies made is not permitted.

Any offer containing the condition of post supply inspection will be out-rightly rejected. It is

therefore, mandatory for the bidders, while quoting, to indicate in clear terms the requirement

of post supply inspection by any outside agency

9.0 Maintenance

The system shall provide suitable diagnostic procedure for troubleshooting for all system

components and equipment. Any card failure/abnormality shall be reported by the system

explicitly. The vendor shall provide maintenance tools such as the following:-

8.1 Any tools/instruments required for diagnostics.

8.2 Adequate maintenance/service manuals, including block diagrams, troubleshooting

procedures, test point/signature for every module, back of panel/motherboard etc.

10.0 Guarantee

The control system shall be capable of regulating the control devices to achieve the

performance guarantee specified on stand-alone basis as per the international codes and

23

practices, applicable national standards/OEM Standards for all conditions of operation and

performance of the of the system envisaged in the technical specification.

a. The Vendor shall guarantee the performance of the control system in total against any

defects of design, engineering etc., for a period of 24 months from date of issue of

total completion certificate after commissioning.

b. Any damage or defects of items connected with this tendered system hardware

/software during this period shall be replaced / rectified free of cost. Any damage or

defects of items that may be undiscovered at the time of issue of completion

certificates or may arise or come to light, thereafter shall be rectified or replaced by

the vendor at his own expense as deemed necessary and as per instructions of

purchaser within time limit of 48 hrs.

c. During guarantee period, the vendor shall make available whenever necessary, the

services of specialist engineers at HWPM site within 48 hrs from the time of

communication, telephone or otherwise.

d. Any changes, revisions, de-bugging patches, etc. to the system and application

software shall be provided to HWPM on a continuous basis as and when they are

released/ developed by the vendors or the principal manufacturer and same shall be

given free of cost during guarantee period. Similarly the updates to documentation

shall be provided

e. During the guarantee periods, critical spares shall be kept at HWPM site by the

supplier. The guarantee shall also include the following:

• Planned preventive calls: 2 per year.

• Preventive maintenance: Minimum 2 days per six months in the year.

• Shutdown maintenance: 4days per 2 years.( can be clubbed with one of the

preventive maintenance visits )

• Emergency call: Unlimited.

11.0 Earthing Requirement

The existing earthing system available at HWP (M) shall be utilized; however,

interconnection of earthing system and required accessories shall be in vendor’s scope.

12.0 BROAD SCOPE OF SUPPLY:

The system shall be broadly consisting of the following items:

11.1 Digital configurable Governor with control cabinet, power supply units.

24

11.2 Speed probes with required lengths of cables and connectors with over speed

protection as described above in point no. ‘w’ of clause 1.0 of Section – B.

11.3 Electric to Hydraulic converters with required piping and required modifications for

installation.

11.4 Field instruments for the governor system as per specific requirement( Refer BOM).

11.5 Solenoid Valves not required. Existing Trip Solenoid Valve is to be used in new

system as it is in good working condition.

11.6 Proximity type Limit switches for open & closed indication of ESV( emergency stop

valve) to be provided.

11.7 Required cables in addition to existing cables & accessories, junction boxes etc.( refer

BOM)

11.8 Required Isolators for interface of signals to EHTC and DCS( Refer Ann-A2)

11.9 Required modifications, while mounting the cabinets in control room and field

instruments.

11.10 Nil

11.11 Skid Assembly

11.12 Duplex filters with spare filter elements

11.13 Isolation Valves required

11.14 Arrangement for communication with existing DCS is preferable

11.15 Spares as mentioned in the attached BOM (Annexure A3).

Note:-Detailed bill of materials has to be furnished in the bid and any other items required for

system completion is in the suppliers scope.

The scope of supply should mainly consist of the above but not limited to the above. It

should be understood that the job is of retrofit in nature; hence the vendor should take care of

all the requirements from field to control room, so that the existing EHTC is totally replaced

with the new system. It should have all the technical inputs and modes of operation in

existing system.

13.0 General Outlay

Vendor shall furnish the proposed layout for the system offered along with the bid. Vendor

can visit the HWPM site & see the existing layout of the control room and the existing

cabinets, space available etc., before designing the system layout.

14.0 Vendor Qualification Criteria:

13.1 The bidder should have done one similar kind of work of one controlled and one

uncontrolled extraction in Turbine. Similar work means the work carrying out the

25

retrofitting like work of replacing the existing governing control system with offered

electronic governor in last 7 years.

13.2 The bidders must enclose completion certificate from client as evidence which shall

be certified by an officer not below the rank of project manager/section head or

equivalent.

13.3 Address and contact no. of organization where the work has been carried out may be

submitted along with the required details like PO etc.

13.4 The GOVERNOR system offered should be working satisfactorily for the last 7

years at minimum 3 locations in India. The details of these installations, supplied

systems along with satisfactory performance certificates to be submitted along with

the offer.

13.5 The vendors shall produce customer reports and shall arrange for site visits to

ascertain the satisfactory working of the system offered by them.

13.6 Vendor shall guarantee the freedom from obsolescence for the supplied system for at

least 10 years after the final acceptance of the system, and give the necessary support

for the spares and services. The necessary letter from the OEM to be furnished by the

bidder in case the vendor is not OEM for the above.

15.0 Site Conditions

The equipment offered and the installation shall be suitable for continuous operation under

the following site conditions:

Ambient Temperature : 50 oC (Max), 90 oC (Min)

Max relative Humidity : 90 % condensing

Elevation above mean Sea level : 60 meters (Approximately)

16.0 Documents

Documents to Be Submitted By the Bidder:

16.1 Acceptance Of Technical Specifications:

Bidder has to submit signed copy of technical specifications along with the Bid as a

mark of Acceptance of the Terms & conditions, Scope of work, Technical

Specification etc.

16.2 Deviation From Tender Specifications:

In case of any deviation from the Technical specifications or conflict between any

clause of this specification or any clause in the offer submitted by the bidder, same

shall be specifically brought out by the bidder as deviations in their offer by grouping

all such details in a separate “Deviation Sheet”. The deviation should clearly indicate:

1.1.1 Section no

26

1.1.2 Clause no

1.1.3 Deviation against this clause.

16.3 Documents To Be Submitted Along With Bid:

Refer table C – 1.

16.4 Documents To Be Submitted & After The Placement Of PO:

Refer table C – 2.

27

Table C – 1: Vendor Qualification Criteria Related Documents to Be Submitted Along With Bid

Sr.

No

Clause

no

Description With

bid(No.

of sets,

Hard

copies)

1 Documentary evidence of the retrofitting job ( EHTC based) done by supplier on

one controlled and one uncontrolled extraction in Turbine in last seven years

2

2 Documentary evidence for average annual turnover for the immediate last 3

consecutive financial years

2

3 Average annual turnover, profit and loss statements certified by chartered

accountants for last 5 years shall be submitted. Annual reports can be submitted in

addition to these.

2

4 Completion certificates from client as evidence for the jobs carried out so far for

the EHTC system

2

5 Address & contact nos. of the organizations where the offered EHTC system is

installed

2

6 Technical support and spares for minimum 10-15 years after the date of

obsolescence of the EHTC system. Letter in this regard from the OEM linking to

the present case of purchase shall be submitted along with the technical bid

2

7

Table C – 1.1: Technical Documents to Be Submitted Along With Bid

Sr.

No

Description With

bid(No. of

sets , Hard

copies)

1. Our detailed Tender specifications duly signed & stamped by the bidder. 2

2 Deviation list to the Tender specifications 2

2 Detailed Architecture offered for the Electronic Governor and associated devices 2

3 Functional diagram along with write-up of the complete governing system. 2

3a Block diagram of hookup of new system with the existing EHTC and hydraulic

28

system

4 Hard ware details: Details of make & model no & technical catalogue of each type of

component offered as per Architecture.

2

5 Quantity against each type of modules offered as per the architecture should be

shown in BOM

2

6 Brief write up on cards/modules and devices used in Governing System supported by

catalogues if any.

2

7 Governor Scheme 2

8 Details of Control, Protection and Instrumentation for the Governor offered also put

in copied after PO .

2

10.j Details of the Panel which will be supplied along with the system. 2

10.n Make, Model, Brochure of the Galvanic Isolators/barriers used. The quantity of each

type of Isolators offered should be specified.

2

10.o Total power requirement for system (with break-up for each part of the system.

The supplier must indicate the following in the offer :

Total electrical load.

Power supplies shall be used.

Frequency variation permissible. However, the vendor’s system either

should be capable of operating in 50 Hz ± 4% Hz frequency variations or if

required, separate frequency regulator shall be provided by the vendor.

2

12 Vendor should submit the detailed time schedule of the Activities starting from

placement of Order showing the schedules for

• Detailing of the system

• Submission of Documents for approval

• Application Development

• FAT

• Delivery

• SAT

• Installation & commissioning.

2

13 Vendor shall submit the BOM/SOR (Annexure-A3) format dully filled with

quantities only for the system offered by them. The rates should not be filled in the

technical offer (unpriced commercial offer).

2

14 All the relevant documents asked in the tender and which are not brought out above 2

15 Interface and protocol details of required communication ports (RS 485) as asked at

section C Sr no 10.0 e to be submitted along with offer.

29

Table C – 2: List of documents required after the Placement of PO

Sr.

