DCPL-K9A02

VOLUME : IIH

SECTION-III

OPERATION AND CONTROL PHILOSOPHY

1.00.00 The basic operation and control related to the ash extraction & removal
system will be independent for each unit and will be carried out in
co-ordination from different local panels located near the system/equipment,
either in automatic interlocked sequential mode or remote/ local de-interlocked
manual mode as explained hereunder.

1.01.00 All instruments like pressure indicators, pressure switches, level control
instruments, level indicators, level switches with alarm contacts, level control
valves, flow indicators etc., as indicated in the enclosed single line flow
diagram to facilitate effective control of the system, shall be furnished by the
Bidder. Any other instrument not categorically shown in the flow diagram or
mentioned in this specification but considered necessary for the safe &
satisfactory operation of the system shall also be furnished by the Bidder.

1.01.01 All drive motors & motorised actuators & pneumatic valves will be controlled
either from respective local panel (if any) or AHS main control room PLC with
starting interlocks & permissive in remote mode as also from local start-stop
station in de-interlocked local mode by means of "Local/Remote Selection"
switch. The power circuit for the above will be in the MCC and HT/LT
switchgear located in the switchgear room. Emergency lock out trip switch
will be provided with all major drives with necessary interlock. All Air/Electric
valves will be operated / controlled from AHS main control room. Local
operation shall also be possible through manual override to be provided on
locally mounted air line equipment (solenoid valve) for the actuators.

Generally, evacuation of Bed ash and fly ash shall be carried out
continuously .

1.01.02 Broadly, the ash handling system operation/control scheme can be

described as below :

Presently there are mainly two zones of operation viz. ash Hopper Area &
Silo Area. The drives, valves & field instruments of these two areas are
controlled by the AHP PLC (Hot Stand-by Configuration) located in AHS
Main Control Room (MCR).

Various controls and interlocks shall be provided for the trouble free
operation of the plant.

The various local junction boxes/local panels shall be located near the
respective equipment in different areas.
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Common Systems, viz., Ash Water, Fly/bed Ash Unloading system, fluidizing
system & various Sump Draining systems are all controlled through AHP
PLC.

Silo area Utility panel will be located in the Utility building adjacent to the
Silo. This panel will also house control switches, lamps etc. for local
operation. The I/O from this area shall communicate with the AHP PLC in
AHS main control room through RIO Unit.

One Silo Unloading panel with control switch and lamps is also there on
each Silo Unloading floor. The silo unloading operation will be done from this
panel.

Suitable alarm / annunciation system shall be provided to warn of any mal-

functioning of the ash handling system.

The Recovery Water area control system shall be relay based. One (1)
Recovery water pump control panel shall be provided.

2.00.00 CONTROL LOCATIONS

Control provision for various systems shall be as follows.

SL. PROPSED LOCATION OF CONTROL

SUB SYSTEM
NO. SYSTEM
(i) Bed Ash and Coarse Ash PLC control through MMI from Ash
Handling handling Plant control room.
No LCP envisaged.

(ii) Fly Ash Handling PLC control through MMI from Ash
handling plant control room.
No LCP envisaged.
(iii) Fly ash system equipment PLC control through MMI from Ash
(Conveying Air compressor handling plant control room.
& Instrument Air No LCP envisaged.
Compressor)
(iv) Silo area PLC control through MMI from Ash
handling plant control room as well as
from [Link] of RIO unit in silo
area shall be considered.
vi Recovery ash water The Recovery Water area control
pumping system system shall be relay based. One (1)
Recovery water pump local control
panel shall be provided.

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3.00.00 CONTROL PHILOSOPHY:

For Bed Ash and Coarse Ash Handling, Fly Ash Extraction and removal,
Operation of Fly Ash System Equipments, Sequential operation of Blowers,
Extraction Gates, and Pumps etc., common Programmable Logical Control
System with remote & local I /Os has been envisaged. The control system
shall be capable of communicating with client’s DCS (to be located in Central
Control Room at Power House Building) through Gateways for status
monitoring of selected parameters through Optical Fiber [Link]
synchronization of the system shall be done with client’s Master Clock to be
located at central control room. The converters and other hard wares as
needed at PLC end (for interfacing and time synchronization) shall be at
bidder’s scope.

