DESIGN, SUPPLY, INSTALLATION AND COMMISSIONING OF REMOTE I/O PANEL AND MODIFICATION IN THE EXISTING PLC BASED CONTROL

SYSTEM FOR INCORPORATION OF NEW FACILITIES

ANNEXURE CABLE & JB SCHEDULE

REMOTE IO CABLE SHEDULE Type Function /Utility Tags Description DI 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 FCV Area FCV Oil Pressure Low FCV Oil Level Low FCV Opened FCV Closed Pressure after FCV FCV Control Signal FCV Feedback Signal FCV-201 FCV-201 FCV-201 FCV-201 PT-209 FCV-201 FCV-201 Oil Pressure in FCV Low Oil Level in FCV Low FCV Fully Opened FCV Fully Closed Pressure after FCV Open/Close FCV FCV % Opening 1 1 1 1 1 1 1 NO NO NO NO 24 V DC 24 V DC 24 V DC 24 V DC (7787+) -3 (7728+) -1 (7787+) -4 TBDI1-27,28 TBDI1-29,30 TBDI1-31,32 TBDI1-33,34 TBAI1-21,22 TBAO-1,2 TBAI1-23,24 3MDL DI1-14 3MDL DI1-15 3MDL DI1-16 3MDL DI2-1 3MDL AI1-11 3MDL AO1-1 3MDL AI1-12 PLC JB-PAN-227 C-PRPL-AUG-PAN-06 12Cx1.5 1,2 3,4 5,6 7,8 1,2 3,4 5,6 JB Near FCV (Digital Signal) 1 1 1 R4 R5 R6 1 1 1 R1 R2 R3 DO AI RTD AO Relay RELAY 24V DC NO. CONTACT TYPE NO NO NO 24 V DC 24 V DC 24 V DC NO NO NO 24 V DC 24 V DC 24 V DC NO NO NO NO NO 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC (7756ac) -1 (7756ac) -2 (7756ac) -3 (7796+) -1 (7796+) -2 (7796+) -3 (7796+) -4 (7796+) -5 (7796+) -6 (7756ac) -4 (7756ac) -5 (7756ac) -6 (7756ac) -7 (7756ac) -8 (7756ac) -9 Signal Level MPLU Area 24 V DC 24 V DC 24 V DC ZENER No. Terminal No +Ve,-Ve TBDI1-1,2 TBDI1-3,4 TBDI1-5,6 TBDI1-7,8 TBDO1-1,2 TBDO1-3,4 TBDO1-5,6 TBDI1-9,10 TBDI1-11,12 TBDI1-13,14 TBDI1-15,16 TBDO1-1,2 TBDO1-3,4 TBDO1-5,6 TBDI1-17,18 TBDI1-19,20 TBDI1-21,22 TBDI1-23,24 TBDI1-25,26 TBRTD-1,2,3 TBRTD-4,5,6 TBRTD-7,8,9 TBAI1-1,2 TBAI1-3,4 TBAI1-5,6 TBAI1-7,8 TBAI1-9,10 TBAI1-11,12 TBRTD-10,11,12 TBRTD-13,14,15 TBRTD-16,17,18 TBRTD-19,20,21 TBRTD-22,23,24 TBRTD-25,26,27 Interconnections PLC MODULE NO. 3MDL DI1-1 3MDL DI1-2 3MDL DI1-3 3MDL DI1-4 3MDL DO1-1 3MDL DO1-2 3MDL DO1-3 3MDL DI1-5 3MDL DI1-6 3MDL DI1-7 3MDL DI1-8 3MDL DO1-4 3MDL DO1-5 3MDL DO1-6 3MDL DI1-9 3MDL DI1-10 3MDL DI1-11 3MDL DI1-12 PLC LS2-MP3 RTD-1 RTD-2 RTD-4 RTD-1 RTD-2 RTD-3 RTD-4 RTD-1 RTD-2 RTD-5 RTD-6 RTD-7 RTD-8 RTD-9 RTD-10 RTD-11 RTD-12 RTD-11 RTD-12 PT-207 PT-208 MP3 Seal Leakage MP3 Pump DE Temperature High MP3 Pump NDE Temperature High MP3 Pump Casing Temperature High MP3 Pump DE Vibartion X-axis MP3 Pump DE Vibartion Y-axis MP3 Pump NDE Vibartion X-axis MP3 Pump NDE Vibartion Y-axis Pump Axial Vibration MP3 Pump Key Phaser Vibration MP3 Moter Bearing DE Temperature HIGH MP3 Moter Bearing NDE Temperature HIGH MP3 Winding 1 Temperature 1 High MP3 Winding 1 Temperature 2 High MP3 Winding 2 Temperature 1 High MP3 Winding 2 Temperature 2 High MP3 Winding 3 Temperature 1 High MP3 Winding 3 Temperature 2 High MP3 Motor DE Vibration MP3 Motor NDE Vibration Pressure After MP2 Discharge Pressure After MP3 Discharge 3MDL DI1-13 3MDL RTD1-1 3MDL RTD1-2 3MDL RTD1-3 3MDL AI1-1 3MDL AI1-2 3MDL AI1-3 3MDL AI1-4 3MDL AI1-5 3MDL AI1-6 3MDL RTD1-4 3MDL RTD2-1 3MDL RTD2-2 3MDL RTD2-3 3MDL RTD2-4 PLC 3MDL RTD3-1 3MDL RTD3-2 3MDL RTD3-3 3MDL AI1-7 3MDL AI1-8 3MDL AI1-9 PLC (7787+) -2 TBAI1-19,20 3MDL AI1-10 JB-PAN-226 C-PRPL-AUG-PAN-5 12CX1.5 3,4 JB1-MP3 C-PRPL-AUG-PAN-04 16,17,18 19,20,21 22,23,24 25,26 27,28 1,2 Analog JB 40CX1.5 PLC JB2-MP3 C-PRPL-AUG-PAN-03 40CX1.5 JB3-MP3 C-PRPL-AUG-PAN-02 12CX1.5 3,4 1,2,3 4,5,6 7,8,9 10,11 12,13 14,15 16,17 18,19 20,21 1,2,3 4,5,6 7,8,9 10,11,12 13,14,15 MP-3 Temperature Monitoring8 RTDs MP-3 Temperature & Vibration Monitoring From to Tag Type PLC Core 1,2 3,4 5,6 7,8 9,10 11,12 13,14 15,16 17,18 19,20 21,22 23,24 25,26 27,28 29,30 31,32 33,34 1,2 Seal Leakage Status Signals Remarks