No

Description Copies

required

within one

month of

PO(Hard

copies)

Copies

required within

2 months(Hard

copies)

Final Copies

required within

4 months(Hard

copies)

Copies

Required of

Certified final

drawings after

commissioning

(3 hard copies

&3 nos. of CDs)

1 Detailed

configuration &

Architecture offered

for the Electronic

Governing System

2

2 Data sheets of all the

Hardware & Software

items for Approval of

Purchaser

2

3 Technical Catalogues,

specifications s &

data sheets of each

component shown in

Architecture for

approval

2

4 Bill of Material for

approval

2

Details of Control,

Protection and

Instrumentation for

the Governor offered

also put in copied

after PO (within one

month).

2

6 Power consumption 2

30

and heat load for

system

7 Detailed time

schedule of activities

starting from

Placement of PO till

commissioning

2

8 System Configuration

Manuals

2 2 4

9 Layout drawings of

the electronic

governor, panels

cabinets, OS, Servers

2 2

10 GA (Internal &

External) drawings of

the Electronic

Governor Panel.

2 2 4

11 Dimensional

drawings & test

certificates for the

electronic governor

panel.

2 4

13 Detailed Quality

Assurance Plan for

the system

2

14 I/O list Database &

Assignments

2 2 4

15 Tag database for

Electronic Governor,

2 2 4

16 Cable schedule &

Signal Wiring

diagrams of all the

panels showing

terminations details of

field cables to the TB

in panel to isolators to

2 2 4

31

Electronic Governor.

19 Power supply wiring

diagram for the

electric governor

system Panel.

2 2 4

20 System grounding

Diagrams.

2 2 4

23 Control program for

each loop.

2 2 4

24 Description of the

function of each

program.

2 2 4

25 Software Schemes for

Control /Interlock

Logic.

2 2 4

27 Final Loop diagrams

showing all terminal

details.

2 4

28 Interconnection Cable

Schedule

2 2 4

29 Operation,

Maintenance and

service manual for the

system, sub-system

and individual units

/modules.

2 4

30 Manuals for bought

out items

4

31 List of software’s and

their Detailed

Manuals

2 4

33 Concise ready

reference manuals

shall be provided for

2 4

32

operations,

maintenance of

software

34 Test certificates of the

system Hardware,

intrinsic safe

certificates for

barriers

2 4

35 FAT Procedure 2

36 Final graphic display

(HMI) drawings.

4

37 Test reports on the

test conducted during

FAT

4

38 Test reports on the

test conducted during

SAT

4

39 Final report on FAT,

SAT &

Commissioning

4

33

SECTION-C(FUNCTIONAL REQUIREMENTS)

1.0 INTRODUCTION:

a) The 30 MW single controlled 32 ATA steam extraction and 8ATA steam extraction

uncontrolled (externally controlled) extraction TG set is provided with mechanical hydraulic

governing system model SR IV and also having Electro Hydraulic Turbine controller parallel

to the Hydraulic Governor. It is proposed to replace the existing governing system with

electronic governor. To meet the requirement it is intended to procure one number electronic

governor with I-H converter, pickup probes and other accessories. The functioning of the

existing EHTC system to be taken care in the new system.

b) Existing EHTC & Hydraulic control system block available at site is given in brief as per

Annexure-B4. The main changes in scope of supplier are also shown in the drawing. In the

present system in case of failure of EHTC the hydraulic governing system (SR-IV) comes in

line and avoids the tripping of turbine. The supplier to preferably maintain the same

philosophy of operation.. The detail of the new system has to be brought out clearly in the

offer with proper block diagram and description.

c) The governor will be installed on the control desk directly. Operator will use governor panel

as operator control panel. The new governor panel will be installed at the existing location of

governor panel. Annexure-A1 shows the complete interface between the new governor, new

governor panel and the existing DCS with a distance between them and the existing or the

new cables to be used for the signals.

d) The list of IOs to be hooked up to EHTC is as per TABLE X Annexure-A2. Apart from this

the list of existing inputs which are to be hard wired to governor and existing DCS system is

also given as per TABLE Y, Z of Annexure-A2. This also has to be done by supplier.

2.0 BRIEF FUNCTIONAL SPECIFICATIONS OF THE NEW GOVERNER SYSTEM

a) Governor should be configurable as per the requirements

b) Speed measurement channel should be more reliable. Healthiness of speed measurement

sensor should be indicated with proper diagnostics.

c) The Speed PID controller shall have two sets of dynamics: off-line and on-line, as system has

variable response times, due to changing system conditions, these dynamic variables shall

allow the Speed PID to be tuned for optimal response.

d) Sensitivity of the inputs in such a way that it should maintain the required parameters as per

the operator requirement.

e) Online PID tuning of the controller for smooth operation.

34

f) It should meet the all turbine dynamics.

g) Extraction map can be fed to the governor as per the turbine design.

h) Shutdown relay must be in energized condition during normal running operation.

i) Galvanic/optical Isolation should be provided for all the inputs.

j) Valve stroking feature should be available to check the valve functioning.

k) HP and LP valve limiting function can be adjustable by operator.

l) Proximity type Limit switches for open & closed indication of ESV to be provided.

m) Over speed test functionality, as described in point no. ‘w’ of clause 1.0 of Section – B,

should be there to check the electrical and mechanical over speed settings.

n) Governor should incorporate following controls as existing in the existing system

• Speed control

• Load control(kW)

• Extraction pressure control

• Frequency control

• Inlet Steam Pressure Control

Detailed I/O requirement given in the section below

o) Preferably all the existing I/Os in the running plant logic to be considered for engineering and

spare I/O’s also to be considered for future.

p) The control will be on digital electronic governor. In case of problem with the unit it should

be preferably possible to changeover to hydraulic systems online without any interruption.

q) The I/Os should be galvanically isolated preferably opto-isolation, so that any fault is limited

to the particular Input channel only.

r) The job is basically retrofit in nature, and the suppliers can visit the site before quoting, for

understanding the nature and volume of jobs clearly and the study of the total system aspects

and quote accordingly. It is prudent for the vendors to visit the site for understanding the

system before bidding.

s) It should be possible to incorporate the control features of frequency and Import/Export

control in the system for plant requirements.

t) The technical specifications are given to the possible extent, the gaps if any to be taken care

by the supplier during their visit to site and any additional requirements to meet the working

of the system is in the scope.

u) It is not the intent to specify completely herein all details of the design of system However,

the system shall conform in all respects to standards of engineering, design and workmanship

and shall be capable of performing in continuous commercial operation.

35

3.0 Existing Power Supply:

The power supplies to be made suitable for existing power supplies. The required modifications to

suit for the existing power supply are in the scope of bidder.

a) DC supply: + 24V DC

b) DC Supply: 220V DC

UPS supply: 110 V Single phase, 50 Hz is available at Distribution Panel. If this is required

necessary cabling shall be done by vendor to the EHTC Panel. Separate redundant feeders shall be

made available at site for 110 V AC UPS and 24 V DC supply.

Further distribution from these feeders to any other voltage required for the system shall be done

with help of redundant power supply units and via redundant power supply bus and the responsibility

of this will be in the scope of vendor. Diode oring module shall also be used along with the

redundant power supplies.

Governor shall be powered with DC Power supply +24V DC. Power supply variation between

18V DC to 32V DC shall be allowable.

d) All power supplies in the system shall be provided with 100% redundancy.

e) Information of failure and standby take over shall be annunciated on Operator station of DCS.

All equipment, relays, contactors, Push button etc., used in the cubicle shall be suitable for the above

auxiliary supply. The auxiliary relays used in the governing equipment shall be of plug in type and

shall have LED indicator.

4.0 Location of Governor Panel:

It is proposed to locate the microprocessor based governor panel in the existing power plant control

room. The existing room is air conditioned. Any inter panel wiring/cabling is also in the scope of

supplier.

5.0 Skid & PIPING:

All pipes, Pipe specials like collars, bends, unions, and flanges etc., required for modification works

shall be supplied. Quantity shall also include wastage/re-work which is often inevitable during

erection. Necessary Oil filters with sufficient spare filter elements, adapter plates for fixing I/H

Converters, Isolation Valves and Gauges etc., shall be supplied.

All piping connections whether existing or new shall be provided with new gaskets and fitted.

Rectification of oil leaks in the complete oil system wherever necessary shall also be carried out.

Pressure testing shall be carried out for all pipes and welds before putting it to use.

The piping system shall be designed so that the hydraulic system can be brought into line, with the

electronic system isolated. The modus of changeover shall be mentioned by the bidder

36

6.0 Technical Feature:

The Electronic Governor offered shall be provided with all modern improvements, developments and

microprocessor technology and it should meet the requirements of turbine dynamics. The governor

circuit shall be of micro controller based, integrated circuits mounted on printed circuit boards. They

shall be designed to be substantially immune to noise, transients and stray magnetic fields as per IEC.

All the electronic components shall be solid state, amply derated to provide long life.

Electronic governor shall be of modular design, facilitating easy and quick fault detection and

rectification. Servicing of the governor shall be simple and easy to carry out.

The speed governing shall be performed by combination of the proportional, integral and derivative

actions and by suitable non-linear characteristics. This combination shall achieve excellent quality of

control.

