THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
OROT-RABIN POWER STATION, UNITS 1, 2, 3 and 4
SPECIFICATION MM-2701
PLANT CONTROL & MONITORING SYSTEM (PCMS)
ANNEXURE "B"
PROJECT SPECIFICATION
THE ISRAEL ELECTRIC CORPORATION LTD. Engineering Division
B - 1 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
Annexure "B" Table of Content
1. Purchaser 2. Name of project 3. Location of project 4. Scope of work 4.1 Scope of Engineering and Supply 4.2 Special Equipment, Tools and Instruments 4.3 Contractor Services 4.4 Work by Others (Facilities and Services to be provided by Purchaser) 4.5 Terminal Points and Terminal Connections 4.6 Commissioning and Combustion Tuning 4.7 Guaranteed Performances and Testing 5. Supplements 6. Standards and Codes 7. Quality assurance and quality control 8. Shipment and Handling of Goods and Documentation 9. Safety, Noise, Environment and Loading Requirements 9.1 Safety 9.2 Noise 9.3 Environmental data 9.4 Earthquake Loads 10. Project system security standard specification 11. Technical Documentation 12. Spare and Renewal Parts 13. Existing Power Station Description 13.1 Existing Power Station Description 13.2 Existing main systems included in project's scope 14. Technical Requirements 14.1 General requirements 14.2 Functional requirements 14.3 System architecture 14.4 Reliability, Availability & Maintainability (R.A.M.) 14.5 Redundancy 14.6 PCMS Embedded Cyber Security (PCMS-ECS) 15. Plant Control & Monitoring System Design Requirements 15.1 Combustion Control System 15.2 Burner Management System (BMS)
PCMS Annexure B June 2017 B - 2 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal 16. Control System Equipment Requirements 16.1 Accuracy and Resolution 16.2 Process Data Highway 16.3 Input/Output Equipment 16.4 Processing Controllers 16.5 Communication links 16.6 Auxiliary Equipment 16.7 Power Supplies 16.8 Human-Machine Interface 16.9 Application Requirements for Data Processing and Monitoring 17. Electrical Requirements
PCMS Annexure B June 2017 B - 3 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal SPECIFICATION for Plant Control & Monitoring System (PCMS)
1. PURCHASER: The Israel Electric Corporation Limited.
2. NAME OF SITES: Orot-Rabin Power Station, Units 1, 2, 3 and 4
3. LOCATION OF SITES: Orot-Rabin, Near Hadera On the Mediterranean Sea Shore.
4. SCOPE OF WORK:
General
The Scope of Work for this specification includes Engineering, Equipment and Services for a new Plant Control & Monitoring System (PCMS) and modernize main HMI for Orot-Rabin Power Station for one (1) Unit (as basic scope) and for three (3) additional Units (optional scope). The project does not include replacement of field devices and field cables. It is essential that the new control equipment shall be compatible with the existing field devices, especially the drive units which are controlled by pulses.
The scope of work shall include, but shall not be limited to the following:
4.1 Scope of Engineering and Supply:
Within the scope of engineering and supply the contractor shall, as applicable, design, develop, engineer, manufacture, preserve, assemble, tune, shop test, pack and furnish with export packing the following:
4.1.1 Basic and Optional Scope of Engineering and Supply, subdivided as follows:
4.1.1.1 Basic Scope of Supply for one (1) Unit, of Orot-Rabin Power Station.
The Plant Control & Monitoring System shall include, as a minimum, the following:
a.1 Complete new System, based on DCS technology, including the following:
PCMS Annexure B June 2017 B - 4 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal a.1.1 Combustion Control System (CCS) in accordance with existing Combustion Control System (CCS) function requirements.
a.1.2 Burner Management System and Boiler Protection System (BMS), for ignition gas, light oil (first elevation only), heavy oil and coal firing to allow safe, reliable and efficient operation of the Unit.
a.2 New Human Machine Interface (HMI), based on compatible hardware and software platform include, as a minimum, the following:
a.2.1 Two (2) Operator Workstations, each with four (4) 24" screens, desktop mounted with touch screen option.
a.2.2 Two (2) Operator Workstations, each with two (2) 55" Large Screens.
a.2.3 Two (2) Shift Engineer Workstation, each with one (1) 24" screen, desktop mounted.
a.2.4 Three (3) Engineering Workstations, each with one (1) 24" screen.
a.2.5 Reserved.
a.2.6 One (1) pair (for redundant configuration) of servers for data transmission to DPMS system (provided by others) using OPC.
a.2.7 Three (3) A4 color laser printers.
a.2.8 Back-up devices including a backup server and local software shall be provided to enable periodic backup of the data and complete image backup of the workstations.
a.2.9 Data storage server for Historical data for a minimum period of one year of data.
a.2.10 All the required up-to-date software: programs and applications to ensure performance of complete integrated system and of its subsystems according to this specification (including licenses). The application software shall include the application software (protocol conversion) for all the communication interfaces and the development of 100 graphic displays.
PCMS Annexure B June 2017 B - 5 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal a.2.10 Emergency panel with Emergency pushbuttons and additional hardwired Control devices.
a.2.11 All the hardware and software which provide the implementation of Embedded Cyber Security (ECS) requirements, as stipulated in paragraph 14.6 and throughout this specification.
a.2.12 All the necessary hardware and software in order to synchronize the system with an external IRIG-B format signal generated by Plant GPS clock per subsystem.
a.2.12 Two (2) firewalls to protect the PCMS Operation Network from external connection.
4.1.1.2 Optional Scope of Supply for up to three (3) additional Units of Orot Rabin Power Station, to be exercise for each Unit.
The optional Scope of Supply will be similar to the Basic Scope, item 4.1.1.1 above.
4.1.1.3 Contractor's Basic Scope of Design
The detail design for the implementation of the new/retrofitted control systems shall be performed by the Contractor and shall include, but shall not be limited to:
a. System configuration design and implementation, based on the logic provided by Purchaser (IEC) or different manufacturers, to ensure that all inputs/outputs required by the logic, are engineered into the new system.
b. Evaluation of the existing equipment to ensure that the new/upgraded equipment meets the project requirements. The Contractor shall be also responsible for the Coordination between the new Combustion control and the existing Turbine control for maximum stability and Unit response.
c. All hardware design, software development and implementation of the new Plant Control & Monitoring System.
PCMS Annexure B June 2017 B - 6 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal d. Cable listing of all internal cables for data highways and cables between control cabinets or other equipment forming part of Contractor's Scope of Supply.
e. Development of a database for all tags that are required to be implemented in the Plant Control & Monitoring System, including inputs, outputs, calculated values, graphic tags, etc.
f. Design and implementation of the graphics for the Operator Interface (display content, menus, object dynamic behavior, colors, etc.) as correlated with system database.
g. Establishing procedures and instructions as may be required for the systematic dismantling of the old equipment.
h. Establishing procedures and instructions as may be required for the orderly installation of the new equipment.
i. Establishing grounding requirements and providing procedures and instructions for proper operation of the Equipment. The Contractor will provide an evaluation of IEC's existing grounding system as part of the Field Service scope.
j. Establishing an itemized priced list of recommended test and spare equipment (if necessary) to be used in maintaining, troubleshooting, calibrating, and repairing of the Control System and associated hardware provided per this specification.
k. Engineering for all the communication interfaces within the Plant Control & Monitoring System and for communication interfaces with DPMS (supplied by others), including hardware characterization, software development, protocols conversion, HMI, etc.
l. The Contractor will take into consideration that if one Unit is in operation and the other is in the maintenance mode, the functions for the common equipment should be in operation continuously.
The Contractor shall organize Design review (DR) meetings for each stage of design, for each system.
4.1.2 The Equipment for each Unit shall be supplied complete with appurtenances and accessories as specified herein, to form a complete system which will achieve
PCMS Annexure B June 2017 B - 7 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal and assure safe and reliable operation with best overall performance at all loads and modes of operation. All components, appurtenances and accessories shall be of proven design.
4.1.3 Detailed Scope of Supply: The Plant Control & Monitoring System shall be of DCS type, based on state of the art technology, incorporating an integrated design.
The System shall include:
a) Processing cabinets, for I/O cards, processing units and marshalling/termination cabinets for field cables connection. The Contractor should consider using the existing control and instrumentation field cables (due to the infrastructure and space problems), meaning that existing termination cabinets shall be used for marshalling (if applicable), or that new cabinets shall be designed according to the existing cables layout, otherwise the Contractor shall consider using I/O cabinets in Central Electronic room and define additional space required for the control, communication and computer's equipment. The solution shall be reflected in the proposal. The cabinets shall be secured with lock and provided with cooling fans for heat dissipation.
b) All computers, servers and communication devices shall be located in Computer Room or Electronic Room and not in the Main Control room. Therefore, cabinets required to accommodate these computers shall be supplied. The Contractor shall also provide all the necessary devices and cables (such as KVM extenders) connecting computers to their related screens, keyboards and mice (the distance between them is approx.200m).
c) Every cabinet housing the servers and computers shall have a local maintenance station enabling local support including a keyboard & screen.
d) All redundant power supplies, power distribution and power regulating devices.
e) All the required signal conditioning and interfacing equipment, transducers, interposing relays, etc.
PCMS Annexure B June 2017 B - 8 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal f) Redundant Data highways and redundant communication interfaces between highways. Cabinets for installation of communication equipment (switches, routers, bridges, etc.) shall be provided.
g) All the required Workstations should provide a complete integrated HMI (single window to process) according to this specification.
h) Printers, displays, keyboards, mice, data storage and back up devices.
i) All the required software: programs and applications to ensure performance of complete integrated system and of its subsystems according to this specification. Complete programming, including flow-charting, coding, program entry, debugging and simulation shall be provided. The System shall be based on the Contractor's last version of equipment available on the market at the bid date.
j) Development and implementation of 100 process graphic displays per Unit.
k) All the hardware and software which provide the implementation of Embedded Cyber Security (ECS) requirements, as stipulated in paragraph 14.6 and throughout this Specification, for the complete PCMS.
l) Emergency Panel with all the necessary Emergency Pushbuttons and other Hardware control devices.
m) All the necessary hardware and software in order to synchronize the system with an external IRIG-B format signal generated by Plant GPS clock.
n) All the prefabricated cables interconnecting the components within Contractor's Scope of Supply.
o) Any special test equipment required for operation and maintenance of the system (if required).
p) All the necessary hardware and software for communication interfaces to external systems (external cables will be provided by Purchaser).
PCMS Annexure B June 2017 B - 9 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal q) The System shall include 20% (for each Subsystem) implemented spare capacity for I/O’s (I/O's termination facilities, I/O modules, power supplies, internal wiring, etc.). The Contractor shall include also at least 20% additional spare capacity for future expansion. Specifically this means spare space to mount I/O modules and their associated terminal units (the extra spare I/Os and extra space shall be provided for each type of I/O). In addition, spare capacity within the Workstations (both Operators' and Engineers'), Servers to expand the database and application programs.
4.1.4 The Contractor shall be responsible to ensure that the equipment supplied under this Contract, shall perform the entire scope of functions and assignments detailed or implied by this specification, individually, as well in combination with the existing equipment. The Contractor shall organize Site survey for full understanding of the existing system's function/interfaces and Design Review (DR) meetings for each stage of project, for each system.
4.1.5 Components that are herein specified in regard to manufacturer brand and model or type shall be considered the standard of supply. The Contractor may make an appropriate substitution, but all substituted Components offered shall be noted as EXCEPTIONS to this Specification and are subject to review, comment, and approval by the Purchaser.
Additionally, while everything else being equal and without derogating from Contractor's responsibilities under the Contract, the Contractor shall endeavor to include in the scope of design and supply, components and accessories manufactured in Israel.
4.1.6 Contractor shall provide, in the required format and form and in a timely manner, all documentation required by this Specification and/or required by applicable Standards and Codes and/or as specifically detailed in the Documentation Submission Schedule (DSS), Annexure "J". A consistent nomenclature shall be used project-wide in naming all component parts within the Scope of Work. This shall apply to all drawings, Instruction Books, Bill of Materials, special instructions, etc. Engineering design shall commence immediately after Contract award. The cost of correcting inconsistent nomenclature shall be borne by the Contractor.