4.00.00 OPERATION PHILOSOPHY:

Main ash Handling system control room shall be equipped with the following:-

a) PC based operator console (3 nos) with 21” color monitor, keyboard,

printer, mouse is envisaged. Please refer to attached control system
architecture drawing.

b) PC based engineering station (2no.) with 21” color monitor, keyboard,

printer, mouse is envisaged. Please refer to attached control system
architecture drawing.

c) A Back-up control panel at control room with requisite instruments are

envisaged.

d) Two colour printers.

Followings are to be taken care of:-

i) Provision of RIO unit in silo area.

ii) A dynamic mimic with LEDs depicting the entire system shall be
provided.

iii) Local Control Panels shall house necessary start/stop push buttons,
indicating lamps and selector switches,relays as required.

iv) Time synchronization of complete system with Master clock.

v) PLC system shall have interface with station DCS.

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vi) All HT motors shall be provided with requisite temperature and

vibration sensors at winding and bearings for monitoring.

vii) Control and monitoring of Electrical Distribution System shall be

implemented in PLC.

viii) Proper sized UPS System with battery back-up (Ni-Cd Battery) for
entire C&I System for 30 minutes power blackout shall be considered.

5.00.00 SILO UTILITY LOCAL PANEL (SULP)

Silo area control panel will be erected in silo area MCC room. This panel is
also having control switches, lamps etc. One silo unloading panel with
control switch and lamps is also there in silo unloading platform which will
bring the inputs & outputs to silo area control panel. The silo area operation
will be done from this panel however that can be monitored from AHP PLC in
main AHS control room. Provision shall be kept, so that inputs & outputs
and field instrument signals of silo area will be taken to AHP PLC through
RIO Unit located in Silo Area MCC room/Utility building.

6.00.00 SILO UNLOADING LOCAL PANEL (SUNLP)

One silo unloading local panel with control switch and lamps will be there on
each Silo unloading floor which brings the inputs & outputs to silo area
control panel. The silo unloading operation will be done from this panel

7.00.00 RECOVERY WATER LOCAL PANEL

One recovery water local panel area shall be provided in recovery pump
house. This will be relay logic based panel. Start/Stop P.B & Selector Switch
& indication lamps for ON/OFF/TRIP will be provided on this panel. The
starter of these drives will be in the recovery pump house area MCC. This
relay based control panel will be interfaced with the MCC. Two out of three
Recovery Water Pumps will run at a time for two units. If one motor trips the
third motor will be permitted to run.

8.00.00 LOCAL PUSH BUTTON STATION (LPBS)

Local push button stations will be provided (ONE FOR EACH MOTOR) to
facilitate deinterlocked field trial operation of the respective drives/equipment
and will be located near each respective drives/equipment .Each of the push
button station will incorporate one lockable “STOP” push button and located
near respective equipment.

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Local operation by-passing process interlocks of each drive / power actuator

can be carried out by putting respective “TRIAL-NORMAL” selector on HMI
in “TRIAL” position. In “NORMAL” position of the selector, the drive can be
started from MMI, through respective PLC; except three nos. Recovery
Water Pumps in recovery pump house, Priming Pump, if any & motors
related to Clarifier system. Stopping of these motors can be effected through
actuation of STOP switch at any control location irrespective of selection of
“NORMAL” or ‘TRIAL” position.

9.00.00 Manual Override of solenoid Valve

Local override operation knob to be provided on the solenoid valves.

10.00.00 GENERAL PHILOSOPHY OF OPERATION FOR PNEUMATIC

PRESSURISED ASH CONVEYING SYSTEM FROM ESP/APH TO ISH

In pneumatic pressure conveying system ash will be conveyed by master

slave arrangement. ESP hoppers below each pass of each field of any
particular unit may be envisaged to have master slave system. Similarly APH
hoppers may be chosen as per the arrangement provided by BTG vendor.
The conveying pipes emerging from each Master-slave arrangement shall
be connected to main conveying line by a number of 2/1 way switch valve.
Only one master-slave arrangement among a number of master-slave
arrangement connected with a particular ash conveying line will operate at a
time. This is achieved by aligning the switch valve towards the system
selected for operation.