The electronic governor shall comprise of the following.

i) Micro Processor unit.

ii) Electric to Hydraulic converter.

iii) Speed pickup unit.

6.1.1 SPEED CONTROL:

The actual value of speed is acquired in digital form Magnetic Pickup probes. Speed pickups

shall be mounted on the turbine to sense the speed from a gear mounted on the turbine shaft.

The pickup shall be mounted as close as possible to reduce speed errors caused by shaft

vibration and run out. Suitable mounting arrangement shall be made for Speed Pickup probes

in the pedestal. This is completely in the scope of supplier.

Three Speed sensors probes (as in the existing system) with preferably in median

selection configuration in the governor controller and 2oo3 (2 out of 3) logic for over

speed protection to be provided. In case only 2 speed probes are used as inputs to

governor controller, supplier to provide a separate over speed protection system which

will use three probes for protection in 2oo3 logic mode. In the three probes used for over

speed protection, two probes already used for control in governor can also be used.

Further, in case of two probes, in case of fault in any of probe, it should be preferably

possible to replace with spare without disturbing the governor control. Further, Failure

of any probe should generate an indication to operator.

Speed signals are fed to Speed Controller (PID). In the event of fault on any channel the

control system continues to work without interruption. The defective channel is switched out

electronically and fault alarm is initiated. At the same time the actual value of speed is also

compared to a limiter which initiates a signal to the remote tripping gear before the trip speed

is exceeded. This signal acts in parallel with the mechanical-Hydraulic over speed trip.

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The speed set point is adjusted from EHTC Control Panel or it can be remote set-point from

DCS. The maximum rate at which the remote input signal can change the speed set-point is

programmable. When the remote set-point is enabled, the speed set-point will move at a much

slower rate until the two settings are matched, at which time the speed set-point will be

allowed to move at the maximum rate. The remote speed function can be enabled and

disabled as required from the front-panel keypad, remote contact inputs or the communication

line.

In case of Speed exceeding the over speed setting, governor shall generate trip command to

trip the Turbine.

It is desirable to avoid certain speeds or speed ranges (or pass through them as quickly as

possible) due to excessive turbine vibration or other factors. Two critical speed avoidance

bands shall be provided. Either the Idle/Rated or the Auto Start Sequence functions must be

programmed to perform critical speed avoidance. Within a critical speed range, the speed set

point at the critical speed rate shall be programmed and does not allow the speed set point to

stop within the critical speed avoidance band. If the turbine is accelerating through a critical

avoidance band and excessively high vibrations are experienced, selecting the speed set point

lower command shall bring the unit back to the lower limit of the band.

In the event of an emergency trip, the speed set point is set automatically to -1% and when the

generator circuit breaker is open, to 100%.

6.1.2 POWER CONTROL:

The actual value of power is obtained with a load transducer, which produces a signal of 4 to

20mA corresponding to 0 to 35 MWe from the instrument transformer currents and voltages.

Power set point can be set by hand at EHTC Panel (Internal load reference) or by load

Imp/Exp. Controller (External load reference) depending on selection on control plaque.

When import export controller selection is switched on, the selection shall be max out of

internal set point and external set point (through hardware max signal selector or through

software max signal selector) and the set point changeover shall be with ramp rate

configurable. In case of selection is in External load reference and the external load reference

fails, the system shall take over to internal reference to avoid major disturbance to plant

operation (Internal load reference shall track the external signal when selected for Imp/exp

control) and import export control selection shall be switched off automatically

The operator shall be able to set internal load reference from EHTC Panel.

If the TG is to be operated with load Imp/Exp. controller the Internal load reference should be

set less than actual load. The reference from load Imp/Exp. control will take over set point

control as soon as it acquires an instantaneous value greater than Internal load reference when

selected for external load reference.

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The output of power controller is set to the output of initial pressure controller and is

prevented from coming into service when initial pressure controller comes into operation due

to decrease in initial pressure below set point.

6.1.3 FREQUENCY CONTROL:

Auto tracking frequency shall be provided up to a minimum limit of 49Hz below which

tracking will not be done and will be limited to 49Hz. In the event of islanding machine tries

to keep the frequency tracked to frequency just before islanding with lower limit of 49Hz.

The actual frequency is acquired by a frequency transducer. It converts frequency of 45 to 55

Hz into 4 to 20 mA. The frequency set point can be adjusted from control room.

In parallel operation, the frequency influence is set to zero automatically in a stepless way.

6.1.4 INITIAL PRESSURE CONTROL:

The initial pressure controller shall be used as a limiter in order to restrict the turbine output,

when the min. initial steam pressure is reached and to assist the steam generator control

system. The initial pressure controller can only be switched on during parallel operation and

switched off for isolated operation. Switching off by hand shall be possible in isolated

operation.

The output of the initial pressure controller is limited to a min. value such that at this min.

pressure, the turbine is able to supply the station service load

6.1.5 EXTRACTION PRESSURE CONTROL:

Extraction pressure set point can be adjusted steplessly by means of LOWER/RAISE push

buttons in EHTC Panel. Extraction controllers can be over ridden by means of extraction

pressure controller output limiters. The Extraction pressure controller becomes inoperative

when extraction pressure controller output limiter is set to 0%.

Extraction Pressure controller shall become active only when load exceeds preset value

(12MW) settable by operator. However once Extraction pressure control becomes active, it

shall not disable when load falls below the above preset value.

6.1.6 CONSTANT VALVE CONTROL/ RATIO CONFIGURATOR:

The constant valve control facility has the following functions:

1) To maintain the preset power constant during extraction pressure control action.

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2) To maintain the extraction pressure constant during change in valve position affected

by the speed, frequency or power controllers.

HP and LP Valve Limiters The HP and LP valve limiters shall be configurable to limit the HP and LP valves to aid in

starting and shutting down the turbine. The limiters are adjusted through the keypad, external

contact closures, or Modbus commands from DCS. When raise or lower commands are

received the limiters move up or down, respectively, at the programmed rate. The output of

the HP valve limiter is low-signal selected with the output of the ratio/ limiter. The lowest

signal will control the HP valve position, thus the HP valve limiter limits the maximum HP

valve position. The output of the LP valve limiter is high-signal selected with the output of the

ratio/ limiter.

LP secondary oil pressure signal to existing Load limiting device shall be retained as it is.

Trip oil signal to HP and LP drain speeders shall be retained as it is.

6.2 Architecture:

The architecture includes the Governor in the control room in addition to the field

equipment.

The Captive Power Plant is being operated through Microverse DCS. Electronic governor offered shall preferably have facility to interface with MAPL It is proposed to hook up all the required parameters of Turbine generator from/to DCS through Modbus RTU protocol over RS485 bus. The system architecture and protocol details of the governor shall be furnished to the client during engineering, to enable them to interface with the DCS system. The controller offered shall be of preferably of open Architecture and easily up gradable. The controller shall be supplied with software for interface and included in their offer. The necessary license for the software shall be provided by the supplier.

6.3 Earthing Terminals:

Earthing terminals to be provided within the panels and existing earthing cables to be

terminated.

7.0 SPARE PARTS AND MAINTENANCE EQUIPMENT:

7.1 The Tenderer shall quote separately for all the mandatory spares mentioned as per the Bill of

Material attached in Annexure A3.

7.2 The manufacturer and type of spares offered shall be same as those offered along with the main

equipment.

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8.0 PERFORMANCE REQUIREMENTS:

8.1 STABILITY:

i) The governor system shall be capable of controlling in a stable manner, the speed of the

turbine at all power outputs under various extraction conditions, between zero and maximum

power output when the generating unit is operating isolated, or in parallel with other

generators. The response of the control system should be in the order of few miilisec, for the

application.

ii) Under sustained conditions, the steady governing load band shall be as per the standards

stipulated for turbine operation.

iii) Under sustained conditions, the steady state governing speed band under speed, no load or

loaded condition shall be stated in the Bid.

iv) Following rejection of load to zero from any load within the capability of the governed

unit, speed shall be returned to the set point.

8.2 SPEED DROOP/ REGULATION:

The permanent speed droop/ regulation shall be capable of adjustment to values between ‘0’ percent

and ‘10’ percent. The speed versus generator output curve shall be substantially linear over the full

range of generator output.

8.3 OVER SPEED:

Over speed during full load loss shall be limited to 8% of the rated speed.

8.4 RANGE OF SPEED CHANGER ADJUSTMENT:

Adjustable steady state speed regulation shall be provided between +3% to +8% of rated speed.

8.5 Speed Load Changer

The governing system shall be equipped with speed and load changers to control the speed or power

output of the steam turbine within the limits. The speed/load changer provided shall be capable of

adjusting the speed of the turbo set to any value in the range of 0% to 106% of rated speed to

synchronization of the generator with the bus. It shall be capable of varying the load on the machine

from no load to full load.

8.6 Load Limiting Device:

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The governing system shall be equipped with a load limiting device capable of being operated for the

purpose of limiting the amount of opening of the governor controlled valves to set the load at a pre-

determined limit, while the turbine is in operation. A remote position indicator shall be provided on

the governor control panel for indication of the setting of the load limit.

9.0 System I/O Requirements in the new system

Governor inputs:

Pulse (speed) inputs : 3 nos.