4.1.7 Changes in design already approved by the Purchaser are normally unaccepted. However, should such changes become necessary on an exceptional basis, the
PCMS Annexure B June 2017 B - 10 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal Contractor shall obtain the Purchaser's approval prior to introducing any such change.
4.2 Special Equipment, Tools and Instruments (if required)
4.2.1 Contractor shall provide all special equipment, tools and instruments required for safe and secure transport of all components from ex works to final destination, and for test and maintenance of Equipment provided under this Contract. Said equipment, tools, and instruments should be in Contractor's Proposal where it should be clearly stated which are provided on a loan basis and which are included in the Contract Price.
4.2.2 The Contractor shall furnish all necessary special tools, instruments and/or test equipment which are required to fulfill the approved test procedure for equipment tested by Purchaser.
4.2.3 Maintenance equipment and tools provided under this specification shall be new and of best quality. They shall be shipped to the job site in a suitable separate box, clearly marked with the name of the equipment they are intended for.
4.3 Contractor Services
The Contractor shall provide the services listed in the following sub-articles as part of the basic Scope of Work or as Purchaser’s option, at the per diem or lump sum rates, all as stated in the Summary of Prices and Delivery Schedule, Annexure “C1”. Field personnel provided by the Contractor shall be capable and qualified to perform the required duties to the satisfaction of the Purchaser. They shall be vested with authority to make decisions that could affect the status of the Equipment and which are binding on the Contractor.
4.3.1 Erection Services:
Contractor shall provide the services of competent advisors to direct and instruct Purchaser's personnel during erection, including, without limitation, identifying the equipment, unpacking, intermediate storing, erection sequencing and erection checking as may be required to assure proper and successful erection and installation of the Equipment provided under this Specification.
4.3.2 Commissioning and Start-Up Services:
Contractor shall provide the services of competent engineers to calibrate, tune, commission the Systems and to direct Purchaser's personnel and assure proper,
PCMS Annexure B June 2017 B - 11 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal complete and successful commissioning, starting, placing into service of the Equipment provided under this Contract with the balance of equipment at the related power station Unit(s).
4.3.3 Training:
Contractor's personnel shall conduct a thorough training course on site pertaining to the equipment furnished under this Specification, for Purchaser's personnel (operation, maintenance and engineering/design teams), covering, without limitation, correct design, start-up, safe operation at all modes of operation, safe shutdown and general maintenance. The Contractor shall verify that the trainees are completely familiar with all phases of such procedures and are capable of operating and maintaining the equipment successfully.
In addition, Contractor’s personnel shall conduct a thorough training course for Purchaser’s maintenance personnel with respect to The Plant Control & Monitoring System Equipment, including hardware and software of control logic system. The course shall be conducted at the Contractor’s or Subcontractor’s sites before conducting Equipment Field Performance Test. The Purchaser’s maintenance personnel, qualified through said training course, shall take part in Contractor’s or Subcontractor’s factory tests of the Control Equipment.
4.3.4 Acceptance Test
4.3.4.1 Inspection and Testing - General
The Purchaser shall have the right at all reasonable times to inspect and test the work. Contractor shall make all necessary arrangements and provide all reasonable facilities and access for such inspection and testing, either at Contractor's shop or offices or at the shops or offices of any manufacturer where any part of the work is being designed, fabricated or manufactured.
The Contractor shall receive the list of anticipated inspections by the Purchaser and shall give ample notice as to the time and place when each part of the work will be ready for such inspection. Purchaser may reject any part of the work found to be defective or not in accordance with the Contract. Such inspection by the Purchaser shall in no way relieve the Contractor from his obligation to furnish the work in accordance with the Contract.
In the event the Contractor fails to provide the Purchaser with reasonable
PCMS Annexure B June 2017 B - 12 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal facilities and access for such inspections and if, in the opinion of the Purchaser, it is necessary to dismantle the equipment for such inspection, then Contractor shall bear the expense of such dismantling and reassembly.
The Factory Testing shall be performed, according to Annexure “D” - Equipment Performance Guarantees, for the new equipment and subsystems within the Contractor's Scope of Supply that can be mounted on factory: e.g. Combustion Control, Boiler Management System and the related HMI and communication equipment (data highways, servers, HMI's, etc.). The Site Field Test shall be performed for the complete system, including new and existing/upgraded equipment and subsystems.
4.3.4.2 Factory Acceptance Test (FAT) shall be conducted according to Annexure “D” - Equipment Performance Guarantees.
4.3.4.2.1 Contractor shall perform a complete cyber security test prior to the FAT according to paragraph 14.6.
4.3.4.2.2 The Contractor shall perform, according to Contractor's Standards, a complete functional test of the Systems at the factory, to assure that the System components are properly interconnected and that the control strategy is properly configured. The Purchaser shall participate in the FAT. The Purchaser shall be notified of the test dates in writing at least sixty (60) days prior to the tests and shall be given a list of the proposed test procedures with that notification. FAT procedures should be provided for Purchaser (IEC) approval. All system subassemblies such as modules, power supplies, workstations, disks, peripherals, etc. or subassemblies identical in design and construction shall have undergone tests under ambient temperature conditions as specified herein without malfunction or degradation of performance.
4.3.4.2.3 The test shall demonstrate that all the specified types of modulating and logic functions, including unit, function and protection levels, are satisfactorily accomplished. The demonstrations shall include the operator stations with their keyboards, and any other equipment as well as all inter-connections within and between equipment cabinets. Input and output signals of the field equipment not available during the preliminary test, shall be simulated by the Contractor, using his equipment (hardware and software).
Each type of drive control loop shall be tested with simulation equipment.
PCMS Annexure B June 2017 B - 13 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
4.3.4.2.4 Contractor's tests shall also include the following:
a. Physical inspection for conformance to drawings and appearance of equipment;
b. Demonstration of the proper functioning of all the types of hardware by a thorough exercising of each device, including CPU's and distributed processors, individually and collectively;
c. Demonstration of a complete system software generation; the system being tested should be generated from scratch using the resource media provided;
d. Demonstration of the proper functioning of all the software, including test cases with normal and exception data;
e. Simulation of alarm(s) and status change conditions;
f. Simulation of a subset of process inputs from convenient test panels or simulator, which allow individual analog inputs to be varied over the entire input range via individual setters and individual digital and pulse inputs to be acquired;
g. Demonstration of input conversions, calibrations and transformations;
h. Simulation of input noise and transient conditions;
i. Deleted;
j. Demonstration of all HMI interface functions in English and Hebrew;
k. Simulation of failure situations and failure of each component that is redundant (controllers, communication, power supplies, workstation(s), etc.);
l. Demonstration of data base management software of the Engineering Station, including tests to verify on-line addition/deletion of points and modifications to various system and application data files;
m. Demonstration of the display generator/editor, log generator/editor and other software maintenance functions;
PCMS Annexure B June 2017 B - 14 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal n. Demonstration of the Graphic Displays in English and Hebrew;
o. Demonstration of on-line editing, controller programming, testing and integration;
p. Demonstration that average and peak load system timing requirements have been met while exercising all vendor-supplied software;
q. Demonstration of the use of on-line and off-line diagnostics and test programs; Demonstration of simulated DHW error detection and recovery. Simulation of all interfaces (links) from other systems. Simulation of IRIG-B synchronization. Demonstration that spare capacity and response time requirements have been met, including execution of a simulated maximum sized application program;
r. 1. Recovery from AC power source failure, if applicable. r. 2. Recovery from DC power supply failure.
s. Random inspections to verify the accuracy of hardware and software documentation;
t. Demonstration of the accuracy of the system performance monitoring software.
Contractor shall supply detailed test reports including the results of items above.
4.3.4.2.5 Changes necessary for the system to perform the specified functions shall be made in a permanent on-line manner and re-tested before completion of the test activities. All costs arising from factory simulation tests, including replacement of damaged materials, shall be borne by Contractor. The Contractor shall submit a written test report.
4.3.4.2.6 When the Contractor has completed his simulation, the Purchaser reserves the right to perform a "hands-on" demonstration of all the equipment. When the Purchaser is satisfied with all the above tests and test report is signed by both parties, the FAT is considered complete.
PCMS Annexure B June 2017 B - 15 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal 4.3.4.2.7 Prior to shipment, all necessary components of the system shall have experienced power-on-operation of at least thirty (30) days unless otherwise agreed. The test shall include a two hundred (200) hour continuous run and provide a report of any failed items during this period. The assembled system includes I/O circuitry cabinets, communication devices, peripherals such as printers, digital displays, recorders, screens, etc., workstations of all kinds and the data highway, with all system software configured, uploaded and running.
4.3.4.2.8 Factory tests shall be scheduled early enough before shipping, to permit debugging the hardware and/or software problems which may occur during the tests. Tests shall cover all functions to be performed by the System.
4.3.4.2.9 Upon satisfactory completion of the System tests, the equipment shall be considered completed and no hardware shall be changed, replaced substituted or otherwise altered except upon written agreement with the Purchaser. Under no circumstances may the System hardware be used to supply parts for tests or substitution in other tests in the Contractor's facilities.
4.3.4.2.10 All procedures during installation, assembling, connecting, loading and testing during FAT, packing and shipping shall be in accordance with Security of critical project performed by vendor abroad, supplement 5.1.5.
4.3.4.3 On Site Field Test – Site Acceptance Test (SAT) shall be conducted according to Annexure “D”.
4.3.4.3.1 The Purchaser will run an extensive field performance test, which shall be carried out after the complete system has been fully erected, installed, connected to mounted field equipment and placed in service. The purpose of this test is to demonstrate compliance of the delivered system with plant requirements. Criteria and procedures for Acceptance Testing are to be developed by Contractor and mutually agreed upon by Purchaser and Contractor. The successful accomplishment of this field test shall certify the unqualified acceptance of the delivered system and mark the beginning of the warranty period.
4.3.4.3.2 The following procedure shall apply: Submission of a Test Plan
PCMS Annexure B June 2017 B - 16 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal The Contractor shall prepare a detailed plan of the suggested tests to be carried out on site. The plan shall follow the factory performance test and shall include:
a. A set of tests to verify that system performance is equal to the performance during factory tests.
b. A start-up and on-line tuning procedure of all loops.
c. One cycle of plant start-up and shut-down.
d. An uninterrupted running of the entire control system (including as many plant start-ups and shut-downs as dictated by process considerations) for a period of 4 weeks. Any interruption of the power generation due to system failures, shall cause a renewed counting (repetition) of the 4 weeks period.
e. A set of tests (performance tests) to verify that the guaranteed values are fulfilled.
4.3.4.3.3 Testing
The Contractor shall provide all special equipment, tools and instruments needed for the acceptance tests. The Purchaser will document every single step of the tests performed, including: date, identification of logic channel, functions and devices tested, test results, comments and signature. Unsuccessful tests, factory acceptance test as well as on-site field test, shall be repeated after the defect (whether in design, hardware, software, documentation or installation) has been rectified by the Contractor at his own expense. Contractor shall rectify any defects within a reasonable period not exceeding 2 weeks. Replacement parts are to be supplied at the expense of the Contractor.
4.3.4.3.4 Acceptance Document
Upon successful completion of the on-site tests, an acceptance certificate will be issued by the Purchaser. Purchaser will issue a qualified acceptance document if 98% or more of the performed tests were successful, under the provision that the Contractor shall rectify any outstanding defects within 3 months.
PCMS Annexure B June 2017 B - 17 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal An unqualified acceptance document will be issued if less than 98% but more than 80% of the tests were successful. No acceptance document will be issued if less than 80% of the tests were successful.
4.4 Work by Others (Facilities and Services to be provided by the Purchaser)
In performing its duties the Contractor shall not be required to provide facilities, services and equipment as detailed below [further details with respect to Purchaser's undertaking regarding qualifications, quality, quantities and scheduling should be in accordance with Contractor’s information defined in scope of design and should be stated in Contractor’s proposal]:
4.4.1 Purchaser's Scope of Supply:
- Cables (Power, instrumentation and control) - Cable Trays - Fire detection and protection system.