MP-3 Sunction Valve

MOV-223

MP-3 Discharge Valve

MOV-224

MOV 223 Opened Staus MOV 223 Closed Status MOV 223 Available MOV 223 Healthy MOV 223 open command MOV 223 close command MOV 223 Stop command MOV 224 Opened Staus MOV 224 Closed Status MOV 224 Available MOV 224 Healthy MOV 224 open command MOV 224 close command MOV 224 Stop command MP3 Suction Pressure LOW MP3 Discharge Pressure HIGH ESD Near MP3 MP3 Seal Leakage

24 V DC 24 V DC 24 V DC

PLC

JB-PAN-225

C-PRPL-AUG-PAN-01

40CX1.5

MP-3 Controls & Feedback

MP-3 Suction Pressure LOW MP-3 Discharge Pressure HIGH ESD Near MP-3 MP-3 DE Seal Leakage MP-3 NDE Seal Leakage Pump DE Temperature Pump NDE Temperature Pump Casing Temperature Pump DE Vibration Xaxis Pump DE Vibration Yaxis Pump NDE Vibration X-axis Pump NDE Vibration Y-axis Pump Key Phase Vibration X-axis Pump Key Phase Vibration Y-axis Moter Bearing DE Temperature Moter Bearing NDE Temperature Winding 1 temperature 1 Winding 1 temperature 2 Winding 2 temperature 1 Winding 2 temperature 2 Winding 3 temperature 1 Winding 3 temperature 2 MP3 Motor DE Vibration MP3 Motor NDE Vibration Pressure After MP2 Discharge Pressure After MP3 Discharge

PS-212 PS-213 ESD-205 LS1-MP3

(7756ac) -10 TBRTD-28,29,30 (7756ac) -11 TBRTD-31,32,33 (7796+) -7 (7796+) -8 (7787+) -1 TBAI1-13,14 TBAI1-15,16 TBAI1-17,18