Analog inputs : 6

Analog outputs : 2(dedicated) for I/H converters and 6 should be configurable

Digital Inputs : 4 (Dedicated) and 12 inputs configurable

Digital Outputs : 2 (Dedicated) and 6 outputs programmable

10.0 Specifications of I/Os of EHTC system area and I/H Converter are given below

Analog Inputs:

a) Inputs for load should be Isolated.

b) All other analog input channels will be preferably be individually isolated.

c) Bidder to specify the Isolation level of inputs to chassis

d) The inputs from field to be taken to system through individual isolators of reputed

make with response time better than 100msec.

e) Overall accuracy shall be better than +0.2% of full-scale at 25 DegC

f) The drift due to change in ambient temperature shall be specified.

g) Resolution of inputs shall be preferably 16 bits for 0-25mA range.

h) All analog inputs shall be provided with external isolators with three part isolation of

reputed make.

Speed Inputs:

i) Inputs for speed should be Isolated from each other and also with chasis.

j) Range shall be settable between 100 to 15000Hz.

k) Bidder to specify the Isolation level of inputs to chassis.

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l) The inputs from field to be taken to system through individual isolators of reputed

make.

m) Minimum 12 bit resolution for speed inputs.

n) The drift due to change in ambient temperature shall be specified.

o) Speed range to be software selectable.

p) Software or hardware filtering is required to avoid noise. Software filtering is

preferable .

q) Electromagnetic interference with any communication device nearby shall not affect

the speed measurement.

r) Accuracy shall be preferably better than 0.03%.

Digital Inputs

a) All Digital Input channels shall be preferably individually isolated.

b) Interrogation supply for Digital Inputs shall be through isolated 24 VDC from

Governor.

c) Digital inputs from external system shall be provided with Relay isolation.

d) Preferably, Change of state for duration less than 15mSec shall be filtered out.

e) Signal levels:

- guaranteed low level- bidder to specify

- guaranteed high level: bidder to specify and shall be ≥16V DC.

f) Isolation level of Digital Inputs with internal circuits shall be specified

Analog Outputs

a) All Analog Output channels shall be preferably individually isolated.

b) Signal level of analog outputs shall be 4-20 mA.

c) Analog output circuits shall be able to drive a load upto 600 ohms. 360 Ω maximum

load on the 4–20 mA version from actuator outputs.

d) Accuracy for analog outputs shall be preferably + 0.25% at 25 Degc.

e) For actuator outputs, Current read back on each channel preferably to be available, to

detect over/under current.

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f) The drift due to change in ambient temperature shall be specified .

g) The analog outputs will be going to field through the isolators of reputed make.

h) Preferably, Dither on actuator outputs shall be software selectable upto 10mA.

However this is to be taken care in I/H converter.

i) Resolution shall be preferably 10 bits for full scale range upto 25mA.

Digital Outputs

a) All Digital Output channels shall be preferably individually isolated,

b) All the DOs shall be relays based with form C contacts and software configurable

c) Inbuilt relays shall be able to drive atleast 5A at 24V DC.

d) Vendor shall provide 24 V.D.C. relays rated at 5 A. / 230 V.A.C. resistive load, duly

wired, wherever necessary

Modbus Communications Ports:

1. minimum one and preferably two isolated Modbus communications ports.

2. Supports RTU and ASCII protocol.

3. Baud rates upto 57600 configurable.

4. Supports RS-485 hardware interface. Preferably also RS-232, RS-422, hardware interface

5. Maximum network cable length ≥ 4000 feet (50 feet with RS-232).

Personal Computer Communications Port

1. One isolated PC communications port.

2. Supports RS-232 only.

3. Baud rates to 57600.

4. Maximum cable length is 50 feet.

Built-In Operator Interface

1. LED display 2. multi-function keypad. 3. Emergency stop and overspeed test buttons.

4. Alarm and over speed test LED indicators.

Software Specifications Speed/Load Control preferably NEMA D or better speed regulation.

Nominal Software Execution Rate shall be preferably

1. Speed/Load Control: 10 ms

2. Extraction Pressure Control: 20 ms

3. Auxiliary/ Load Control: 20 ms

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4. Cascade Control: 40 ms

5. Remote Speed Setpoint: 120 ms

6. Remote Extr/Adm Setpoint: 120 ms

7. Remote Aux Setpoint: 120 ms

8. Remote Cascade Setpoint: 120 ms

9. Sync/Load Share Control: 40 ms

10. Ratio/Limiting: 10 ms

11. Actuator Outputs: 10 ms

12. Shutdowns: 10 ms

13. Alarms: 20 ms

14. Relays: a. Trip Relay: 10 ms b. Alarm Relay: 20 ms c. Configurable Relays: 120 ms

15. Readouts: 40 ms

16. Contact Inputs:

a. External Trip & Configurable Inputs: 10 ms

b. Reset: 40 ms

c. Speed Raise & Lower: 20 ms

I/H converter specifications:

These converters are required to position the Governing valves with Servo motor.

a. Input electrical signal & trip oil, and output controlled secondary oil pressure preferably with

status indication shall be extended to Control Room.

b. Converter shall be Oil contamination resistant.

c. Precise fluid pressure control with preferably built in PID controller.

d. Stable and Linear valve control

e. Preferably Included valve linearization table

f. Standard mounting and Hydraulic connections

g. Preferably Self-cleaning valve algorithm

h. Preferably, Control pressure read out should be available.

i. Preferably, Status & health indication shall be available.

j. Preferably Software service tool with trending must be possible.

k. Compliant with applicable Directives-ATEX, Machinery, PED and EMC or equivalent.

l. Preferably Software service tool should be easily configurable, calibrate and adjust all internal

functions & PID control settings.

m. Manual stroke function from field should be available

n. Accuracy: Preferably < ±0.2 % of full range

o. Repeatability: Preferably 0.1 % of full range

p. Temperature Drift: to be specified ( q. Pressure stability: to be specified .

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r. Configuration: Computer based Service Tool (RS-232 communications port)is preferable s. Environmental

• Operating Temperature Range: (–40 to 70) °C preferably upto 85 °C

• Hydraulic Supply Temperature: (15 to 70) °C

• Emissions: EN61000-6-4 (2007) or as per other international test standard

• Shock: US MIL-STD-810C method 516.2, procedure 1 (10 GPeak, 11 ms duration,

saw tooth waveform) or other international shock test standard and procedure.

• Vibration: US MIL-STD 810F, M514.5A, Cat. 4 (0.015 G²/Hz,(10 to 500) Hz, 1.04

Grms) or other international vibration test standard and procedure.

• Ingress Protection: IP66 per EN 60529

11.0 I/O interface to DCS . The minimum I/Os from field and EHTC which will be interfaced to

DCS are as per Annexure A1. However, all the I/Os mentioned in the list are interfaced to DCS

either through Hardwiring and which are not possible through hardwiring then that through Modbus

communication interface.

Interface and protocol details of required communication ports (RS 485) as asked at Sr no 10.0 above

to be submitted along with offer. The testing of these interfaces will be done during FAT. Further the

EHTC shall work as slave on this communication interface/port.

It is preferable that interface is capable to convert all the data into 16bit integer format with proper

scaling before transmitting to DCS and also on receiving data in 16bit integer format from DCS. Also

it is preferable that the data (Registers and Coils) shall be available in serial address order without

break.

12.0 Environment Conditions:

The equipment will be installed in an Air Conditioned room and it shall be suitable to operate normal

lifetime under the conditions mentioned below:

- The normal operating temperature and humidity condition is normally 26 degree Celsius

and 50% RH. In abnormal situations ie., during air conditioner failure, the condition will

be 30 º to 50º Celsius temperature and 20 to 95 % RH non-condensing)

- Dust level of coal based power plant should not affect the performance of the system

- There shall not be any adverse effect in the system functioning due to R F interference

from VHF Trans receiver sets being used in the vicinity/factory premises. Usage of

Walkie-Talkie sets near control panels shall not affect the system performance.

13.0 General Technical Requirements:

- Extensive self-diagnostic facilities shall be provided for all electronic modules and

annunciated.

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- All input/output cards shall preferable have LED indication for card healthy, card faulty,

communication healthy, etc.

- It should be understood that the job is of retrofit in nature; hence the vendor should take

care of all the requirements from field to control room, so that the existing EHTC is

totally replaced with the new system. It should have all the technical inputs and modes of

operation in existing system. The bidder can visit the site for assessment of the

requirements before bidding.

- Vendor shall furnish point-wise confirmation / deviation / comments on Tender

Document, and tenders to be submitted in duplicate.

- It is mandatory for the successful bidder to furnish details for all the electronic hardware

manufactured. For the bought out items, detailed specifications and troubleshooting shall

be submitted.

- The entire software resident in the system shall be licensed original software and license

shall have lifetime validity.

- The software for configuration and programming of the governor to be also supplied with

life time validity license.

14.0CABINETS

- Cabinets’ shall be provided and standardized in accordance to the

following:

Panel color should be RAL 7032/7035 shade

- Self-standing type, min. 2.3 mm thick good quality steel plates, with channel

base .

- The doors, side and back panels shall have 1.6 mm thickness.

- Cables entry - From the bottom.

- Cabinet access - From rear & from front with locked doors complete with

keys.

- Copper grounding bars. As a minimum, safety grounding and signal grounding

shall be provided with a grounding strip.