4.4.2 Purchaser's Scope of Design:
- Designating tag numbers for Control cubicles, electrical and control equipment, junction boxes, cables, drawings, etc. - Electrical design, including connections to field equipment, junction boxes, external connections, etc. - Electrical feeding to Contractor's electrical equipment. - Electrical Rooms: - General arrangement drawings. - Data for civil design. - Equipment erection and base frames. - Cable tray system. - Cable routing. - Grounding system external to the PCMS - Electrical installation drawings and documentation. - Fire stops and fire breaks. - Lighting and power system. - Air condition system. - Fire detection and protection system. - Basic I/O list - Graphic displays' drafts - Control Logic Diagrams (CLD)
4.4.3 Purchaser's Erection Services
PCMS Annexure B June 2017 B - 18 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
Purchaser shall provide all the necessary labor force, general purpose tools and facilities in order to dismantle, erect and install the Equipment provided under this Specification, following Contractor’s instructions and according to Contractor’s procedures and supervision.
4.4.4 Commissioning, Start-up and Performance Test Services
Purchaser shall provide all the necessary labor force, general purpose tools and facilities in order to perform commissioning and start-up of the Unit and to perform performance tests following Contractor’s instructions. Contractor shall take into account that due to the broad scope of the System, several experts may be required to be in the field simultaneously.
4.5 Terminal Points and Terminal Connections
Contractor shall terminate the Equipment provided under this Specification at the agreed upon terminal points with the appropriate terminal connections taking into consideration that:
4.5.1 All electrical and control cabinets shall be terminated at the terminal blocks for incoming and outgoing cables.
4.6 Commissioning and Combustion Tuning
The commissioning and combustion tuning of the Equipment shall be conducted in accordance with the provisions set forth in Annexure “D” to the Contract – Equipment Performance Guarantees.
4.7 Guaranteed Performances and Testing
The performances of the Equipment shall be verified by a site test in accordance with the provisions set forth in Annexure “D” to the Contract – Equipment Performance Guarantees.
PCMS Annexure B June 2017 B - 19 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal 5. SUPPLEMENTS:
The following supplements are attached hereto and their requirements form an integral part of this specification - to the extent they are consistent and conform with the requirements specifically set forth herein. In the event of a variance between the requirements of the Supplements and the particular requirements set forth in the Specification, the requirements specifically set forth in the Specification shall take precedence.
5.1 Purchaser's general documentation, quality assurance, quality control requirements:
5.1.1 Standard 01-1E Standard Specification for Contractor’s Drawing and Data Transmittal.
5.1.2 Q-APP-02-PR: Quality requirements from suppliers.
5.1.3 General Security Safeguard Requirements for Control and Data Acquisition Systems in IEC - Power Stations.
5.1.4 Detailed Security Safeguard Requirements for Control and Data Acquisition Systems in IEC - Power Stations– Project MM-2701 [Later].
5.1.5 Security of critical project performed by vendor abroad [Later].
5.2 Purchaser's standard electrical requirements and data sheets:
5.2.1 EPD-A.03/04 Control Cubicles – Electrical Wiring Requirements
5.2.2 Deleted.
5.2.3 EPD-A.20/04 Contact Rating of Mechanical, Electromechanical and Solid State Devices
5.2.4 EPD-A.19/04 Nominal Voltage, Frequency and Phase rotation of Instruments and Control units
5.2.5 EPD-2/99 Standard requirements for painting and corrosion protection of electrical equipment.
5.2.6 EPD-B.32/05 PLC/DCS Based Control Systems Control and Operation of Typical Devices.
PCMS Annexure B June 2017 B - 20 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
5.3 Purchaser's drawings
5.3.1 System configuration Drawings: MD0/05-I15-N00001-IC, Rev 01
5.3.2 Functional diagrams
5.3.3 Electronic Room general arrangement
5.3.4 Control Room arrangement
5.3.5 Typical logic diagrams (final elements)
6. STANDARDS AND CODES:
6.1 Standards and Codes referenced in this Specification and in the Supplements to this Specification form an integral part of this Specification - to the extent their requirements are consistent and conform to the requirements specifically set forth herein. All such Standards and Codes are to the issue, including all amendments, supplements, etc., current as of the date of the Contract, unless indicated otherwise. In the event of a variance between the requirements of the Standards and Codes and the particular requirements set forth in the Specification, the requirements specifically set forth in the Specification shall take precedence.
6.2 The Equipment to be provided under this Specification, including all appurtenances and accessories, shall be designed, fabricated, inspected, tested, stamped and preserved to the extent indicated in said referenced Standards and Codes. Where this Specification does not include such reference, The Equipment, or any of its components, shall be designed, fabricated, inspected, tested and preserved, as applicable, to comply with currently recognized International and/or Contractor's Standards, whichever are tighter and more restrictive.
6.3 The Contractor may propose Standards and Codes as alternates for, or additions to those specified herein. A copy of each proposed Standard and code, if any, shall be submitted (in English) for Purchaser's approval. In case Purchaser's approval is granted, the Contractor shall remain responsible for the compatibility of the design and the physical interfaces between the supplied Equipment and the equipment supplied by others.
PCMS Annexure B June 2017 B - 21 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
6.4 The Purchaser shall assist Contractor in identification of Israeli codes and standards applicable to the Work. In all cases Contractor shall adhere to and comply with the requirements of Israeli official standards found to be more restrictive than those specified herein.
6.5 Subject to the provisions stated above, the equipment shall be designed, manufactured, erected, tested operated and maintained in accordance with the standards, regulations, directives and publications of the following agencies and organizations:
ANSI: American National Standards Institute, Inc. NEMA: National Electrical Manufacturer's Association. ABMA: American Boiler Manufacturer's Association. NFPA: National Fire Protection Association. ISA: Instrumentation, Systems and Automation Society IEC: International Electrotechnical Commission. NEC: National Electrical Code. IEEE: Institute of Electrical and Electronics Engineers OSHA: Occupational Safety and Health Administration, as applicable
6.6 Furthermore, without derogating from the technical requirements stipulated in this specification, the items listed bellow shall be designed in accordance with the standards specified herein or their equivalents:
6.6.1 Control Logic:
- NFPA 85 - Standard for the prevention of furnace explosions/implosions in multiple burner boiler-furnaces. - NFPA 850 - Recommended practice for fire protection for electric generating plants. - NFPA 70 - National Electric Code.
6.6.2. Fire detection and protection: a. National Fire Protection Association Standards (NFPA) or b. British Standards (Great Britain) and European standards c. Local industry standards
7. QUALITY ASSURANCE AND QUALITY CONTROL:
PCMS Annexure B June 2017 B - 22 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal 7.1 Without derogating from the provisions of the General Conditions, Contractor's quality system shall meet the requirements of Purchaser's Standard Q-APP-02- PR, "Quality Requirements", and of the requirements of the Inspection and Test Plan, all as further detailed in Annexure "M" to the Contract.
7.2 The Contractor and the main subcontractors shall be certified to ISO-9001-2000 by a certification body qualified to EN-45004 levels A or C or otherwise as may be acceptable to the Purchaser.
7.3 The Contractor shall submit upon request a copy of its Quality Assurance Manual including Quality Procedures.
7.4 The choice of main subcontractors shall be subject to Purchaser's approval and the Contractor shall be responsible for assuring that their quality assurance/quality control programs, including their organizations, procedures, personnel qualifications, etc., meet Purchaser’s quality requirements. Contractor [also Suppliers at the first stage of proposal evaluation] may propose additional possible sub-suppliers by submitting to the Purchaser a formal request for approval with sufficient details for evaluation including country of origin for design and manufacturing, proven experience with respect to equipment of the same size and functionality, quality assurance, catalogues, functional parameters and technical data.
8. SHIPMENT AND HANDLING OF GOODS AND DOCUMENTATION
The Contractor shall comply with the requirements for Shipment and Handling of Equipment set forth in Annexure "R" to the Contract and additionally with the following supplementary requirements:
8.1 All components or accessories shipped detached for field mounting or field assembly shall be suitably tagged to allow easy identification. Tags shall be stamped with cross reference data such as Manufacturer's Name, Contract No., Power Station, Unit No., reference drawing and Equipment Designation, and shall be exceptionally durable and securely tied to items by wire or other methods approved by Purchaser.
8.2 Major pieces of Equipment shall be supplied with nameplates.
8.3 Unless specially designated, all Equipment and other items shall be packaged for outdoor storage until erection. Where required by the nature of the Equipment, the Contractor shall furnish and install necessary covers to protect the Equipment from sand, rain, hail, wind, dust and salt spray. Equipment shall
PCMS Annexure B June 2017 B - 23 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal be adequately sealed and protected during shipment to prevent corrosion and entrance of foreign matter. All exposed machined surfaces shall be protected where required with a suitable antirust compound or covers before shipment, for shipment and storage until erection.
8.4 Before packing, the equipment shall be cleaned to remove all dirt and waste material left for fabrication, to the extent that it can be put into service without further cleaning.
8.5 The top, back and bottom ends of the control cabinets shall be provided with a temporary enclosure, tightly sealed to prevent entry of foreign matter during transport and storage at the job site. The entire panel or console shall be adequately protected to prevent damage to components during handling and transport.
8.6 The control cabinets and all equipment shall be carefully packaged to ensure arrival to the plant site undamaged by handling and weather.
9. SAFETY, NOISE, ENVIRONMENT AND LOADING REQUIREMENTS
9.1 Safety
The Equipment supplied under this Specification shall meet the U.S. "OCCUPATION, SAFETY, AND HAZARD ADMINISTRATION" (OSHA) requirements.
9.2 Noise
The noise level of the supplied Equipment shall not exceed an A-weighted sound level of fifty five (55) dB(A) at a distance of one (1) meter from any major surface.
9.3 Environmental Data
9.3.1 The Control equipment shall be located in air-conditioned rooms. However, during the periods the air conditioning unit is out-of-service, the ambient temperature may range from 1C to 50C and the relative humidity of the air may rise up to 100%. The equipment shall be designed to operate without limitation under these conditions, with no reduction of its life expectancy. Fans will be included in new cabinets where necessary to obtain max. 50C.
PCMS Annexure B June 2017 B - 24 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal 9.3.2 All electrical components mounted outdoors shall be provided in an outdoor weatherproof enclosure, NEMA 4X or IP65 with corrosion protection, and shall withstand the following conditions:
- Room Ambient temperature: 1 50C. The temperature inside the cabinets my reach 60C when air-conditioning is out of service. - Humidity: up to 100%, non condensing. - EMI: according to MIL-Std. 461B. - RFI: FFC Class A.
9.4 Earthquake Loads
9.4.1 The seismic design of buildings and structures in Israel is governed by the provisions of the Israeli Standard 413 “Design Provisions for the Earthquake Resistance of Structures”. According to this Standard, the seismicity of the site is expressed by the expected horizontal ground acceleration coefficient Z.
The expected horizontal ground acceleration coefficient Z expressed as:
Z = ah,max/g.
The maximum expected ground acceleration ah,max has the meaning of peak horizontal ground acceleration, expressed in m/sec2, with a 90% probability not to be exceeded over a 50 years period. The gravity acceleration g = 9.81 m/sec2.. The expected horizontal ground acceleration coefficient (Z), per provisions of the Amendment 2 (2004) to the Israeli Standard 413 is 0.11 for the Orot-Rabin Power Station.
9.4.2 Seismic environment for electrical equipment The seismic environment is defined according to IEC Publication 60068-3-3 ("Seismic test methods for equipment") for "General seismic class".
1. For the Scope of Work the peak acceleration at the ground level shall be taken 2 m/sec2.
2. The value of the super-elevation factor (k) shall be: k=1 for equipment mounted on rigid foundation k=1.5 for equipment rigidly connected to buildings k=2 for equipment installed on stiff structure connected rigidly to building
PCMS Annexure B June 2017 B - 25 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
3. The equipment shall comply with the relevant Qualification Criterion, according to paragraph 4.3 of IEC Publication 60068-3-3, which fulfils the required functionality statements.
10. PROJECT SYSTEM SECURITY STANDARD SPECIFICATION
The Contractor shall comply with the general requirements for Project system security standard specification set forth in Supplement 5.1.3 (General Security Safeguard Requirements for Control and Data Acquisition Systems in IEC - Power Stations) and as furtherer detailed in Supplement 5.1.4.