Hence total master-slave arrangement evacuating at a particular time from

one particular unit will be equal to number of working conveying lines
emerging from that unit.

Hopper level probe:-

One number level probes is mounted in each surge hopper connected below
each ESP/APH. When selected in probe mode, a system conveying cycle
will normally start when the permissive level has picked up.

Switch valve alignment:-

Once any particular system is selected for operation, switch valves will align
as required. If the alignment is not confirmed with a preset time, respective
switch valve fault is declared. Then system logic will start scanning for the
next system in queue.

Pneumatic system start/stop push button

One number “Pneumatic conveying system start” and one number

“Pneumatic conveying system stop” buttons are devised on PC graphics.
Complete pneumatic ash handling system of an unit will be started as soon

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as the ““Pneumatic conveying system start” push button of that unit is

pressed. Now the conveying cycles of these systems will be started based
on their respective enabling conditions.

Whenever “Pneumatic conveying system stop” push button is pressed , all

the systems of that unit will complete their current conveying cycles in
progress and then stop.

OPERATION PHILOSOPHY OF ASH CONVEYING FROM HOPPERS TO

ISH

This system can run in timer or probe mode. One no. probe / timer selector
switch will be devised on Graphics for this purpose.

The pneumatic conveying system normally works in probe mode. In this

mode, once there is enough material in the hopper as checked by the level
probe in that hopper, the conveying cycle starts subject to the enabling
conditions are fulfilled.

In timer mode, level probe is by passed. On completion of one cycle, a cycle

gap timer picks up. For this time the system will remain inactive. After the
preset time, the next conveying cycle starts subject to the enabling
conditions being met.

Starting Procedure: -

The conveying system shall be started in the following sequence.

 Start / stop selector switches on the pneumatic panel as well as on

the graphics are put to start position.

 Select the mode of operation ( Level Probe / Timer )

 “Pneumatic conveying system “ button is put to start position.

NOTE: - Vent filter mounted on top of the selected ISH shall be automatically
switched ON when “Pneumatic conveying system “ button is put to start
position.

Enabling Conditions: -

 Pneumatically operated Valve between surge hopper and ash vessel

is properly closed. (Surge hopper is generally connected with
corresponding ESP/APH.).

 Vent valve is closed.

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 Ash Vessel ( vessel fitted below surge hopper)Pressure is low and

within preset limit.

 Conveying air pressure is within preset limit.

 Selected ISH level is not high.

System Operation: -

As soon as all the enabling conditions are met, system cycle will become ON
and a cycle ON indication is displayed on Graphics. If during the progress of
cycle any of the enabling conditions is not satisfied, then also the conveying
cycle progresses except for “Pneumatically operated Valve between surge
hopper and ash vessel is properly closed” condition, which is to be
rechecked before admitting conveying air in to the vessel.

If the system is selected for operation but its cycle does not start within a
preset time, cycle fail alarm will be generated and the system logic will now
start scanning for the other sub system in sequence.

Conveying Cycle:-

When start command is given and all the enabling conditions are met,
system will first operate one purge cycle. If during the initial purging, vessel
pr low is not achieved within a preset time. It will be considered as a Line
Block and the system will perform its line block cleaning cycle. Once the line
block is cleared, system will start its normal conveying cycle. At first, when
the cycle ON command comes, Pneumatically operated Valve between
surge hopper and ash vessel & vent valve opens by energizing
corresponding solenoid to allow material in to the ash vessel. After a pre set
time, Pneumatically operated Valve between surge hopper and ash vessel
& vent valve closes by de- energizing the corresponding solenoid .

Whenever Pneumatically operated Valve between surge hopper and ash

vessel & vent valve gets closed , closing confirmation, either generated by
close position limit switch or inflated seal back pressure shall come within a
preset time. If any closing confirmation of Pneumatically operated Valve
between surge hopper and ash vessel &/or vent valve is not achieved
within preset time,” valve not closed” or “seal fault” alarm comes and the
corresponding indication on the graphics starts flashing. In this case, the
operator shall check if only any re-adjustment is required or the seal has got
damaged and its replacement is required.