- Terminals-Weid Mueller/Phoenix 2.5 mm2.

- Cables fixing through cable glands of SS 304 material.

- Service power socket with 230V AC 50 Hz 500 Watt.

- Forced Ventilation from top of the cabinets/side of the cabinets are required

for all the cabinets. .Failures of fans shall not degrade the system performance.

- Sufficient clearance for smooth opening and closing the doors shall be provided

to avoid touching of any module or cables.

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- Internal Light: Duplex fluorescent type complete with switch (on/off) 230 V,

50 Hz.

- Incoming and outgoing cables/wires from and to the cabinets shall terminate at

terminals in the cabinets. All these internal wiring, termination and

interconnection between cabinets, system cabinets and panels shall be executed

by Vendor.

- Cable ducts - Dedicated for power, signal and non-signals. Cable ducts shall be

of plastic with cover (150mm) sized to allow loading coefficient of 80% only.

- Spare terminals: Min. 15% .

- Spare fuse links for power supply: min 10%.

- Lifting eye bolts (4 Nos. per cabinet) required.

- All the cabinets shall be of the same type and color, their front and backs shall

be easily inspected by means of removable hinged doors, with key locks.

- The cabinet shall be constructed and designed so as to reduce interconnections

to a minimum.

- Cutout with removable plate (for drilling as required) shall be provided.

- Power supply packs shall be positioned so as not to generate electromagnetic

interference to the electronic component and shall be installed on top.

- The cabinet shall be supplied complete with all the materials and accessories

for wiring in the most workman like manner, with fixing brackets and cable

clamps for customer’s in/out cables also.

- All cabinets shall be mounted with anti-vibration pads.

- The panels shall be well sealed against dust preferably IP51 as per IEC 529 for

indoor applications and IP54 for outdoor and in wet areas.

- Illumination of 300 lux inside panel is required. Light sources shall be of the

fluorescent type.

15.0 ADVANTAGES TO BE DERIVED BY RETROFITTING THE CONTROL SYSTEM TO

DIGITAL CONTROL GOVERNOR SYSTEM

• Accurate speed control: In island mode the frequency can be maintained at set value,

irrespective of load.

• Automatic changeover from grid parallel mode to island mode without load disturbances.

• Boiler stability: The RPM variation being low, output of boiler is more or less constant and

hence is very stable.

• Extraction control: Accurate extraction pressure control for all load variation.

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• Constant load control: Load output maintained constant during grid frequency fluctuations,

automatically.

• Load shedding: Optionally configurable

• Automated run up: Ensures uniform ramp up of speed and load leading to reduced material

stresses and fatigue. Ease of operation reduces operator fatigue.

• Communication: The control system communicate directly with plant DCS , through

communication ports

• The response time of the system will improve. The retrofit system will provide the response

time to the range of few milliseconds.

• Provides automation and remote control operation. Certain operation like raise extraction

pressure can be done directly from control room without disturbance to load control.

• User-friendly field programmable hardware and software. It should be very simple to

configure and easy to operate.

• As the response of the new system is expected to be faster than the existing system, it

provides faster closing and opening of the throttle valves saves steam energy.

• Speed control/droop mode is possible.

• KW control, Inlet pressure control is possible.

• Precision in measurements and readouts display on main panel of the controller.

• Maintenance free control system as there are less moving parts.

• Important critical speed avoidance by ramp rate adjustment is possible

• It should also be possible to interface to Import/Export control.

Note:-1) The supplier should indicate the benefits that can be derived from the system offered in the

bid as mentioned above.

2) The credentials of the supply of the system along with their satisfactory performance to be enclosed

with the offers.

3) The bidders are informed to visit the plant site for getting familiarization before the bidding as the

job is of retrofit in nature.

4) The bidders are informed to quote alternate models in their scope for review and selection.

5) The vendor to make necessary arrangements for integrating the system quoted with the plant DCS

system.

16.0 Test Reports:

i) Three copies of type test reports shall be submitted to the purchaser after conducting the tests for

purchaser reference.

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ii) Three copies of factory acceptance test reports shall be submitted to the purchaser. One copy will

be returned duly certified by the purchaser and only thereafter shall the materials be dispatched.

iii) Three copies of test reports for tests conducted during manufacture shall be submitted by the

supplier. These shall be produced for verification as and when requested for by the purchaser.

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Section-D (General Terms & Conditions)

1.0 Pre-Bid Vendor's Visit To The Site:

Bidders should visit HWPM before submitting their Offers without fail to understand

the system integration in detail for their own clarity of the site location.

2.0 Acceptance Of Technical Specifications:

Bidder has to submit signed copy of technical specifications along with the Bid as a mark of

Acceptance of the Terms & conditions, Scope of work, Technical Specification etc.

3.0 Deviation From Tender Specifications:

In case of any deviation from the Technical specifications or conflict between any clause of

this specification or any clause in the offer submitted by the bidder, same shall be specifically

brought out by the bidder as deviations in their offer by grouping all such details in a separate

“Deviation Sheet”. The deviation should clearly indicate.

• Section No.

• Clause No.

• Deviation against this clause.

4.0 Civil Work:

The scope shall include all the necessary civil works to be carried out by the supplier.

5.0 Kick-Off Meeting:

A kick-off meeting between vendor and HWB/HWPM for EHTC system will be set up in

order to define final time schedule and documents to be supplied. In addition regular project

meetings shall be performed.

6.0 Delivery Terms And Period

6.1 Supply of material to site : within 4-5 months from placement of LOI/PO

6.2 .Installation & commissioning: Within 2 months of receipt of material to site 6.3 Time for installation & commissioning at site: Approx. 15 days( bidder can visit the

site to review the same)

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7.0 Prices:

The vendor shall quote for the complete system including installation & commissioning.

Detailed breakup of prices as per the BOM (Annexure-A3) shall be provided.

The vendor is advised to check and ensure that all items are included in the offer In any case,

it is deemed that the vendor has studied the tender specification documents entirety and no

increase in value shall be permissible, if the tender specification specifications remaining

unchanged. The offer shall be in Indian Rupees; however the extent of taxes and duties shall

be indicated separately.

8.0 Payment Terms:

Payment terms shall be as per the standards of Directorate of Purchase & stores, Department

of Atomic Energy.

9.0 Services Supplied By HWP (M) During Erection.

• Construction Power Supply:

a. The vendor shall indicate in his bid peak construction power in the tender. Free

construction power supply will be provided at one point in the unit. All extensions

required should be arranged by the vendor. The electric power supply would be made

available at the nominal 230 V single phases 50 cycles. The vendor shall install his

incoming mains board, duly equipped with proper protections etc. The vendor shall

also install at his own cost, required cable, meter and other materials for tapping of

and distributing power from the terminal point.

b. It shall be responsibility of the vendor to provide and maintain the complete

installation on the load side of the supply as well as his incoming mains board with

the due regard to the safety requirement at the site. The vendor’s installation shall

comply in all respects with the appropriate statutory requirements given in various

acts, rules and regulations.

c. The purchaser would not be liable for any loss or damage to the vendor’s equipment

as a result of variations in the voltage or frequency or interruptions in the power

supply. For any failure/stoppage of power supply for continuous period, the vendor

will be eligible for only reasonable extensions of time and not for any compensation

on his account while the department would make efforts to make available reasonable

continuous power supply.

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d. The construction power supply would be made available by the department at a point

in the Control Room, within a radius of 250 meters from the area of construction

activity, or at any other place which may be mutually agreed upon.

e. The vendor’s temporary distribution system, including metering, shall be subjected in

every respect to the approval of the Department and shall be arranged so as to avoid

any interference with the operation of other agencies on the site.

• Construction Water Supply: Water will be unfiltered river water and supplied free

of cost at a point in HWP (M).

• Contractor manpower stay and transport to site: The contractor shall make his

own arrangement for providing all facilities like accommodation and transport for his

employees at his own cost. However, accommodation can be provided on chargeable

basis subject to its availability. Department shall not be responsible for any risk faced

by the contractor while transporting the personnel to and fro from site. Two types of

accommodations, depending on the availability, are available in the colony.

a. Guest House Rs.200/- per bed ( A/C)

b. Hostel Rs 150 /- per bed (non- A/C)

• Supply of Crane: Crane for loading & unloading of material at site shall be supplied

by HWP (M) on chargeable basis. Charges for hiring 12T crane is approx. Rs.2230/-

per hour & for 8 Ton crane is 2070/- per hour.

• Workshop facility for installation of new speed probes shall be provided by HWPM

• Medical Facilities: No medical facilities will be provided to the employees of the

contractor by the department.

• Insurance: While carrying out the above work, necessary insurance coverage for

contractor workmen and material should be done by the contractor. If any

accident/injury occurs to the working personnel, the contractor only has to bear all the

expenses for any sort of the compensation payable to the injured person. The

department will not be responsible in any manner in this regard.

• Food for Contractor Employees: Contract employees can avail food from the

departmental Canteen at the specified rates for the contract employees subject to

availability of food at the Canteen.

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• Storage: The Contractor shall arrange his own storage facility at plant site in place

allotted to him by the department at their own cost.

• Stores & Equipment: The contractor shall be responsible for all the materials, which

he is storing in the storage room and the department will not bear any responsibility

for the loss/damage to the contractors’ material by any reasons whatsoever it may be.