11. TECHNICAL DOCUMENTATION
The Contractor shall provide all documentation required by this Specification and by applicable Standards and Codes, in the required format, form and submission schedule, as detailed in Annexure "J" - Documentation Submission Schedule.
12. SPARE AND RENEWAL PARTS
The Contractor shall provide upon purchaser's request as purchaser's option spare parts at their itemized prices, subject to the applicable terms and conditions, all as further detailed in Annexure "C1"- Summary of Prices and Delivery Schedule.
PCMS Annexure B June 2017 B - 26 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal 13. EXISTING POWER STATION
13.1 Existing Power Station description
13.1.1 Steam Generator Description
The M.D. “A” Power Station consists out of four (4) drum type steam generators, Manufactured by Babcock & Wilcox Canada Ltd. Each unit burns pulverized coal and heavy oil. The steam generator is a radiant tower type generator with natural circulation. The maximum continuous capacity of each unit is 2,441,000 lb (1,107,238 kg) of steam per hour at 2050 psig (144 kg/cm2 gage) and 1005ºF (540ºC). The units are designed to produce the maximum continuous capacity either by burning pulverized coal or heavy oil. At over pressure and 'top heater out" condition the units can produce continuously 2,556,300 lbs (1,159,538 kg) of steam per hour at 2150 psig (151 kg/cm2 gage) with both superheat and reheat temperatures at 1005ºF (540ºC). Based on the original design, the superheater and reheater steam temperatures are controlled at 1005ºF (540°C) by spray attemperation and gas recirculation, respectively, when heat absorption is greater than required. At the present, due to operation problems, the Superheater and Reheater steam temperatures are controlled at 977ºF (525°C) and the flue gas recirculation control is disabled. The furnace is 54 feet wide, 32 feet deep and 196 feet from the center line of the lowest furnace wall headers to the center line of the drum. The furnace water– cooled surfaces consist of a front wall, two side walls, a rear wall and two division walls.
13.1.2 Fuel System
The Fuel System includes eight (8) coal feeders, eight (8) coal pulverizers and twenty four (24) burners. The type of the feeder is gravimetric and was manufactured by Stock Equipment Co.
PCMS Annexure B June 2017 B - 27 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal The pulverizers are of type EL size 76 manufactured by B&W Canada Ltd., each with a capacity of 18 tons per hour with coal grindability of 50 HGI and coal fineness 70/200. The sealing air for the coal feeders and pulverizers is supplied by two 2) seal air fans which were manufactured by Sheldon's Manufacturing. The Primary Air both dries and carries the pulverized coal from the pulverizers through the coal piping to the burners and furnace. There are three (3) 15¼” (387 mm) I.D. coal pipes per pulverizer, each pipe is connected to a burner at the same elevation at the front or the rear wall.
13.1.3 Burners
Each unit is equipped with twenty four (24) circular burners arranged at four elevations, six at each elevation, three on the front and three on the rear walls. The burners arranged in two common windboxes: one for the three lower elevations and one for the most upper elevation. Each coal nozzle with its burner pipe is located in the center of the burner opening. The throat size is 35” (889 mm) diam. while the secondary air register size is 42” (1067 mm) diam. The throat is packed with refractory. The pulverized coal and hot Primary Air mixture is discharged into the furnace by the coal nozzle.
The impeller at the end of the coal nozzle deflects the coal out into the whirling secondary air stream where ignition takes place. Ignition is initiated by high capacity gas igniter located in the throat in such a way that the lighter frame extends into the coal stream beyond the end of the coal nozzle.
Each burner is equipped to fire heavy oil by means of B&W steam atomizers racer type sprayer plate. Total twenty-four (24) oil burners are sized to produce full load steam flow. The burners cannot fire simultaneously heavy oil and coal. It is possible to control the fuel type firing (heavy oil or coal) for each group of burners (each
PCMS Annexure B June 2017 B - 28 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal elevation consists of two (2) groups of burners, one at front wall and one at the rear wall). The lower elevation of burners is also equipped to fire light oil with air atomization for boiler pressure raising and low load carrying up to 20% Of MCR. The B&W spark ignited gas igniters are rated 10,000,000 BTU/h (2,520,000 kcal/h) each at gas pressure of 4.8 psi (0.34 kg/cm2) above furnace pressure & igniter cock (100% open) when using propane as ignition gas but can be adjusted manually to a lesser output as determined by the ignition characteristics of the coal.
13.1.4 Pulverizer
The Babcock & Wilcox “El Pulverizer” employs the ball-bearing principle of grinding. The rotating bottom ring is mounted on a shaft driven by spiral bevel gears, which are housed in the base of the pulverizer and completely separated from the grinding zone. The non-rotating top ring is held in position by dual- purpose springs, which furnish the compression for grinding as well as preventing rotation of the top ring. Raw coal enters at the top of the pulverizer and toward the grinding zone. Primary Air, after passing through the throat, carries coal from the grinding zone to the static classifier, through louvers, where oversized coal is rejected back to the grinding zone via the tailings discharge seal. Properly sized coal continues to the burner with the Primary Air. Foreign material that may enter the pulverizer collects in the pyrites trap and is removed periodically.
13.1.5 Air and Flue Gas Flow
The Primary Air system consists of two Primary Air Fans (each providing 50 % of the required capacity), one steam coil air preheater, one Ljungstrom regenerative air heater and associated ducting. Primary Air Fans draw the air from the Forced Draft Fan outlets at a ramped pressure of approximately 9.5 in (241 mm) w.g. maximum static pressure. The
PCMS Annexure B June 2017 B - 29 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal Fans are Sheldon's type 800 with a test block requirement of 393,100 lbs. (178,310 kg) of air per hour at 125ºF (51.7ºC) and 54.6 in (1387 mm) w.g. The bulk of the Primary Air passes through the smallest of the three Ljungstrom regenerative air heaters supplied for the unit. The air heater is J. Howden & Parsons Model 21V1RP42 with an effective heating surface of 33,450 sq. ft (3,108 m). The heated Primary Air is ducted to the pulverizer's windboxes. A fraction of the air which bypasses the air heater is used for tempering, thus controlling the Primary Air temperature to each pulverizer as required by the moisture content in raw coal and thus maintain a constant coal/air mixture temperature at the pulverizer outlet. This fraction of air joins the main flow of the Primary Air flow upstream of the pulverizer air flow measuring device.
The secondary air, which comprises approximately 80% of the total combustion air when firing coal, is supplied by two axial flow Forced Draft Fans. The Air From the Fan's outlets flows to the two (2) steam coil air preheaters, two Ljungstrom air heaters and then to the front and rear burner boxes. Each air heater has a heating surface of 191,570 sq.ft (17,797 m2).
Flue gas formed in the furnace passes over the superheaters, economizer and air heater's surfaces transferring heat to the cooler media. Downstream of the economizer four (4) gas collecting hoods remove a fraction of the total gas flow for use in gas recirculation while the main bulk of gas flows to the three Ljungstrom air heaters, then through two precipitators, two Induced Draft Fans and through the stack. To facilitate the option of by-passing the P.A. fans for oil firing and provide impeller cooling air to the oil burners in service when both P.A. fans are not running, a P.A. fan by-pass duct with a tight shutoff damper is installed.
There are a total of 24 - 6” (152 mm) butterfly valves installed in impeller cooling air ducts (one for each duct). These dampers are open to supply air to impellers of oil burners, which are in service.
PCMS Annexure B June 2017 B - 30 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal 13.1.6 Spray Attemperators
There are two (2) SH spray type Attemperators on each unit. Each Attemperator handles steam from one-half of the boiler width and delivers it through secondary superheater inlet headers and to be distributed on the other one-half of the boiler width .i.e. the right hand side primary superheater steam goes to the left hand side secondary superheater and vice versa. This arrangement has been incorporated to minimize the effect of unbalanced firing and to insure a uniform final steam temperature across the secondary superheater outlet header. RH outlet steam temperature is controlled by using one (1) spray type Attemperator which is installed in the RH inlet.
13.1.7 Condensate and Feedwater systems
Each unit includes: three condensate water pumps, three Low pressure heaters and two High pressure heaters, one dearator and one steam driven turbine
feedwater pump and one electrical feedwater pump.
PCMS Annexure B June 2017 B - 31 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
13.2 Existing main systems to be included in the PCMS
13.2.1 Combustion Control System
13.2.1.1 The main control loops are: Load demand; Fuel demand; Air demand; Throttled Pressure Control; Boiler Demand Limit Regulator (BDLR); Hard- Runbacks; Feedwater control; Air flow and Furnace pressure control; Drum-level control, Deaerator level control and Heater drain level control. Pulverizer provides coal flow, primary air flow and temperature control in accordance with fuel demand signal. The primary air flow control is fulfilled by primary air flow damper. The a.m. fuel demand signal is generated by heat release signal. Primary air control provides primary air fans inlet dampers control on base of total pulverizers' demand with number of pulverizers in service feed forward. Superheat and reheat temperature control provides proper steam temperature by spray valves.
13.2.1.2 The existing combustion control system comprises of four main parts: a. The original 'Leeds and Northrup Co.' (L & N) manufactured DEB-300 dated early 1970's. This part is based on electronic cards that process the Inputs and outputs of the system to and from all the field devices. These electronic cards also include the main and auxiliary control loops for the air, water and fuel control. b. In the 1990's processors based controllers and workstations were added, to mainly accommodate the requirements for Unit Load Runbacks. These DPU's (controllers) include the Front End demands for the main control loops. c. In 2006 the Workstations were upgraded to MAX DNA by Metso (acquired MAX Controls / Leeds & Northrup). The communication network and workstations are common to pairs of units (1+2 and 3+4). d. Field actuators that include drive units by Limitorque 3 phase, L&N one phase, Jordan one phase, Auma 3 phase, controlled by pulsed power switches.
13.2.1.3 In addition, the Contractor shall be responsible for the integration between the new Combustion Control System and the existing Turbine control system (Turbine Boiler Coordinated control).
PCMS Annexure B June 2017 B - 32 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal The Turbine control system was retrofitted during 2000's to Ovation control system, manufactured by Emerson.
13.2.2 Burner Management System and Boiler Protection System (BMS)
13.2.2.1 The Burner Control / Management System's logic is implemented by the BAILEY 762 equipment dated from the early 1970's. The equipment consists of logic cabinets, flame scanners, four oil elevation sections and eight separate coal elevation sections. The Burner Management System is designed to ensure a safe, orderly startup and shutdown sequence of the fuel firing equipment and to prevent errors of omission and commission during execution of these operating sequences. The System provides safety interlocks to protect against potential emergency situations in the event of malfunction of fuel firing equipment and associated air systems. Boiler Lockout Relay (located in the electrical cabinet) acts parallel to the Burner Management System in order to increase reliability of the comprehensive system.