PLC

JB-PAN-228

C-PRPL-AUG-PAN-07

12Cx1.5

Analog JB Near FCV

CABLE SCHEDULE REMOTE IO

Page 1

REMOTE IO CABLE SHEDULE Type Function /Utility Tags Description MOV 225 Opened Staus MOV 225 Closed Status MOV 225 Available MOV 225 Healthy MOV 225 open command MOV 225 close command MOV 225 Stop command MOV 226 Opened Staus MOV 226 Closed Status MOV 226 Available MOV 226 Healthy MOV 226 open command MOV 226 close command MOV 226 Stop command MP2 Speed Monitoring MP2 Current Monitoring MP3 Speed Monitoring MP3 Current Monitoring MP2 Speed Control MP3 Speed Control Start MP2 VFD Stop MP2 VFD Permissive MP2 Process Trip MP2 Start MP3 VFD Stop MP3 VFD Permissive MP3 Process Trip MP3 MP2 HT Breaker ON MP2 I/P Transformer Fault MP2 Loss of Speed Signal VFD-1 Fault VFD-1 Ready to Start MP2 Panel Fan ON VFD-1/MP2 Running VFD-1 in Remote MP3 HT Breaker ON MP3 I/P Transformer Fault MP3 Loss of Speed Signal VFD-2 Fault VFD-2 Ready to Start MP3 Panel Fan ON VFD-2/MP3 Running VFD-2 in Remote MP2 Breaker Available MP2 Breaker Tripped HT Incomer Available HT Incomer Tripped Transformer Breaker Available Transformer Breaker Tripped MP3 Breaker Available MP3 Breaker Tripped HT Incomer Available HT Incomer Tripped Transformer Breaker Available Transformer Breaker Tripped MP3 Breaker Remote Close MP3 Breaker Process Trip HT Incomer Remote Close HT Incomer Remote Trip Transformer Breaker Remote Close Transformer Breaker Remote Trip MP2 Breaker Remote Close MP2 Breaker Process Trip HT Incomer Remote Close HT Incomer Remote Trip Transformer Breaker Remote Close Transformer Breaker Remote Trip Spare Spare Spare Spare Spare Spare DI DI DI DI DI DI 54 55 56 57 58 59 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 R11 R12 R13 R14 R15 R16 R21 R22 R23 R24 R25 R26 DI 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 R7 R8 R9 R10 R17 R18 R19 R20 24 24 24 24 24 24 24 24 V DC V DC V DC V DC V DC V DC V DC V DC NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC 24 V DC SPARE DI 1 1 1 R30 R31 R32 1 1 1 R27 R28 R29 DO AI RTD AO Relay RELAY 24V DC NO. CONTACT TYPE NO NO NO 24 V DC 24 V DC 24 V DC NO NO NO Signal Level 24 V DC 24 V DC 24 V DC ZENER No. Terminal No +Ve,-Ve TBDI1-91,92 TBDI1-93,94 TBDI1-95,96 TBDI2-1,2 TBDO1-53,54 TBDO1-55,56 TBDO1-57,58 TBDI1-3,4 TBDI1-5,6 TBDI1-7,8 TBDI1-9,10 TBDO1-59,60 TBDO1-61,62 TBDO1-63,64 TBAI1-23,24 TBAI1-25,26 TBAI1-27,28 TBAI1-29,30 TBAI1-3,4 TBAI1-5,6 TBDO1-9,10 TBDO1-11,12 TBDO1-13,14 TBDO1-15,16 TBDO1-33,34 TBDO1-35,26 TBDO1-37,38 TBDO1-39,40 TBDI1-35,36 TBDI1-37,38 TBDI1-39,40 TBDI1-41,42 TBDI1-43,44 TBDI1-45,46 TBDI1-47,48 TBDI1-49,50 TBDI1-63,64 TBDI1-65,66 TBDI1-67,68 TBDI1-69,70 TBDI1-71,72 TBDI1-73,74 TBDI1-75,76 TBDI1-77,78 TBDI1-51,52 TBDI1-53,54 TBDI1-55,56 TBDI1-57,58 TBDI1-59,60 TBDI1-61,62 TBDI1-79,80 TBDI1-81,82 TBDI1-83,84 TBDI1-85,86 TBDI1-87,88 TBDI1-89,90 TBDO1-21,22 TBDO1-23,24 TBDO1-25,26 TBDO1-27,28 TBDO1-29,30 TBDO1-31,32 TBDO1-41,42 TBDO1-43,44 TBDO1-45,46 TBDO1-47,48 TBDO1-49,50 TBDO1-51,52 TBDI2-11,12 TBDI2-13,14 TBDI2-15,16 TBDI2-17,18 TBDI2-19,20 TBDI2-21,22 Interconnections PLC MODULE NO. 3MDL DI3-14 3MDL DI3-15 3MDL DI3-16 3MDL DI4-1 3MDL DO2-11 3MDL DO2-12 3MDL DO2-13 3MDL DI4-2 3MDL DI4-3 3MDL DI4-4 3MDL DI4-5 3MDL DO2-14 3MDL DO2-15 3MDL DO2-16 3MDL AI1-13 PLC VFD Panel-2 VFD Panel-2 VFD Panel-2 VFD Panel-2 VFD Panel-2 (7787+) -6 (7787+) -7 (7787+) -8 (7728+) -2 (7728+) -3 3MDL AI1-14 3MDL AI1-15 PLC 3MDL AI2-1 3MDL AO1-2 3MDL AO1-3 3MDL DO1-7 3MDL DO1-8 3MDL DO1-9 3MDL DO1-10 3MDL DO2-1 3MDL DO2-2 3MDL DO2-3 3MDL DO2-4 3MDL DI2-2 3MDL DI2-3 3MDL DI2-4 3MDL DI2-5 3MDL DI2-6 3MDL DI2-7 3MDL DI2-8 3MDL DI2-9 3MDL DI2-16 3MDL DI3-1 3MDL DI3-2 3MDL DI3-3 3MDL DI3-4 3MDL DI3-5 3MDL DI3-6 3MDL DI3-7 3MDL DI2-10 3MDL DI2-11 3MDL DI2-12 3MDL DI2-13 3MDL DI2-14 3MDL DI2-15 3MDL DI3-16 3MDL DI4-1 3MDL DI4-2 3MDL DI4-3 3MDL DI4-4 3MDL DI4-5 3MDL DO2-11 3MDL DO2-12 3MDL DO2-13 3MDL DO2-14 3MDL DO2-15 3MDL DO2-16 3MDL DO2-21 3MDL DO2-22 3MDL DO2-23 3MDL DO2-24 3MDL DO2-25 3MDL DO2-26 3MDL DI4-6 3MDL DI4-7 3MDL DI4-8 3MDL DI4-9 3MDL DI4-10 3MDL DI4-11 PLC VFD-PANEL-2 C-PRPL-AUG-PAN-11 2PX1.5 3,4 1,2 3,4 5,6 7,8 9,10 11,12 13,14 15,16 17,18 19,20 21,22 23,24 25,26 27,28 29,30 31,32 33,34 35,36 37,38 39,40 1,2 3,4 5,6 7,8 9,10 11,12 13,14 15,16 17,18 19,20 21,22 23,24 25,26 27,28 29,30 31,32 1,2 3,4 5,6 7,8 9,10 11,12 13,14 15,16 17,18 19,20 21,22 23,24 VFD-PANEL-2 C-PRPL-AUG-PAN-10 2PX1.5 3,4 1,2 VFD PANEL-2 VFD-PANEL-2 C-PRPL-AUG-PAN-9 2PX1.5 3,4 1,2 VFD PANEL-2 From to Tag Type PLC Core 1,2 3,4 5,6 7,8 9,10 11,12 13,14 1,2 3,4 5,6 7,8 9,10 11,12 13,14 1,2 VFD PANEL-2 Remarks