• Working Hours: The General Shift working hours of the plant is from 0900 hours to

1700 hours. The contractor should follow these working hours. If a particular job

could not be completed within the stipulated period, contractor can continue beyond

the above-mentioned hours with the permission of the competent authority.

10.0 Contact details for visit to HWPM site

a. HWB Mumbai : Manager(I), Heavy Water Board , V floor, VIKRAM BHAVAN, ANUSHAKTI ANAGER, MUMBAI-400094. e-mail : swadhwa@mum.hwb.gov.in phone 022-25487509

b. HWP, Manuguru: Dymm(I_U), HWP MANUGURU,PO GAUTAMI NAGAR, ASWAPURAM, KHAMAM DISTT, AP-507116. e-mail : dymm_iu@man.hwb.gov.in , phone : 08746- 233209

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Section-E (QUALITY ASSURANCE PLAN FOR GOVERNOR SYSTEM & OTHER

DEVICES CHECKS AND ACCEPTANCE TESTS)

Inspection, testing and commissioning:

1.0 FACTORY ACCEPTANCE TEST (FAT)

• System testing shall be carried out in the best quality test like manner in conformity with the

international/OEM standards and other relevant specifications, codes of practices of the

bureau of standards of country. If the systems are imported, then supplier has to submit the

QAP of the manufacturer and furnish the test certificates.

• The supplier shall submit sufficient documents and other test certificates from reputed/govt.

approved test lab for confirming their claim for complying the std testes as mentioned in

stage-I PRE-FAT TEST Table below . If the tests have been carried out by the OEM of the

system, then the test certificates shall be submitted.

• FAT procedure shall be finalized after award of contract and shall be binding upon both

Purchaser and Vendor. Vendors shall offer the system for FAT only after the system is

completely tested to meet total functional requirement. The dispatch clearance shall be given

only after all the discrepancies/ anomalies have been resolved at vendor’s works.

• In the event that certain requirements of the tests conflict with the requirements of the tender

specifications, the latter shall govern. The system shall be inspected at Suppliers works. The

tests for the major critical items of the supply are given below.

a) Electronic Governor:-All the standard tests, as per OEM standard shall be performed and

certificates will be furnished. The instrument shall be checked at vendor’s works for

i) Booting of the system

ii) Checking of all I/Os by simulating I/O.

iii) The configuration checks.

iv) Checking of the different modes of operation. Performance of the unit should be demonstrated as

per specification. Checking will be performed by taking the program online and simulating the same.

b) I-H Convertor:-All the standard tests, as per OEM standard shall be performed at the Vendor’s

works and test certificates shall be furnished. The vendor shall provide the calibration certificate

conforming to the calibration range and the results of various characteristics checks as per OEM

standard. The performance of the unit is to be demonstrated as per specification.

c) Field Instruments:-All the standard tests as per OEM standard shall be performed and certificates

will be furnished. The performance of the instruments is to be demonstrated as per specification.

55

Alos refer to the common test for FAT and SAT ( 3.0 below)

2.0 SITE ACCEPTANCE TEST (SAT)

The equipment shall be accepted, after the following site acceptance tests, and acceptance criteria.

1) The hydraulic system shall be run at rated pressure for a period as needed for flushing the oil before

installing the electro hydraulic Convertor to ensure cleaning of oil to acceptable standard as specified.

2) The I/H converter shall be calibrated to match the actuator to check the linearity and hysteresis of

the actuator.

3) The startup sequences, ramp rates shall be configured, as specified. The same shall be tested and

proven.

4) The over speed trip setting shall be checked and required adjustments will be made if required.

5) Speed control shall be tuned in isochronous mode running isolated from the grid to meet the

relevant NEMA standard. After synchronization with the grid, satisfactory operation in droop mode

shall be demonstrated.

6) The system shall be set to Auxiliary control mode and tuned for KW control to meet the relevant

NEMA standard.

7) The system shall be tested for load throw-off of rated load to the maximum extent possible, and

checked to ensure the temporary speed raise does not exceed the trip value.

8) 100 hours continuous satisfactory operation of the system shall be demonstrated at site.

9) The performance guarantee shall be governed by Section C 8.0 as mentioned in technical

specifications..

STAGE-I PRE-FAT TESTS (Submission of test certificates)

The type test certificates

Sr

no.

Components of the

System

Type Tests: Relevant

Standards

Acceptance

criteria

1a Testing of system

components Such as

I/O modules , CPU

modules,

Communication

modules , power supply

modules etc.

Vibration As per Relevant

IS/ IEC/OEM

standards.

Compliance to the

Standard/Test

1b --do-- Immunity to Climatic conditions

such as Dry heat and cold with

As per Relevant

IS/

Compliance to the

Standard/Test .

56

stand tests, IEC/OEM/equiv

alent standards

1c --do-- Pollution resistance tests As per Relevant

IS/

IEC/OEM/equiv

alent standards

Compliance to the

Standard/Test .

3.0 Common test of FAT and SAT

During FAT, below mentioned test to be performed by simulating IOs and during SAT, the same tests

to be performed by actual signals.

STAGEII : FAT TEST -

The following tests shall be carried out during -FAT along with customer representative. The vendor

shall carry out all these tests on its own before calling the customer. The vendor shall submit the test,

results and all the relevant documents one week in advance before the customer is called for tests. The

vendor shall submit the filled test reports and get it vetted by purchaser after the tests are over.

FOR GOVERNOR PALQUE, GOVERNOR, NEW CONTROL PANEL

Sr

no

.

System

Description

Type of Tests Extent of Check Reference

drawings

Acceptance criteria

1 Documentation

of the system:

Hardware,

Software and

Operation

Manuals

Checking of

documents

Full checking as

per the system

requirements

As per

approved

BOM

The documents should

be complete in all

respects.

2 Complete system Dimensional

checks , GA checks

100% Approved GA

drawings

Conformance to

approved GA

drawings.

3 Complete system Overall system

architecture

100% Conformance to

approved drawings..

57

4 Panel wiring Visual inspection 100% Approved

wiring

drawing

Correctness of wiring,

ferruling, dressing,

segregation of power

and control cables.

5 Crimping quality,

color coding and

grounding schemes

100% Approved

wiring

drawing

Correctness of wiring.

6 Complete system Power-up/power

down test for

system

Complete system

to be switched

off and automatic

start up after

resuming power

Approved test

procedure

Satisfactory starting of

system after system is

switched on.

7 Complete system Communication

tests for integrated

system.

Interface with DCS

system

All

communication

buses to be

checked for

healthiness and

redundancy

Overall system

architecutre

All system buses

should be healthy and

operational wherever

provided. All

diagnostic messages

appear appropriately.

8 Complete system Checking of all

I/Os by simulation.

Speed channels

Analog input,

Analog Output,

Digital Input,

Digital Output

100% I/O allocation

drawing and

termination

details

approved

document

. I/Os will be checked

by simulation with

suitable calibrators

during FAT.

9 Complete system Detail software and

logic simulation (

Refer details at

(B.SOFTARE

TEST DETAILS)

below

Complete

software and

logic should be

tested by

simulating I/O

conditions

Approved

purchasers

requirements

The system should

meet purchaser’s

requirements.

10 Complete system MMI Configuration

checks.

MMI of

controller to be

checked for static

and dynamic

displays

Approved

screen-

dumps/ soft

copies

Correctness of pages

as per purchaser’s

requirements .

58

11 Complete system System Diagnostics Controller

diagnostics

As per

specification

for hardware

and software

All diagnostics

displays as

purchaser’s

requirements. Power supply

diagnostics

14 Panel wiring Megger & high

voltage test

Insulation

resistance to be

checked at

500VDC.

HV breakdown to

be test at

1.5kVAC

IS: 4237 Insulation resistance

should be greater than

100 mega ohm and no

insulation break down

occurs at 1.5kV AC

15 Complete

Integrated system

Continuous Run

test of the system

with 50 % Inputs

and outputs at

ambient

temperature

100% Full system

be kept

running for

100 hours on

continuous

basis

No failures should be

reported. Acceptance

shall be based on the

relevant standards. If

any fault is observed,

the same should have

technical reason and

should be rectified and

the test shall be

repeated again.

B. Software tests

Type of Test Test Instrument used Relevant standards Remarks

1. System initialization

check.

2. Configuration of the

governor for HWPM

application.

3. Functionality checking of

the Governor for different

simulated conditions.

Test fixture consisting

closed loop simulator

for speed and other

analog inputs during

FAT.

During SAT, logic

IS/IEC/OEM/supplier

Standards

The tests will be

carried out and results

will be verified.

59

4. Communication with

DCS

5. Auto start up sequence up

to 3000 rpm

6. Emergency shutdown

logics

7. Over speed tests

8. Checking Alarms

activation and resetting.

9. Controller checking

verification and

software checks will

be performed by Field

signals.

MODBUS

COMMUNICATION

1. Check the Modbus

communication with DCS and

mapping of I/O details.

Test fixture consisting

of PC with Modbus

drivers during FAT.

During SAT, Modbus

signals will be

checked with existing

DCS directly.

IS/IEC/OEM/supplier

Standards

The tests will be

carried out and results

will be verified.