PCMS Annexure B June 2017 B - 33 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal 13.2.3 Existing I/O
13.2.3.1 CCS – Boiler Control I/O
ANALOG + MAX I/O
VOLTAGE/ I/O RANGE/ N I/O TYPE CURRENT/ COMMENTS NUMBERS TYPE RESISTANSE DIGITAL 1 156 V 115 VAC INPUT ANALOG PASSIVE 2 100 I 4 - 20 mA INPUT TRANSMITTERS ANALOG 3 53 mV TYPE E THERMOCOUPLES INPUT
ANALOG 100 Ω 4 2 Ω RTD INPUT PLAT
ANALOG 10 Ω 5 2 Ω RTD INPUT Cu
DIGITAL 220 VDC / RELAY 6 212 OUTPUT 115 VAC DRY CONTACT ANALOG CONTROL 7 16 mA 4 - 20 mA OUTPUT OUTPUTS ANALOG CONTROL 8 6 PULSE OUTPUT OUTPUTS ANALOG 9 58 mV 10 - 50 mV TO DPMS OUTPUT
ANALOG FEEDER DEMAND 10 8 V 0 - 10 V OUTPUT CONTROL OUTPUTS
ANALOG 11 11 V 0.2 - 1 V TO DPMS OUTPUT
ANALOG 12 5 V 1 - 5 V TO INDICATORS OUTPUT 1 Ø SLIDE (POSITION) DRIVE UNIT 13 44 V 115 VAC FEEDBACK INTERFACE PULSE 0 - 15 VDC 3 Ø SLIDE (POSITION) DRIVE UNIT 14 15 V 220 VAC FEEDBACK INTERFACE PULSE 0 - 15 VDC
PCMS Annexure B June 2017 B - 34 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal ON/OFF CONTROL OUTPUT DRIVE UNIT 1 Ø DIGITAL FEEDBACK 15 16 V INTERFACE 115 VAC 115 VAC ( OPEN/CLOSED POSITION)
TOTAL 704
13.2.3.2 Burner Control – Burner Management System I/O
BURNER CONTROL I/O
I/O VOLTAGE/ RANGE/ N I/O TYPE COMMENTS NUMBERS CURRENT TYPE
DIGITAL 1 650 V 125 VDC FIELD INPUTS INPUT CONTROL ROOM DIGITAL 2 200 V 24 VDC INTERFACE (PUSH INPUT BUTTONS) ANALOG 3 1 mV TYPE E THERMOCOUPLE INPUT 250 VDC /0.5 A DIGITAL RELAY 4 33 OR OUTPUT DRY CONTACT 250 VAC/5.0 A DIGITAL 115 VAC/7.0 RELAY 5 343 OUTPUT A DRY CONTACT 200 mA DIGITAL CONTROL ROOM 6 240 V (max load) OUTPUT INTERFACE (LAMPS) 24 VDC FLAME SENSOR ANALOG 7 48 mA 4 - 20 mA OUTPUTS OUTPUT TO DPMS
TOTAL 1515
PCMS Annexure B June 2017 B - 35 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal 14. TECHNICAL REQUIREMENTS
14.1 General requirements
All components, appurtenances and accessories shall be of proven design, verified by Power Plant Operation. The Plant Control & Monitoring System (PCMS) shall be of DCS type, based on state of the art technology, incorporating an integrated design, according to the following:
-Integration, based on the same hardware/software platform for all subsystems.
-Connectivity with existing DPMS using OPC.
-Field instruments will be hardwired to the system via terminal blocks.
-Maximum use of the existing field instruments, drive units, cables and infrastructure.
-Maximum use of the existing Electronic Room cubicles' arrangement. Where existing cabinets can be reused without disturbing the field terminations, the existing equipment will be removed from the cabinet and new I/O panels installed and wired to the existing field terminal blocks by Purchaser (IEC). In this case the existing field terminal blocks will be considered as marshalling terminals, For other systems Contractor shall provide new I/O cabinets which include terminal blocks to match the existing terminal points as much as possible. Terminal blocks with disconnecting capability shall be provided.
-High system's Reliability, Availability and Maintainability.
Basically, the system automation level shall match the existing conditions. Explicit requirements will be discussed during detailed design.
14.2 Functional requirements
14.2.1 The PCMS shall provide a complete and integrated functional arrangement using microprocessor based DCS, complete with all devices, to provide efficient and reliable control of the light oil, heavy oil, coal and ignition gas systems with respect to their safe start-up and shutdown. The functional requirements for the PCMS included herein are directed at establishing the criteria for the power station operation, control and supervision.
PCMS Annexure B June 2017 B - 36 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal However, it is not intended to limit the operation, functions and safeguards to those either mentioned or implied.
The Contractor is expected to make any additional suggestions or recommendations that will improve the proposed operational procedures or method of plant operation and supervision. All the system engineering and hardware needs to form a fully integrated, complete and operable start-up and on-line control system shall be supplied whether or not specifically detailed.
The PCMS's functions are: - Process Control as executed with the existing system with the additional control function, as listed in this Spec. - BMS and boiler protection - Operation and supervision of the controlled systems from the integrated HMI - Signal conditioning - Storing and archiving of the PS data and means to present data to the operator - Control system self-diagnostic and testing - On-line engineering and maintenance of system software configuration, including integrated system drawings and documentation. - Alarm management. - Alarm annunciation and display. - Data transfer to the DPMS.
14.3 System architecture
The System shall support a decentralized, hierarchical structure that is capable of being physically distributed to remote plant locations (if required). The system shall permit data acquisition and control functions to be performed at various plant area locations while providing the capability to monitor and control the distributed functions from a central facility. The system shall be flexible enough that it can be configured to a wide range of process control applications at the loop and component level without changes to the hardware.
The System's architecture must maintain as a minimum the following:
a. All requirements as listed in this Specification.
b. Distribution of controllers, I/O's and other processing tasks.
PCMS Annexure B June 2017 B - 37 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
c. Full implementation of the redundancy concept as required by this Specification.
d. Availability of information to/from third party computerized systems through the use of standard communications, protocols and data structures.
e. Availability of all information and operation functions in all Workstations.
f. All protection signals involved a trip signal to a major equipment in between processors shall be hardwired and not via communication.
g. Each subsystem (BMS and Combustion Control) shall be controlled by separate redundant controllers.
14.4 Reliability, Availability & Maintainability (R.A.M.) The system shall utilize a combination of redundancy and fault tolerance techniques to maximize system reliability and availability. Contractor's responsibilities shall be verified according to Annexure “D” - Equipment Performance Guarantees.
14.4.1 The system shall be assembled, programmed and configured to survive the failure of any device or single process sensor, with no degradation in the process control capability. The fault tolerance attribute will be included on all the DCS levels as follows:
- Operator Workstations. - Data Communication System. - Process Controllers. - Critical Input/Output Processing. - Power Supplies.
Failure on any level (I/O channel, processing module, Operator station, communication) shall not jeopardize other entities on the same level or above, or prevent them from communicating with each other.
Each single failure shall be clearly reported to the Operator's Station(s).
14.4.2 Failures in the PCMS must not cause the Protective functions to fail. The protective subsystems must be fail-safe.
PCMS Annexure B June 2017 B - 38 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal 14.4.3 A device or System shutdown/failure shall not cause a loss of any data stored for logs or trends. After restart, any data which might have been affected by the shutdown/failure shall be so indicated.
14.4.4 The System Structure shall permit the removal, exchanging and installing of any I/O card, controller, power supply when system is powered and on-line without disturbance to normal functioning of the rest of the system.
14.4.5 Functions performed by the controller modules during normal operation shall continue unaffected if the Workstation(s) is/are out of service. The system shall continue to report alarms if one Workstation is out of service.
14.4.6 Power failure shall always be considered a recoverable system error. On restoration of power, the System shall safely resume operation, generating a message which includes the time of the power failure. No new setting of the internal clock shall be necessary.
14.4.7 The required reliability, availability and safety will be achieved by the necessary functions distribution and/or by using the redundancy for the hardware levels according to the corresponding functions.
The self-diagnostic will provide on-line continuous checking of all components of the system for fault detection. The failure shall be identified by the system up to the card level.
14.5 Redundancy
14.5.1 The System shall be based on redundancy configuration on the Process Controller level. A Redundant Controller will receive a constant updating of its data base. The failure of a primary Controller shall cause an alarm in the Operator Station(s). Switchover to a redundant controller shall be automatically and shall not affect the system functionality and the operator ability to monitor or control any point. The switchover shall not depend on the availability of the communication system and shall be bumpless. Any changes in set-point, output and mode of control, tuning adjustments or related adjustments shall be transmitted to the back-up Controller automatically within one cycle of operation. The secondary Controller will monitor the same I/O channel but will remain passive. The Contractor shall provide the detailed description of the switchover procedure and switchover time in case of a primary controller failure. Any failure of the controller shall be alarmed.
PCMS Annexure B June 2017 B - 39 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
Contractor shall provide the necessary redundant Controller’s and I/O cards power supplies. The contacts' interrogating voltage shall be provided from separate power supplies, "ground isolated". An alarm shall be provided by an I/O card in case of ground fault detection.
14.5.2 I/O Level
The input/output signals integrity will be ensured by using redundancy for sensors and I/O Processing Cards, as required by specific application. The System shall support redundancy from sensors through the I/O processing channels to the controllers.
No single sensor or I/O card failure shall cause a system malfunction. Necessary diagnostic routines shall be provided to detect a failure and identify the failed sensor. The Contractor shall provide continuity checking for all heavy duty relays output circuits. The required majority voting routines will be provided on the controller inputs for the shared input signals and on the controller output for the dedicated input signals.
14.5.3 Communication Level
The Communication Data Highway(s) shall be fully redundant; the throughput shall be such, that at the HMI application level, no entity of information (command, alarm annunciation, monitored value, graphic display, etc) will be delivered or updated in more than 1 sec from the event occurrence. The transfer phase will not cause any malfunctioning of any subsystems.
14.5.4 Power Supply Level
14.5.4.1 Two power feeds from separate reliable distribution centers will be provided for any part of the System that requires AC power (such as interposing relays or filed equipment). An automatic transfer will be provided by the Contractor, so that no interruption occurs in the event of a single supply failure.
PCMS Annexure B June 2017 B - 40 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal 14.5.4.2 D.C. Power Supplies
Redundant power supplies shall be provided for specified services and shall have the following characteristics:
a. Redundant power supplies shall be provided with automatic transfer or with auctioneering connection, so that no interruption occurs in the event of failure of a single supply.
b. An alarm shall be generated, should any power supply fail.
c. A failure in the DC power supply shall be easily identified and components shall be designed for easy removal and insertion into the cabinets. This shall require circuit isolation and monitoring so that if a part of the System becomes isolated, erroneous control action shall not result.
d. Each power supply shall have sufficient capacity to provide 30% future expansion.
e. All internally generated ac or dc logic voltages that are operated ungrounded shall be provided with ground detection alarms and isolation devices.
f. If the power supply to or on any module or printed circuit card should fail or if any printed circuit card or device is removed from its receptacle, the associated system and all the dependent systems shall transfer to manual. An isolated contact output shall be provided upon such a failure.
g. The Contractor shall provide all the necessary equipment required to convert and distribute power to all the field instruments which require a source of electrical power. Distribution shall include a dedicated disconnecting and protecting device for each transducer. Electrical isolation between loops shall be provided.
14.5.5 The System's architecture shall be configured as a fault tolerant control system, utilizing a minimum double redundant configuration of microprocessor-based digital modules for modulating and BMS functions.
All primary control and protection functions shall be performed in identical redundant Control Processor Modules.
14.5.6 The System shall be capable of maintaining proper control and protection upon a single hardware or software failure occurs or when a failure occurs in one of
PCMS Annexure B June 2017 B - 41 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal the redundant I/O devices. This responsibility includes receiving, conditioning, and automatically selecting valid process measurement signal, performing process control calculation, and issuing corresponding output demands, as well as maintaining necessary interlocks and alarm function. The System shall be capable of providing on-line diagnostics, on-line testing, on-line repair, and on- line changes to control set point and overall operation.
14.5.7 The Contractor shall be responsible to provide all means (software and hardware) for Embedded Cyber Security (ECS) to protect the complete PCMS from an unauthorized access, in compliance with paragraph 14.6 requirements.
14.6 PCMS Embedded Cyber Security (PCMS - ECS)
Refer to supplement 5.1.3 and 5.1.4
PCMS Annexure B June 2017 B - 42 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal 15. PLANT CONTROL & MONITORING SYSTEM (PCMS) DESIGN REQUIREMENTS
Each PCMS shall include the following subsystems:
15.1 Combustion Control System (CCS)
15.1.1 The Combustion Control System (CCS) shall operate as an integral part of The Plant Control & Monitoring System.
15.1.2 The Combustion Control System shall perform, but shall not be limited to, all the functions of the existing System.
15.1.3 Contractor shall provide new redundant controllers, I/O cards, power supplies, communication interfaces, etc. in order to implement al the required control functions. The equipment shall interface with the existing field devices especially the drive units. 15.1.4 The existing System includes approximately 3000 points.
15.2 Burner Management System (BMS)
15.2.1 The Burner Management System (BMS) shall operate as an integral part of the Plant Control & Monitoring System. The BMS shall be designed to meet the requirements of the existing system and Purchaser’s (IEC’s) special requirements.
15.2.2 Each BMS shall provide a full control and protection of the related existing boiler according to the latest edition of NFPA.
15.2.3 Functional Requirements
15.2.3.1 The Burner Management System shall be suitable for burning ignition gas, light oil (for first elevation only) , heavy oil and coal.
15.2.3.2 The BMS shall include Master Fuel Trip Relay in order to provide the possibility of the Power Station safe trip.