Once the valve close or seal pr OK is achieved, then the conveying air will
flow to the ash vessel by energizing the corresponding solenoid/valve .
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Once the minimum convey time is over and the ash vessel pr low is
achieved, the system resets after the preset time. After reset, the system will
remain inactive till the enabling conditions are achieved once again.

Ash vessel pressure is monitored through pr. switch. This pressure switch
ensures that the vessel pressure remains within preset limits. When ash
vessel pressure goes above a set point, conveying air valve is closed after a
time delay ( adjustable). When the pressure falls below a preset level
(implied no line blockage), convey air valve is opened with a short gap
(adjustable) and conveying restarts. This pulsing keeps going on till the cycle
is completed or a line block condition occurs.

If the minimum convey time is over and the vessel pressure low is not
achieved, then the conveying air flow continues so that the line can be
cleared. If the line is till not cleared .i.e. vessel pr low is not achieved within
the preset time, the system fault alarm along with line block indication
appears. This is a line block condition and the system locks to that condition
(for particular master-slave arrangement) till the corrective action is taken by
operator. However system logic starts scanning for next enabling condition.

Other Facilities:-

i) Probe Override Push Button:

A probe override push button is provided on the PC graphics as well

as on the air lock vessel/ nuvafeeder / denseveyor pneumatic panel.
A cycle can be started by pressing this button momentarily even
when sufficient material is not filled up to the permissible level in the
hopper. This button is normally used to evacuate the hopper.
Whenever, this command is given, system will first complete the
current conveying cycle and then the next cycle will start immediately
based on this command.

ii) Purge Push Button:

A purge push button is provided on the PC Graphics as well as on

the air lock vessel/ nuvafeeder / denseveyor pneumatic panel. On
pressing the purge push button momentarily, the system shall cycle
once without opening the Pneumatically operated Valve between
surge hopper and ash vessel .i.e. the cycle operates without taking
any material in to the system.

System Faults: -

Following alarms are devised on PC graphics for pressurized pneumatic ash

conveying system:

i) Selected Ash Silo Level High Alarm.

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Control Action:

Current conveying cycle from the systems those are conveying will be
completed and further conveying is stopped.

ii) Selected ISH ash Level High High Alarm.

Control Action:

Current conveying cycle from the systems those are conveying will be
completed and further conveying is stopped. High-High indication on
selected ash silo will start fast flashing.

iii) Pneumatically operated Valve between surge hopper and ash vessel
are not properly closed {or the path between surge hopper and ash
vessel is not cut off properly (ie passing is there)} Alarm.

The alarm will be annunciated when the said valve close command is
given and the same is not achieved for a pre determined time

Control Action:

Visual alarm.

System cycle is stopped till corrective action is not taken.

iv) Convey air pressure low alarm.

Definition:

This alarm will be annunciated if Conveying air supply pressure is low

for more a predetermined time.

Control Action:

Visual alarm.

System cycle is stopped till corrective action is not taken.

v) Line Block Alarm.

This fault occurs when vessel pressure low is not achieved even after
preset time

Control Action:

Visual alarm.

System cycle is stopped till corrective action is not taken.

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vi) Cycle Fail Alarm.

This alarm will be annunciated if system is selected but cycle ON has

not come within the preset time .

Control Action:

Visual alarm.

System escapes that particular master-slave system and the logic

starts scanning of the next system available in sequence.

11.00.00 Operation Of Conveying Air Compressor

The Starting/Running Permissive for REMOTE operation of the compressors

is obtained through PLC by ensuring the following:

i) The isolation valves on selected conveying path are open &

“THROUGH”.

ii) Cooling water supply pressure for compressor is ”NORMAL”.

iii) Cooling Water flow is adequate.

12.00.00 Operation Of Ash Silo Vent Filter Pulse Jet System

The pulse jet sequence circuit of Ash Silo vent filter gets activated by
actuation of “F.A. Pressure SYSTEM START” command from HMI or, ”Silo
Fluidising Air Blower START” command from Silo Unloading Panel . This will
energise a local controller to carry out pulse jetting of the vent filter in an
automatic timer based sequence.