C.:I/H convertor check

Type of Test Test Instrument used Relevant standards Remarks

. Functional testing

1) Calibration of I/H

convertor.

2) Response of I/H

convertor.

3) Sensitivity of I/H

convertor.

4) Check Stroke.

Test fixture consisting of

standard current source,

standard multimeter,

pressure gauges and Test

bench during FAT.

During SAT, I/H

converter signal output

will be fed to Actuator

in field and Stroking will

be checked.

IS/IEC/OEM

Standards

The tests will be

carried out and

results will be

verified.

60

D:.Speed Sensor Test

Type of Test Test Instrument used Relevant standards Remarks

G. Functional testing

1) Check coil Resistance.

2) Check MPU voltage

3) Checking the MPU

frequency for rotating

equipment

Test fixture consisting of

multimeter and test

bench.

During SAT, checking

of the speed of Turbine

will be done by physical

mounting of probes.

IS/IEC/OEM

Standards

The tests will be

carried out and

results will be

verified.

Test Certificates

All routine certificates including test records, performance curves, etc. shall be supplied according to

the distribution schedule.

After acceptance at the factory, all the equipment shall be packed suitably and transported to the site.

As this process may cause some damage to the equipment, they shall be tested again at the site. All

the hardware and software tests done at the factory shall be repeated at the site and equipment shall be

considered suitable for next phase of testing if the results of these site tests are found acceptable. The

tests shall be carried out with actual loops of the plant in line with the complete system (Site

Acceptance Test).

After SAT, the plant shall be taken in line with the new system. This phase is termed as Semi

Industrial run. Duration of this semi-industrial run shall be 7 days, during which time the Supplier

shall be responsible for the maintenance and repair of the system and additional hand holding training

of the operators. Semi- industrial run shall continue by the supplier if any failure or mal function is

observed in the part or whole system.

Commissioning: After successful completion of the semi-industrial run, the equipment shall be

considered as having been accepted & commissioned.

61

After the successful installation & commissioning of the system, the supplier should station their

technical representative for a period of 10 days to give the confidence to O&M staff of HWP (M) and

monitoring the system performance at their cost

ACCEPTANCE OF THE SYSTEM AT SITE

The vendor shall consider the system acceptable only on compliance of the following.

The system with all the subsystem including hardware, software, communication system, and

auxiliaries have been supplied, installed and commissioned to the satisfaction of purchaser

Training has been imparted to the personnel as stipulated above.

All documentation as built as specified elsewhere in the specification as well as those required for

complete comprehensive of the system has been delivered.

All other activities, whether stipulated in this tender specification or not, but which are necessary for

meeting the requirements have been completed by the vendor or by any sub-contractor of the vendor.

(B2) - To Field. New shielded

cables are to be provided by

bidder. (200 mtrs.)

Existing

Microverse DCS

Panel

Signals

directly from

the Plaque

Panel. (C1)

Digital Output Signals (D)

Existing Cables at HWP (M) are to

be used.

Analog Output Signals (B1). New

shielded cables are to be provided

by bidder. (10 mtrs.)

Digital Output Signals (D2)

New shielded cables are to be

provided by bidder. (10 mtrs.).

Signals to new GOVERNOR Panel

(Refer Table Y & Z)

Exis

tin

g W

irin

g

avai

lab

le u

p t

o

Go

vern

or

Pan

el

Signal to DCS (Refer Table Y & Z) New wiring (10 mtrs.).

Analog Inputs (A) – From Field.

New shielded cables are to be

provided by bidder. (200 mtrs.)

Analog Input Signals (A)

New shielded cables are to be

provided by bidder. (50 mtrs.)

Digital Input Signals (C2)

Existing Cables at HWP (M) are to

be used.

Digital Input Signals (C2).

New shielded cables are to be

provided by bidder. (10 mtrs.).

(D1). New shielded cables are to

be provided by bidder. (200 mtrs.) 50 Meters

Analog Output Signals (B1). Existing

Cables at HWP (M) are to be used.

New Panel for

Governor in the

Panel Room on the

existing location of

old Governor Panel.

Analog Output Signals (B2). New

shielded cables are to be provided

by bidder. (50 mtrs.)

10 Meters

New Governor

Location in Control

Room on the

Existing Plaque

ANNEXURE – A1

For A, B1, B2, C1, C2, D1 & D2

refer Table X.

ANNEXURE A2

GOVERNOR I/Os: (TABLE X)

Type of existing signal Work to be done by supplier along with material supplied in the new GOVERNOR panel

ANALOG INPUT ( A) 1. Speed Inputs – 3 Nos. Input from field to GOVERNOR a. Isolator for speed input.

b. Power supply and related wiring c. New cable to be laid from filed to new

panel ( 200 mtrs)and from new panel governor at control plaque(50 mts)

2. Load Jw Input 4-20 mt from field to GOVERNOR a. Isolator. b. Power supply and related wiring c. New cable to be laid from filed to new

panel ( 200 mtrs)and from new panel governor at control plaque(50 mts))

3. HP Extraction Pressure Input 4-20 mt from field to GOVERNOR) a. Isolator. b. Power supply and related wiring c. New cable to be laid from filed to new

panel ( 200 mtrs)and from new panel to governor at control plaque(50 mts)

4. Inlet Pressure Input 4-20 mt from field to GOVERNOR) a. Isolator for 2 wire TX. b. Power supply and related wiring c. New cable to be laid from filed to new

panel ( 200 mtrs)and from new panel governor at control plaque(50 mts)

ANALOG OUTPUTS (B1) 1. Load reference AO signal from plaque to governor panel a. AO signal from new governor to

existing DCS panel

b. Existing cable to be used upto new panel

c. Cable from new panel to DCS panel to be supplied new

2. Speed reference --do- ---do--

3. Extraction set point --do-- ---do--

4. Extraction limit --do-- ---do--

5. Speed --do-- ---do-- 6. Frequency --do-- ---do-- 7 Preferable AO : Frequency

influencer AO – Central panel to GOVERNOR

--do-- --do--

8 Preferable AO :Frequency ref point – central panel to GOVERNOR

--do-- --do--

ANALOG OUTPUTS (B2)

a.

9 Actuator Output 1 Output from GOVERNOR to field b. Isolator for 2 wire signal; to actuator in new panel

c. New cable to be laid from filed to new panel ( 200 mtrs)and from new panel to governor at control plaque(50 mts)

d. Power supply and related wiring 10 Actuator Output 2 output from GOVERNOR to field a. Isolator for 2 wire signal to actuator in

new panel b. New cable to be laid from filed to new

panel ( 200 mtrs)and from new panel to governor at control plaque(50 mts)

c. Power supply and related wiring DIGITAL INPUTS (C1) Existing signal 1. External Trip Input from DCS

2. Emergency stop PB from Desk Input from PB to GOVERNOR Supply of PB and related wiring to GOVERNOR.

3. Generator Breaker close Input from PB to GOVERNOR Supply of PB and related wiring to GOVERNOR.

4. Tile breaker close Input from PB to GOVERNOR Supply of PB and related wiring to GOVERNOR.

5. Speed raise PB Input from PB to GOVERNOR Supply of PB and related wiring to GOVERNOR.

6. Speed lower PB Input from PB to GOVERNOR Supply of PB and related wiring to GOVERNOR.

7. Load raise PB Input from PB to GOVERNOR Supply of PB and related wiring to GOVERNOR.

8. Load lower PB Input from PB to GOVERNOR Supply of PB and related wiring to GOVERNOR.

9. Extraction pressure PB Input from PB to GOVERNOR Supply of PB and related wiring to GOVERNOR.

10. Extraction Pressure PB Input from PB to GOVERNOR Supply of PB and related wiring to GOVERNOR.

11 Preferable Input: :Frequency influencer – Central panel to GOVERNOR

Input from PB to GOVERNOR Supply of PB and related wiring to GOVERNOR.

12 Preferable input Frequency ref point – central panel to GOVERNOR

Input from PB to GOVERNOR Supply of PB and related wiring to GOVERNOR.

13 Frequency raise PB Input from PB to GOVERNOR Supply of PB and related wiring to GOVERNOR.

14. Frequency lower PB Input from PB to GOVERNOR Supply of PB and related wiring to GOVERNOR.

DIGITAL INPUTS (C2)

15. Turbine Trip reset Input from DCS to governor Existing cable to be sued from new panel

to control plaque

DIGITAL OUTPUTS ( D1) 1. Shutdown relay Output from GOVERNOR to field a. New cable to be laid from filed to new

panel ( 200 mtrs)and from new panel to control plaque(50 mts)

d. Power supply and related wiring

DIGITAL OUTPUTS ( D2)

2. Fault alarm output Output from governor to DCS and

annunciator

Existing cable to be used from control

plaque to new panel

3. Over speed test enable/disable

status

Output from governor to DCS and

annunciator

Existing cable to be used from control

plaque to new panel

Note: wherever preferable is mentioned in the description, the respective I/O is not must but is preferable to be provided .