15.2.3.3 The BMS's operation and equipment described in this Specification has been included to serve as a guide to the type of system desired but does not necessarily encompass all design functions.
PCMS Annexure B June 2017 B - 43 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal The Contractor shall be responsible for furnishing a system design that is complete in all respects.
15.2.3.4 The BMS shall provide alarms to advise the operator of abnormal or dangerous conditions.
15.2.4 BMS Requirements
15.2.4.1 The System shall provide equipment and program tasks for “dry” BMS tests for all BMS operations including opening and closing fuel, burner and scavenge valves advancing and retracting oil guns. These tests shall be feasible during ordinary start-up and shut-down operations of the BMS, separately for elevations and for the fuel oil and coal trip valves and relevant equipment.
15.2.4.2 The System shall include extensive self-checking to detect malfunctions of the equipment and other feasible checks that indicate erroneous operation. When such checks show a problem from which the System can recover without intervention by plant personnel, a system error shall be alarmed and operation shall resume. If checks reveal a non-recoverable error, an orderly transfer to a back-up, or if a back-up is not available, it shall be alarmed to allow the operator to shut the System down, if required.
The System shall be provided with the possibility to set solid state output drivers in a preprogrammed mode on processor failure (predictable Failure Mode), retaining of last state position by electromechanical means is not acceptable.
15.2.5 In addition, in Power Station there is Boiler Lockout Relay System, based on electromechanical relays, which implements also Boiler Protection functions. The existing Boiler Lockout Relay System will be dismantled and its logic shall be implemented in the new BMS, in order to provide safe operation of the boiler.
PCMS Annexure B June 2017 B - 44 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal 16. PLANT CONTROL & MONITORING SYSTEM EQUIPMENT REQUIREMENTS
16.1 Accuracy and Resolution
16.1.1 Overall accuracy of the System shall be such that the digital output representation of an analog input signal shall be within 0.10% of the full scale range of the signal, as measured at the field analog input terminals.
16.1.2 Time-tagging of events shall have one (1) second accuracy.
16.2 Process Data Highway
a. The data highway shall provide both functional and physical System distribution capability for communication between the major System elements.
b. The data highway shall be redundant. Fail-over to the alternate cable-circuitry shall be automatic. Any highway failure shall immediately be reported by the System.
c. The highway shall be designed so that no single component failure will cause one or both of the redundant highways to become inoperative. This requirement includes communication cards, line switches, modems and any other related electronic devices.
d. All communication and processing circuitry shall be effectively immune to the types of electrostatic and electromagnetic interference that can be expected in an industrial environment. Coupling circuits must satisfy the requirement of rejection of noise - Floating voltage of a device must not be converted to noise on the highway.
e. The highway shall include all the required communication equipment in order to interconnect all the system elements.
f. The highway protocol shall include sufficient error recovery capability and message security checks.
g. The communication protocol shall provide automatic adaptation after the operation of connecting a new node to the data highway or disconnecting the existing one.
h. Addition or deletion of nodes on line shall not disrupt plant communication.
PCMS Annexure B June 2017 B - 45 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
16.3 Input/Output Equipment
16.3.1 General.
a. The input/output modules shall be microprocessor-based devices.
b. The System shall include analog input modules, capable of reading all existing and additional analog inputs (such as but not limited to: 4 to 20 mA, RTD's (3-wire or 4-wire), thermocouple inputs directly. The System shall provide all the typical analog input linearization, including thermocouples (types, E, J, K, S and T), RTD's and square root functions. Custom linearization functions shall be available. Linearization of thermocouple inputs shall conform to IPTS-68 standard. Reference junction compensation shall be internal. The I/O cards for 4-20mA shall be suitable for 2-wires or 4-wires signals.
c. When a controlled variable exceeds transducer limits it shall be declared unreasonable and alarmed and all affected portion of the System will transfer to manual.
d. Digital inputs will be scanned and status retained for use in system logic algorithms. It shall be possible to assign status designations (on-off, tripped- running, etc.) for each input. Each digital channel shall be individually/group isolated with a dielectric test voltage of 500VAC. No galvanic/opto insulation will be provided for standard 4-20 mA I/O cards.
e. The analog to digital conversion will be a least 12 bit.
f. Each input module shall be separately fused, with a fuse status indicator on the front of the module.
g. Surge protection devices shall be provided for 50 analog and digital signals connected to outdoor field instruments exposed to lightning strikes. The surge protection shall include: -Surge protection power for power supply system -Surge protection for information technology Data systems 4-20mA The surge protection devices shall include status indication or alarm for replacement.
PCMS Annexure B June 2017 B - 46 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal h. All analog input and output field wiring terminations shall be readily accessible, allowing for easy installation and removal while the System is on- line. Any associated printed circuit cards can be installed and removed without disrupting the field wiring and without disturbance of the rest of the system.
i. All input modules shall meet Contractor's standards for surge-withstand test: no false output shall be taken as a result of the electrical power surge described in this specification.
j. Digital output modules shall perform "check before execute" routines on each updating of digital outputs.
16.3.2 Analog Output to I/P Converter or Drive Unit Regulator The System shall include analog output modules, capable of driving all existing equipment such as but not limited to: PAT (Pulse outputs). Controllers shall generate analog position demand signals to final control elements.
Range: 4 to 20 mA into 0 to 600 Ohm standard or up to 1000 Ohm total loop resistance.
Accuracy of the output circuitry: better than 0.25%
Security: Upon loss of power, or in case of disconnection between the controller and the drive unit regulator, the final control element must be held in its last or safe position and switched to manual mode of control.
16.3.3 Digital Inputs
a. The Digital Inputs will include alarm/status points which may be a dry contact either normally open or normally closed type, or solid state (optocoupler).
b. The Contractor shall supply the necessary interrogating voltage such as 48VDC, floating with Ground Fault Detection.
c. There shall be no false signals due to contact bounce up to sixteen (16) milliseconds either on alarm or return to normal.
d. Scan cycle for digital inputs shall not be greater than 125 msec.
e. SER events shall be discriminated within a time resolution of one (1) msec and recorded in their proper sequence.
PCMS Annexure B June 2017 B - 47 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
f. Binary inputs from process and/or other controls shall be dry contacts.
16.3.4 Analog Inputs
a. The scan cycle for analog inputs shall not be greater than 250 msec, unless otherwise specified.
b. An alarm dead-band in percent shall be configurable for each of the analog inputs so that a value returning to normal will not be announced as returned to normal while it is within this band.
c. All analog inputs in the System shall have their values checked concurrently and continually for bad or unreasonable conditions.
d. Thermocouples will be of the grounded and/or ungrounded types. Contractor equipment shall be able to handle them in any combination.
e. Detection of open circuit thermocouples shall be performed. Systems that cause calibration offsets or suffer from time delays are not permitted.
16.3.5 Control Outputs to Devices
a. The output modules will be used to control the field devices (circuit breaker closing and tripping coils, starters and solenoid coils, etc.)
b. For the control of the field devices, dry contacts shall be provided.
The contact ratings necessary shall be at least 3 Amperes for 220VDC utilization categories and 3 Amperes for all AC utilization categories. Heavy duty type of interposing relays is recommended for this purpose.
c. The output relays shall have long mechanical life and high contact reliability at the rated current. The dielectric strength shall be defined by Contractor. The circuits shall have a surge withstand capability equal to that specified in ANSI C37.90a.
e. All relay auxiliary contacts shall be brought up to the terminals at marshalling cabinets, for the Purchaser's use.
PCMS Annexure B June 2017 B - 48 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal Binary outputs to the process systems (interlocks) shall be by dry contacts, with contact rating at least 3 Amperes for 220VDC utilization categories and 3 Amperes for all AC utilization categories
16.4 Processing Controllers
16.4.1 General
As used in this specification, the words "process controller" refers to any device configured to perform a set of control, data processing and monitoring functions.
a. The loss of power to any controller shall not result in loss of memory such that manual reconfiguration is necessary when power is restored. Upon restoration of power, the System will initialize itself to the established configuration and resume operation without error.
b. All of the functions performed by the controller shall be executed within a scheduled time which shall not be altered by changes in configuration or by system loading.
c. Each controller shall update all of its outputs at least every 0.25 seconds during all conditions of operation.
d. It shall be possible to accomplish tuning, configuring and reconfiguring of controllers under key-lock control, through the Engineering Station, utilizing a convenient set of displays specially designed for that purpose and to down-load the configuration to controller(s) via Data Highway.
e. All algorithms needed to perform the specified functions shall be provided pre-programmed and in the System's library. It shall be possible to configure or reconfigure controller solely through the use of pre-programmed algorithms (functional blocks). There shall be no limit upon how many times a particular functional block can be used within the capacity of a controller.
16.4.2 Operational Characteristics
Controller shall:
- Be started up without the assistance of any higher level device such as a computer.
PCMS Annexure B June 2017 B - 49 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal - Utilize a design architecture enabling multiple reduced performance levels prior to a device failure.
- Be unaffected by failure of other devices connected to the communication system.
- Be added to or removed from the communication system at any time without upsetting the System's communications.
- Have a trend memory to store historical data.
If power is lost to the controller, all associated control loops shall automatically transfer to manual. Following a power failure and upon power restoration all loops will remain in manual until selected for automatic by the operator.
16.4.3 Computational Capability
Controllers slots shall be configurable to provide control algorithms and strategies as P, PI, PID control with the following functions:
- cascade or ratio;
- multiplication/divisions;
- square root extraction;
- addition/subtraction;
- lead/lag;
- override;
- high or low signal selection;
- high/low process variable alarming;
- logical gates (AND, OR, NAND, NOR, EXOR);
- time delay;
- interlocks;
PCMS Annexure B June 2017 B - 50 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
- linearization of E type thermocouple signal and of 100 ohm Pt RTD, 10 ohm Cu, etc. signals;
- Compensation for pressure and/or temperature for level and flow measurements.
In addition to the basic control and logic functions, controllers shall also perform the following functions as a minimum:
- scanning -Digital inputs, at least 8 times per second
- Analog inputs according to assigned scan rates
- limit checking - alarm limits for analog inputs
- conversion to engineering units
- change detection - calculating rate of change providing protection against noisy sensors
- status indications can indicate that changes have occurred, instead of being transmitted repeatedly
- on-time count and status change count for digital inputs
- sensor correction - linearization, square root extraction, etc.
- time tagging events
- reasonability checking - coarse checks to exclude data that is checking evidently impossible (like out of range).
- counting
- calibration - examples: cold junction temperature for thermocouples, zero point offset, etc.
- Independent local data base (configuration) to permit all the required tasks. Provisions to download/upload this information from/to and to the Workstations.
PCMS Annexure B June 2017 B - 51 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal - Transmitting input data in engineering units, alarms and status information to other devices such as Workstations or other intelligent modules, according to the requirements or upon request.
- Monitoring of the I/O modules and its own performance.
16.5 Communication links
16.5.1 General
Communication links shall be used for collecting information from the Plant's auxiliary systems and other computerized systems supplied by others. The above mentioned links shall use a standard control-proved communication protocol(s) such as Modbus Plus or equivalent (pending Purchaser’s approval). Contractor shall provide all gates/interface units required in order to accommodate those links.
The Contractor shall specify its requirements and experience regarding the communications type, standard protocols, etc.
The System shall be able to accept and keep the time stamp for each event sent via communication link(s) from the other systems. In case that data does not include a time stamp the System shall apply the time stamp.
16.5.2 OPC Server(s)
a) The System should be provided with OPC DA, EA Servers for data transmission to DPMS.
b) The System includes an Historian Workstation; the Supplier should provide OPC HDA for historian Server.
c) All OPC Server(s) should be OPC Foundation Tested.
d) The HMI software package should include Universal OPC Client software module(s). A clear list of OPC Server types accessible by OPC Client should be included.
16.6 Auxiliary Equipment
PCMS Annexure B June 2017 B - 52 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal 16.6.1 Printers
The Contractor shall provide:
- Three (3) A4 color laser printers per Unit.
a. The printers shall have graphic printout capability.
b. The system shall have the possibility to make a screen copy printout from any of the Workstations.
c. All data to be printed shall be available in all the Operator Workstations. The operator/engineer shall be able to configure for every Workstation the type of data to be printed.
d. Off-line state of a printer or any printer trouble shall not cause a loss of data to be printed.
e. Printer status and trouble information shall be part of the system status information on the Operator Workstations.
f. The printers shall be by manufactured by a well-known company.