13.00.00 Water & Slurry System

Operation of Dust conditioning water pump. , HP ash water pump and

recovery Water Pump

a) The following starting & running permissive will be effective during

operation of Dust conditioning water pump. HP ash water pump and
recovery Water Pump

i) Starting Permissive

- Ash Water Sump level is at or above preset “LOW”.

ii) Running Permissive

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- Ash Water Sump level is above preset “DANGER

LOW”.

14.00.00 Operation Of Various Sump Drainage Pumps

a) The following starting & running permissive will be effective for

operation of the Drainage Pumps :

i) Starting permissive

- Drain Sump level is at or above preset “LOW”.

ii) Running permissive

- Drain Sump level is above preset “DANGER LOW”.

- Respective Drainage pump seal water supply pressure

becomes “NORMAL” within a preset time from pump
starting.

15.00.00 Fluidising Air System

ESP Hopper Fluidising Air-Blower

Starting permissive:

Respective Blower is selected and its “START” command is given from HMI.

16.00.00 ESP Fluidising Air-Heater

a) The following starting and running permissive will be effective during

operation of heaters –

Starting permissive:

Any Fluidizing Blower is `ON’

Temperature is below `HIGH’ as sensed by corresponding

instrument.

Running Permissive:

Temperature is below `HIGH’ as sensed by corresponding

instrument.

17.00.00 Ash Silo Fluidising Air Blower

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Starting permissive:

Respective Blower is selected and its “START” command is given from Silo
Utility Panel.

18.00.00 Ash Silo Fluidising Air-Heater

a) The following starting and running permissive will be effective during

operation of heaters –

Starting permissive:

Any Fluidizing Blower is `ON’

Temperature is below `HIGH’ as sensed by corresponding

instrument.

Running Permissive:

Temperature is below `HIGH’ as sensed by corresponding

instrument.

19.00.00 Ash Silo Unloading

Continuous silo level shall be shown by installation of level transmitter.

Preferably, the silo fluidising should be started 30 minutes ahead of starting
ash unloading from silo and be kept ‘ON’ so long as the unloading system is
‘ON’.

20.00.00 Silo Unloading By Rotary Unloader

a) The following starting and running permissive will be effective for

operation of Rotary Unloader -

i) Water supply pressure to unloader is NORMAL i.e. above a

preset value sensed by a pressure switch.

ii) Instrument air pressure is at or above a preset value sensed

by Pressure switch.

b) The following opening and running permissive will be effective for

operation of the Ash Feed Valve -

i) Rotary Unloader is RUNNING.

c) The conditioning water to ash conditioner will be controlled by a

manual globe valve provided in its water supply line.

21.00.00 Level Control for Ash Slurry Sump

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Bidder shall furnish the followings:

22.00.00 Sump Make up

Suitable Control Valve Complete with all associated accessories (preferably

pneumatic operated) on the make up water line (Low Pressure Ash Water)
actuated from sensing of sump level shall be provided.

23.00.00 Level Control for Ash Water Sump

Bidder shall furnish the following :

Continuous sump level shall be shown by installation of level transmitter. Also

the following shall be available.

23.01.00 High" level & "Low" level alarm in respective control panel.

23.02.00 "Very Low" level alarm with tripping of all running Ash Water Pumps subject to
fulfillment of both sensing through level indicator and actuation of Float
Switch.

23.03.00 Level indication device to monitor level in the remote control panel along with
Local Arrow Scale device.

23.04.00 Suitable Control Valve complete with all associated accessories (preferably
pneumatically operated) on the make up water line (from clarified Water
Source/Raw Water Source) actuated from sensing of sump level shall be
provided.

24.00.00 Pressure indicators, Flow indicators, Level indicators, Pressure Switches etc.
as & where required for smooth functioning of the system shall be furnished
by the bidder.

24.01.00 All complete wiring & hardwares shall be provided by the bidder so that it can
be readily connected to the purchaser's switchgear wherever required.

24.02.00 Besides above so far described which is the min. requirement, the bidder shall
include in his proposal a detailed & complete description of the Control
System for safe, satisfactory & best operation of the plant complete with
Schematic diagrams, description & function of component, rating etc.

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