Additional push buttons from plaque to field

1 Starting device raise PB Existing wiring/cables to be used

2 Starting device lower PB Existing wiring/cables to be used

3 Speeder gear raise PB Existing wiring/cables to be used

4 Speeder gear raise PB Existing wiring/cables to be used

Additional Signals for GOVERNOR & DCS ( TABLE Y)

Analog Inputs

S no

Existing signal to be hooked up by supplier to GOVERNOR & DCS

Type of existing signal Work to be done by supplier along with material supplied in the new GOVERNOR panel

1. Starting device position – LVDT to GOVERNOR

24 Volt DC P.S to LVDT from governor panel & receipt of signal (+10 to -10V) from LVDT to GOVERNORpanel.

a. Existing cable to be used upto new panel b. Isolator for conversion of (+10 to -10 V to 4-

20 mA) in new panel c. Power supply to field and related wiring d. Signal transfer to existing DCS panel e. Cable from new EHTC panel to DCS panel

to be supplied new 2. Oil below the piston – prTx to

GOVERNOR 2 wire 4- 20 mA TX signal coming to governor panel

a. existing cable to be used upto new panel b. Isolator for 2 wire TX in new panel. c. Power supply and related wiring d. Signal transfer to existing DCS panel e. Cable from new EHTC panel to DCS panel

to be supplied new 3. Oil above the piston – prTx to

GOVERNOR 2 wire 4- 20 mA TX signal a. existing cable to be used after new panel

b. Isolator for 2 wire TX. c. Power supply and related wiring d. Signal transfer to existing DCS panel e. Cable from new EHTC panel to DCS panel

to be supplied new 4. Speeder gear position – LVDT to

GOVERNOR 24 Volt DC P.S to LVDT from new panel & receipt of signal (+10 to -10V) from LVDT to GOVERNOR panel.

a. existing cable to be used upto new panel b. Isolator for conversion of (+10 to -10 V to 4-

20 mA) to DCS. c. Power supply and related wiring d. Signal to existing DCS panel e. Cable from new EHTC panel to DCS panel

to be supplied new 5. Acceleration (speed sensor o/p

differentiated in GOVERNOR) Speed sensor signal coming to existing governor

a. Using the speed sensor signal b. Differentiation in GOVERNOR software.

c. AO to DCS d. Cable from new EHTC panel to DCS panel to

be supplied new 6. HP EHC position – LVDT to

GOVERNOR 24 Volt DC P.S to LVDT from new panel & receipt of signal (+10 to -10V) from LVDT to GOVERNOR panel.

a. Existing cable to be used upto new panel b. Isolator for conversion of (+10 to -10 V to 4-

20 mA) c. Power supply to field and related wiring d. Signal transfer to existing DCS panel e. Cable from new EHTC panel to DCS panel

to be supplied new 7. LP EHC position – LVDT to

GOVERNOR 24 Volt DC P.S to LVDT from new panel & receipt of signal (+10 to -10V) from LVDT to GOVERNOR panel.

a. Existing cable to be used upto new panel b. Isolator for conversion of (+10 to -10 V to 4-

20 mA) c. Power supply to field and related wiring d. Signal transfer to existing DCS panel e. Cable from new EHTC panel to DCS panel

to be supplied new 8. HP secondary oil pressure – Field

TX to GOVERNOR Input 4-20 mA from field to governor panel

a. Isolator for 2 wire TX in new panel. b. Power supply and related wiring transfer c. Signal to existing DCS panel d. Existing cable to be used upto new panel e. Cable from new EHTC panel to DCS panel

to be supplied new

9. LP secondary oil pressure – Field TX to GOVERNOR

Input 4-20 mA from field to governor panel

a. Isolator for 2 wire TX in new panel. b. Power supply and related wiring transfer c. Signal to existing DCS panel d. Existing cable to be used upto new panel e. Cable from new EHTC panel to DCS panel

to be supplied new

10. HP valve position Input 4-20 mA from field to governor panel

–do--

11. LP valve position Input 4-20 mA from field to governor panel

–do--

12. Trip oil pressure - Field TX to GOVERNOR

Input 4-20 mA from field to governor panel

–do--

13. Lube oil pressure - Field TX to Input 4-20 mA from field to governor –do--

GOVERNOR panel 14. Governing oil pressure - Field TX

to GOVERNOR Input 4-20 mA from field to governor panel

–do--

15. Actual frequency – frequency trans to GOVERNOR

Input 4-20 mA from field to governor panel

--do--

Additional inputs to be hooked up to existing Microverse DCS( TABLE Z)

Digital inputs

Existing signal to be hooked up

by supplier to DCS Type of existing signal Work to be done by supplier along with

material supplied in the new GOVERNOR panel

1. Inlet pressure OK Input from field to GOVERNOR panel a. Existing cable to be used

b. Isolator. c. Power supply and related wiring d. Signal to existing DCS panel e. Cable from new EHTC panel to

DCS panel to be supplied new

2. HP NRV OPEN Input from field to GOVERNOR panel –do--

3. HP NRV CLOSE Input from field to GOVERNOR panel –do--

4. LP NRV OPEN Input from field to GOVERNOR panel –do--

5. LP NRV CLOSE Input from field to GOVERNOR panel –do--

6. ESV OPEN Input from field to GOVERNOR panel –do--

7. ESV CLOSE Input from field to GOVERNOR panel –do--

62

ANNEXURE – A3

BOM &SCHEDULE OF RATES

A. SOR – EHTC

Sr. No. Description of Material Quantity Make &

Model

Unit Price Total

Price

1. Digital Configurable Governor Kit With Power

Supply Unit (set) 1 set

2. Magnetic Speed Probes With Extension Cables,

Connectors And Mounting Arrangement On

Turbine

3 nos.

3.

Over speed protection system including speed

probes (Separate module if only 2 speed probes

are used for speed sensing in governor controller

refer 6.1.1.of section C)

1 Lot

4. Current To Hydraulic Converter With Mounting

Plate 2 nos.

5. Oil Filter

5.1 Duplex Filter With Filter Elements 1 no.

5.2 Spare Filter Elements 5 nos.

6.

Field Instruments For The Governor System As

Per Specific Requirement

6.1 Kw Transducer (Dual Output) &

frequency transducer 1 no.

7. Required Piping, Fittings etc. For Modification

of the Existing Field System Suitable For

Governor Application

1 Lot

8. SKID Assembly 1 Lot

9. Control panel for Isolators signals interface etc. 1 lot

10. Control Panel/plates For Fixing Governor on

plaque 1 nos.

11. Isolation Valves 1 Lot

12. Push buttons switches etc. on the existing plaque

for increase and decrease of signals to EHTC 1 lot

63

13. Proximity type limit switch for sensing opening

and closing of ESV 2nos

14. Any other component required for EHTC system LS

B. SOR – MISCELLAENEOUS ITEMS

Sr. No. Description of Material Quantity Make &

Model

Total

Price

1.

a. Shielded Cables for speed sensors.

b. Shielded cables for all Analog and digital

input/outout signals and Actuator outputs for

governor and also for interface between

existing DCS panel and new panel being

supplied ( details as per Ann A1 & A2 )

LS

2. Power supplies for panels LS

3. Cables Glands & Junction Boxes LS

4. Isolators as per Annexure A2 LS

5. Push buttons as per annexure A2 LS

6. Max signal selector (optional). Facility can be

provided in software. 2 nos.

7. Any other component required for the system LS

C. SOR – SPARES

Sr. No. Description of Material Quantity Make &

Model

Unit Price Total

Price

1. Digital Configurable Governor Kit With Power

Supply Unit 1 no.

2. Current To Hydraulic Converter 1 no.

3. Magnetic Speed Probe 1 no.

4. Power & frequency Transducer 1 no.

5. 20 % of B4 above as spare Isolators LS

6. 20 % of B5 above as spare Push Buttons LS

64

D. SOR – INSTALLATION & COMMISSIONING

Item Description Quantity

Total

Price

1 Engineering, preparation of drawings, loop diagrams, documentation for

EHTC.

LS

LS

2

Charges for laying of cable,., termination /determination of signals Civil

job, piping modifications, system installation etc required for the

installation and commissioning work

3

Charges for deputation of required manpower (Technicians/Helpers) for

erection and commissioning of system at site. Tentatively 4-5 personnel

(Technicians/Helpers) shall be required for installation & commissioning

during shutdown.

4 Any other work for installation and commissioning of the system

Note:-Detailed bill of materials has to be furnished in the bid and any other items required for

system completion is in the suppliers scope.

TAXES AND DUTIES FOR ALL SORs (A to D) ARE TO BE QUOTED SEPARATELY

ANNEX

XURE – B1

65

66

ANNEXURE- B2

67

ANNEXURE-B3

ANNEXURE B4 ‐‐ Existing EHTC control circuit in brief

(HP Sec Oil Pr)

(LP Sec Oil Pr)

HP EHC

LP EHC

Existing EHTC

M

HP servo motor

LP servo motor

Raise

MW & frequency transducer

Speed sensors

(LP Control signal)

(HP Control signal)

Trip Oil

Oil above piston

Oil below piston

Lower

Starting Device

M

Raise

Lower

Speeder Gear

Hydraulic Amplifier

Trip Oil Primary Oil (Speed)

HP Extrn Pr.

HP Extrn PrTG Inlet Pr

HP & LP EHC Positions

Main Scope of supplier in dotted portion

IMP/EXP ctrl O/PGB Open & CB Open

Hyd LP sec Oil Pr

Hyd HP sec Oil Pr

HP Governing valve

LP Governing valve

HP Turbine

LP Turbine

HP extrn ctrl limit