16.6.2 Back-up Devices
Back-up means for Operator and Engineering stations shall be provided. The capacity shall be adequate to the disks size. User-friendly back-up/restore utilities including all software and hardware shall be included.
16.7 Power Supplies
16.7.1 General Description
The Contractor shall provide whatever DC power supplies and/or step-down transformers that are required to operate the system. The Contractor shall supply the data of the exact power demand from each supply both on normal operation and during start-up (inrush currents).
Two power feeds from separate reliable distribution centers will be provided for any part of the System that requires AC power (such as interposing relays or filed equipment). An automatic transfer will be provided by the Contractor, so that no interruption occurs in the event of a single supply failure.
PCMS Annexure B June 2017 B - 53 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
16.7.2 D.C. Power Supplies
Redundant power supplies shall be provided for specified services and shall have the following characteristics:
a. Redundant power supplies shall be provided with automatic transfer or with auctioneering connection, so that no interruption occurs in the event of failure of a single supply.
b. An alarm shall be generated, should any power supply fail.
c. A failure in the DC power supply shall be easily identified and components shall be designed for easy removal and insertion into the cabinets. This shall require circuit isolation and monitoring so that if a part of the System becomes isolated, erroneous control action shall not result.
d. Each power supply shall have sufficient capacity to provide 30% future expansion.
e. All internally generated ac or dc logic voltages that are operated ungrounded shall be provided with ground detection alarms and isolation devices.
f. If the power supply to or on any module or printed circuit card should fail or if any printed circuit card or device is removed from its receptacle, the associated system and all the dependent systems shall transfer to manual. An isolated contact output shall be provided upon such a failure.
g. The Contractor shall provide all the necessary equipment required to convert and distribute power to all the field instruments which require a source of electrical power. Distribution shall include a dedicated disconnecting and protecting device for each transducer. Electrical isolation between loops shall be provided.
16.7.3 Interrogation Voltage
a. All field dry contacts will be interrogated with 110VDC.
b. Power supplies for the interrogation voltage shall be ungrounded. Short circuit detecting will be provided for analog inputs
PCMS Annexure B June 2017 B - 54 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal Each group of maximum 32 input circuits shall be detected for ground on the interrogation voltage lines (both sides of the contact) by a separate ground detecting circuit.
These detectors shall provide an alarm in case ground is detected. A ground detection indication shall be provided to indicate in which group of inputs a ground has occurred. There will be no need for ground detection push buttons for disconnecting of groups. A diagnostics display shall be included in the System which will show the status of the power supplies.
16.7.4 Supply of Power to the drive units, control valves and the field devices shall be a dual source power with an automatic transfer switch (ATS) which will transfer to the alternative power source in case of a power failure. The transfer shall be done so that no interruption occurs in the event of failure of a single supply.
16.7.5 Loss of Power
Loss of power supply to the System, or loss of power within the System, shall cause affected portions of the System to transfer to manual and an alarm will be initiated. When power is restored, all controls shall stay in manual until reinstated to automatic by the Operator. The loss of power to any drive unit shall be indicated through alarm contacts furnished by Contractor.
The System shall operate normally under the following tolerances:
1. Input voltage 102 to 132 VAC or 204 to 264 VAC.
2. Maximum power interruption of 0.5 cycles.
When the above tolerances are exceeded, the System will transfer to the manual mode and the demand signal to the final control element will not change.
Upon return to normal voltage, the System will remain in manual until the operator will return it to the automatic. The final drive unit shall remain in position upon loss of drive unit motive power and/or loss of power to the controller, transmitter and other logic elements associated with the drive unit or upon loss or interruption of the controller output signal.
PCMS Annexure B June 2017 B - 55 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal Upon restoration of motive or control power, the drive unit shall become available for operation without changing its position even if it has been moved by operating the local hand-wheel. Automatic remote releasing is required.
Manual control of each drive unit or converter shall be possible as long as its specific motive power is available. Manual control shall be independent of the logic power source or any drained voltage.
The circuit interrupting devices that are employed to provide isolation shall be monitored so that erroneous control action does not result from a loss of power to any part of the System.
16.8 Human-Machine Interface (HMI)
The Purchaser shall provide the conceptual design of Main Control Room architecture, which shall be based on the advanced ergonomic practice and shall contain the following:
- Operator Consoles - Large Screen Displays - Electrical Operator Console - Shift Supervisory Console
All the computers shall be provided for 115VAC and 220VAC power supply.
A limited amount of Emergency hardware control devices shall be mounted on Operator Console.
16.8.1 HMI Implementation and Arrangement
16.8.1.1 Operator Console
The Contractor shall provide the Operator Console according to items 4.1.1.1.1, a.3 . The Operator Workstations will be provided with "parallel" redundancy, i.e. any piece of software (e.g. console database, graphic displays, reports, trends, etc.) will be installed in each one of the Workstations. From each Workstation it will be possible to operate and supervise the entire unit, including electrical systems and auxiliary systems. The common systems data for HMI use have to be available in both Units.
The Workstation shall accommodate a minimum of:
PCMS Annexure B June 2017 B - 56 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
- 1,000 graphic displays (pop-up is not considered a graphic display) - 50,000 tags - 2,000 trends
The hardware platform of an Operator Workstation (OWS) will be based upon the most advanced and reliable technology available on the market at delivery date of the first unit. The Operator Workstations will be connected to the data highway, thus accessing all the available real time process data. In addition, for a parallel overview of the entire process four (4) Large Screens per Unit shall be provided. This screen shall display any of the operator workstation displays or several of them at the same time. The Operator Workstations will be provided with keyboards and mice.
16.8.1.2 Engineering Workstation(s)
16.8.1.2.1 The Engineering Workstation is a device meant for on-line configuration, control tuning, and system debugging and documentation management.
16.8.1.2.2 The EWS shall also include all of the operators' workstations functions.
16.8.1.2.3 The EWS shall have raid disks architecture.
16.8.1.2.4 Software
The EWS shall be provided with all software packages required in order to perform the following functions, as minimum: - All operators' functions - System's configuration - Controller programming - Control tuning - System debugging - System database management (based on relational database) - On line system documentation (drawings) - Graphic displays editing - History retrieval - Backup utilities
16.8.1.2.5 The engineer shall be able to display on the screen and/or print the following
PCMS Annexure B June 2017 B - 57 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal additional summaries. These shall enable the engineer to review the up-to-date documentation of the System more quickly than by reference to external hard copy.
a. Summaries of all analog inputs, digital inputs, outputs, calculated variables and booleans, including processing specifications, using a flexible query scheme.
b. Summary of inputs, outputs, calculated variables belonging to a certain device.
c. Summary of all points used by performance calculation programs.
d. Summary of points per serial data link, computer interface or remote I/O cabinet, if applicable.
e. Summary of points per graphic display/per log.
f. Summary of displays/logs per point.
16.8.1.2.6 The Engineering Workstations' software shall enable forcing data inputs/outputs.
16.9 Application Requirements for Data Processing and Monitoring
16.9.1 Alarm Management
Each operator and engineer display shall have an area reserved to display all active alarms. Alarms shall be classified as follows:
- Grouping of alarms will be available for associating characteristics like different alarm sound, filtering, etc.
- Communication alarms.
- System alarms (down to the card level).
- Process alarms shall be assignable to every process variable in the database. Points that shall be alarmed include: analogs, digitals, group digitals and devices.
- There will be capability of selecting different sounds of alarms. Deadbands shall also be available to define how far the points must return inside
PCMS Annexure B June 2017 B - 58 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal the limit in order to be considered returned from the alarm condition. Digitals and devices shall have standard normal/abnormal operating states.
An alarm priority shall be assignable to every variable, or the alarm can be suppressed (or inhibited) It shall be possible to filter out alarms on displays and logging devices by priority. The different priorities shall have different color association.
16.9.2 Logging
16.9.2.1 General
All logs shall be programmed, or configured so that in an easy manner the engineer will be able to edit the printing format of any log. A full-screen report generator shall be provided.
16.9.2.2 Logs to be provided by the System:
16.9.2.2.1 Period Logs
This report is generated at a user-specified interval.
16.9.2.2.2 Event Logs
This report is generated when a user-specified condition is met.
16.9.2.2.3 Trip Logs
This report is generated when a user-specified trip condition is met. A trip report will be printed at the end of the maximum post-trip (40 minutes). This report shall be capable of reporting the Historical Events (0.1 second) data.
-Trigger condition: - User specified, up to 20 digital point value conditions. For meaningful reports, these conditions should be the same as the conditions specified for the Historical Event file.
-Other data used: - Live point values and attributes, lab data files and other user file data.
-Manual request: - Can be generated by manual Operator workstation request. The reference time given by the user will be interpreted as the time of trip.
PCMS Annexure B June 2017 B - 59 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
16.9.2.2.4 One Time Only Logs
This report is generated upon manual request only.
16.9.3 Operator Interface
16.9.3.1 General
The Human Machine Interface (HMI) shall provide an interface to the process and support monitoring and control through dynamic displays. HMI shall not execute control algorithms. Loss of HMI or data highway shall not cause loss of process control.
16.9.3.2 Data Presentation
a. The control displays (samples as provided by contractor), including dynamic graphics, will be completely built and operative on the screen in 1 (one) second or less. All displayed data shall be updated in no more than 1 (one) second.
b. Any operator initiated control action, whether requested by the keyboard, mouse, etc., shall be executed within one second or less. Confirmation that the operator action has been executed shall be displayed on the screens within 2 (two) seconds or less. Execution and confirmation to an operator action shall not be slowed due to high System activity, such as an alarm avalanche during a process upset.
c. The quality of the process data and calculations shall always be indicated whenever the data is displayed, or logged, or used in other calculations, including high level programming language statements.
The system shall be able to determine that data is good, bad or substituted.
These terms mean:
Bad - data beyond the reading range of the System or resulted from calculations with bad data; Substituted - data value that is manually or automatically substituted.
16.9.3.3 Operator Displays
PCMS Annexure B June 2017 B - 60 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal 16.9.3.3.1 The Operator Displays shall be implemented based on EPD-B.32, PLC/DCS Based Control Systems Control and Operation of Typical Devices (Supplement 5.2.6).
16.9.3.3.2 The intent behind the design of the main HMI is to provide the operator with a "single window" to the process.
The operator station shall support the following types of displays:
a. Dynamic graphic and control displays b. Trends c. Start-up/shut down sequence displays d. Alarm lists e. Menus f. System status g. Summaries. h. Alarm history i. Trend history.
The Contractor shall provide the necessary number for each type of displays, as required by Systems' functions. The displays shall permit full process supervision as well as operation of all the corresponding systems. It shall be possible to compose different types of displays on the same screen, as required by the System(s) functions (e.g. graphics/trends/controls).
16.9.3.3.3 Graphic Displays
a. Any selected Workstation shall be able to display graphic pictorials of plant equipment. The Contractor shall fully define and document the graphic editor/viewer software.
b. Contractor shall be able to embed in the graphic displays, Purchaser-defined symbols (dynamic or not).
c. Real-time updating shall be provided for the data values, symbols and display elements when on display. Dynamic graphic symbol updating includes changing symbols and/or colors, based on a logic defined either by Purchaser or Contractor.
d. The system shall have the capability of displaying a minimum of one hundred (100) dynamic analog values or contact status words and a minimum of two hundred (200) dynamic symbols or any combination thereof on any display.
PCMS Annexure B June 2017 B - 61 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
e. Graphic displays shall provide the necessary means to operate the corresponding equipment (modulating or binary) by using pop-up screens or equal.
f. A display definition created for one operator workstation shall be usable, without any reprogramming or editing, on any other type of workstation which is in Contractor's Scope of Supply.
g. The System shall include the flexibility in selection of color, thickness, size of lines and fonts, as in Windows environment.
h) The System shall include the possibility to lower a display to task line and the navigation between displays, without limitation, as in Windows environment.
i) The System shall include the possibility to select each window and to copy it as an object on a Microsoft Office application.
j) The System shall include the possibility of navigation between displays, without limitation, including dragging feature of each window.
k) The System shall include the possibility to mark on the display the element status: out of service, limited, etc.
l) The System shall include the possibility to open graphic displays by system name, using a rapid menu.
l) The System shall include the possibility to simply build graphs from the process displays.
16.9.3.3.4 Analog Control Display
The Pop-up/Faceplate displays shall be included for the Modulating control functions.
The process information provided by the display shall be individually weighted deviations between the process variables and their set points or target values.
Loops in manual control shall be indicated. High and low operator action limits shall be provided for each control loop to alert the operator to an impending process alarm. High and low process alarms shall be shown for each loop when tripped.
PCMS Annexure B June 2017 B - 62 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
The control display shall include the detailed information for the corresponding loop, such as:
- Control Station(s) Faceplate(s)
- Analog points in digital or bargraph form
- Digital point status
- Permissives and control interlocks status
- Logic diagrams displays including the possibility to show the fulfilled/non fulfilled data, using color change.
- Real time trends for process variable, control output, set-point and any corresponding analog points.
Start-up window displays shall include all the required information, such as: start permissive, trip cause, etc.
16.9.3.3.5 Operators' Control Displays
The operator shall be able to manipulate set-point, output, ratio, bias and control modes through the tuning display. For digital points, the operator shall be able to issue commands to the start/stop and open/close two state equipment. Through use of a password the operator shall be permitted or restricted from:
- Changing tuning constants
- Changing process variable zero and span value
- Changing alarm limits
- Changing configuration of any of the loop and gate parameters (control algorithm, signal type and input source, as well as interlocks and delays).
16.9.3.3.6 Trending
The trend displays shall provide continuous on-line representation of up to eight (8) variables. The variables shall be scaled in engineering units. As a minimum, the last 24 hours of trend data shall be available for each trend point.
PCMS Annexure B June 2017 B - 63 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal The sampling period (e.g. 1 second, 15 seconds, 1 minute) and type of trend (e.g. sample, mean, minimum, maximum and summation) shall be configurable.
The possibility to build multi-trend displays (based on the existing display by selection + CNTR) and multi scale function for multi trend displays, as in PI shall be provided.
The user shall be able to configure on-line temporary trends of any point in the System. These trends shall be updated at least every two (2) seconds to show real time data. As a minimum the last two (2) hours of data for the temporary trend points shall be available for recall and viewing.
The zero and span scales shall be capable of being individually scaled, expanded or zoomed for clarity and more detailed viewing. The trend display shall be capable of being panned from the current time back to available historical trend time. Trending data must be capable of on line storage with no external devices.
The trend display shall include the current values of the trend variables, as well as the corresponding past values as the time pointer is moved through the time scale. The operator shall be able to set the grid roll-down speed and the interval between time lines.
The following information shall be displayed on the screen for each of the trending variables, in the color of the respective trace:
a. Tag name. b. Tag description. c. Current value (numeric). d. Zero and full scale value. e. Engineering units. f. Point quality.
16.9.3.3.7 Historical Trends
a. It shall be possible, following a unit trip, to display analog trends of events that occurred, for selected variables.
b. Through the use of historical data storage and retrieval functions described in this Specification, historical trends shall be available to the engineer upon demand, to be displayed on a screen, with different time scales.
PCMS Annexure B June 2017 B - 64 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal
16.9.3.3.8 Control displays
The device sequential control displays shall support the following operator functions:
- Manual device control
- Auto-manual selection (where required)
- Electrical lockout of circuit breakers and starters operation (for device maintenance purposes).
- Monitoring (via feedback from controlled devices) of device status (close/open or start/stop).
- Monitoring of control circuits integrity (disable function).
- Monitoring of abnormal operating conditions and acknowledgement.
- Monitoring of permissive/trip conditions.
- Monitoring or motors/feeders current and throttling valves travel position.
- Synchronizing selection/monitoring (where applicable).
- Sequential control (groups control) selection and actuation, including possibility and guidance for the manual sequence operation.
- Sequential control monitoring/criteria indication, including status of each step and necessary feedback signals.
- The device control through HMI shall be multilevel security code protected against accidental operation.
16.9.3.3.9 Summaries
The operator shall be able to display on the screen and/or print the following, but not limited to, summaries:
- Summary of all actual operating limit alarms.
PCMS Annexure B June 2017 B - 65 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal - Summary of last shift acknowledges alarms.
- Summary of last shift "return-to-normal" alarms.
- Summary of all bad quality points.
- Summary of all points with substituted values.
- Summary of all inhibited points.
- Summary of status of all peripheral devices.
- Summary of status of all workstations, intelligent modules and highways and disk usage.
- Summary of all defined system points, according to the plant system identification codes.
- Summary of assigned trend points.
- Summary of all points belonging to each log on a per log basis.
- Summary of the existing logs and their status.
- Summaries of active graphic control/binary/sequential displays, according to displays type.
16.9.3.3.10 On-screen Menus
The on-screen menus shall provide the following:
a. Simple, consistent, straight-forward procedures to obtain process data/operate corresponding equipment.
b. Simplify operation in communicating with the System and eliminate the need to use reference handbooks.
c. Shorten the time it takes to obtain information by displaying response messages, error messages and various summaries on Screens rather than causing a delay until the information is printed.
d. Reduce operator error when making various functional changes to the
PCMS Annexure B June 2017 B - 66 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal System, by adequate help like color highlighting data allowable to change and menu choices instead of key-ins.
e. Reduce the time of the engineers in making programming changes by enabling functional changes to be made interactively through the screen in other than programming language.
f. If the operator makes a keystroke entry error, the response message will define the specific type of error made, in conversational language and not only as coded error number or program statement.
g. An operator key-in error shall not cause a system error, either fatal or non- fatal.
16.9.3.3.11 System Status Displays
The Workstations shall be capable of displaying a status display in a hierarchical layout. A System status display shall provide an overview of the operational status of the nodes on the communication network. The display shall be accessed by a keystroke without the need for key-locks. From the System display, any node status may be selected and displays of the status of each module. The module display shall provide the status of a particular module, the I/O processing modules and the I/O points.
16.9.4 Function Security
Methods shall be provided for limiting access to functions depending upon the Workstation software module. Individual functions will be enabled or disabled. Security will be defined as part of the Workstation configuration. An error message will be displayed when there is an attempt to access a protected function. Those functions, the control of which is restricted to an engineer, shall be under password control. A preliminary list of those functions is as follows:
a. Taking a point out of scan.
b. Rejection of any log.
c. Changing any information in the database of any variable or the configuration in the intelligent modules.
d. Changes in logs (adding or deleting points, changing trigger conditions, etc.)
PCMS Annexure B June 2017 B - 67 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal or graphic displays.
e. Communication network configuration.
Other functions to be under password control shall be determined by the Purchaser during the System design, if needed. The System shall also have the capability to allow the engineer to add or remove functions to/from the restriction. Contractor shall supply complete instructions on how this is to be done in field.
PCMS Annexure B June 2017 B - 68 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal 17. ELECTRICAL REQUIREMENTS
17.1 General The requirements detailed under this paragraph apply to all Electrical Auxiliary Equipment (cubicles, switches, breakers, lamps, relays etc., cables, terminal blocks, etc.) supplied under this Contract.
17.2 Power Supplies
17.2.1 The Purchaser shall provide the main and auxiliary power supply network.
17.2.1.1 The following electrical power may be provided by Purchaser to The Plant Control & Monitoring System cabinets:
a. 380 VAC + 5%, - 5%, 3Ph, 50 Hz b. Uninterruptible power 120VAC, 50 Hz, single phase. c. 220VDC + 10%, -15% floating, from the station batteries. d. Single phase convenience power 230VAC, 50Hz. e. The power feed to the drive units is 208V, 3Ph, 50Hz.
17.2.1.2 The following main and auxiliary power supply network shall be provided by Purchaser for the Electrical Auxiliary Equipment: a. 6.9kV +5%, 3Ph, 50Hz (for motors above 250 HP) b. 380 VAC + 5%, - 5%, 3Ph, 50 Hz c. Single phase control power 230VAC, 50Hz. d. Single phase convenience power 230VAC, 50Hz. e. Uninterruptible Power Supply (UPS), single phase 120VAC, 50Hz. f. 220VDC + 10%, -15% floating.
17.3 Control Enclosures
17.3.1 Enclosures Requirements
The Control enclosures shall conform to the following standards, as supplemented herein: EPD-A.03/04: Control Cubicles Wiring Requirements. EPD-2/99: Standard requirements for painting and corrosion protection of electrical equipment. In addition the following requirements shall be met:
a. Separate Termination/Marshalling cabinets shall be furnished in order to
PCMS Annexure B June 2017 B - 69 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal permit use of the existing cables. All existing and new field cables will be connected to the a.m. cabinets. No electronic equipment shall be mounted in the termination area.
b. Separate 230V, 50Hz single phase supply shall be provide by Purchaser for convenience outlets. This supply shall be separate and distinct from the control voltage supply.
c. Each cabinet shall be provided with temperature and open door detectors for alarm.
17.3.2 Wiring
Internal wiring shall be made with wires of halogen-free insulation type and shall be made according to EPD-A.03/04 requirements.
7.4 Cables & Wiring
17.4.1 Prefabricated Cables a. Cables will be according to the equipment list. Their types will be subject to Purchaser’s (IEC’s) approval. The cables will be flame retardant. Cables shall meet IEEE-383-1974 Flame test requirements or equivalent VDE 0472 Flame test. Voltage rating is 600V, according to NEMA-IPCEA, or 500V according to VDE. b. Cable connectors will be keyed, to prevent improper connection in the field. The Contractor shall supply all the special tool(s) required for installing the plug- in connectors. c. Plug connectors shall include a locking feature to avoid accidental disconnection. d. The Contractor shall supply all the special tool(s) required for installing the plug- in connectors. e. Plug connectors and cables on both ends shall be tagged with identifying numbers, according to Purchaser’s cable identification numbers. f. The individual pre-fabricated cables shall not be cut until final cutting length information is received from Purchaser.
PCMS Annexure B June 2017 B - 70 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal g. A quantity of about 20% spare plugs and receptacles for each type of connector shall be provided as part of basic scope of supply. h. Monitor and control circuits, in which connectors are used, shall also include provisions for connection
17.5 Control and Distribution Enclosures and Panels
17.5.1 The Control enclosures shall conform with the applicable standards detailed in article 5.2 above (5.2.1 and 5.2.5).
In addition the following requirements shall be met:
17.5.2 The cabinet design shall be modular, with the logic equipment laid out in clearly identified functional groups.
17.5.3 Permanent type nameplates and identification drawings shall be provided in the cabinet to clearly identify and locate individual function devices. Nameplates shall include a functional system of each device as well as a location number.
17.5.4 Adequate space for mounting fire protection detectors on top cover shall be provided within each cabinet. On the top cover a removable plate for this purpose shall be provided with the following dimensions: 250/250mm.
17.5.5 220V, 50Hz, single phase supply shall be provided by the Purchaser for panel lighting and convenience outlets. This supply shall be separate and distinct from the control voltage supply.
17.5.6 The Internal wiring shall conform to the applicable standards detailed in article 5.2.1 above.
17.5.7 The Control equipment shall meet the environmental conditions and related requirements as detailed in article 9.3.1 above.
17.5.8 All electrical components mounted outdoors shall be provided in an outdoor weatherproof enclosure, NEMA 4X or IP65 with corrosion protection, shall meet the environmental conditions and related requirements as detailed in article 9.3.2 above.
Contractor shall design the equipment and advise the Purchaser of the appropriate installation procedures, necessary to prevent any adverse effect on the System due to RFI and EMI noise produced by the noisy environment of the
PCMS Annexure B June 2017 B - 71 THE ISRAEL ELECTRIC CORPORATION LTD. ANNEXURE "B" Engineering Division SPEC.: MM-2701 ISSUE: For Proposal plant, which includes motors, contactors and high voltage switchgear, as well as other external disturbing electro-magnetic fields, like radio transmission devices or communication equipment, including cellular phones.
The Contractor shall take the necessary steps to minimize the effects of lightning strikes on circuits which contain elements located outside the main plant building. This should include proper grounding recommendations, the use of surge arrestors, optical isolators, isolating transformers or any other means which will provide suitable protection.
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