FCV Upstream MOV

MOV-225

PLC

MOV-225

C-PRPL-AUG-PAN-15

12Cx1.5

MOV for FCV

FCV Downstream MOV

24 V DC 24 V DC 24 V DC

MOV-226

PLC

MOV-226

C-PRPL-AUG-PAN-16

12Cx1.5

MOV for FCV

24 V DC 24 V DC 24 V DC Control Room & MCC Area (7787+) -5

MP2 Speed Monitoring MP2 Current Monitoring MP3 Speed Monitoring MP3 Current Monitoring MP2 Speed Control MP3 Speed Control

VFD Panel-2

DO's-VFD Start/Stop, Start Permissive, Process Trip

PLC

VFD-PANEL-2 C-PRPL-AUG-PAN-12

40CX1.5

VFD PANEL-2

Dis-HT Breaker ON/OFF, I/P Transformer Fault, Loss of Speed Ref Signal, VFD Fault,Ready, Panel Fan ON, Motor/VFD running, VFD in remote

VFD Panel-2

PLC

VFD-PANEL-2 C-PRPL-AUG-PAN-13

40CX1.5

VFD PANEL-2

HT Incomer Monitoring

HT Incomer Control

VFD Panel-2

PLC

VFD-PANEL-2 C-PRPL-AUG-PAN-14

40CX1.5

VFD PANEL-2

CABLE SCHEDULE REMOTE IO

Page 2

REMOTE IO CABLE SHEDULE Type Function /Utility Tags Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare Spare DI DI DI DI DI Description 60 61 62 63 64 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 DI 1 1 1 1 1 SPARE DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO DO 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 SPARE AO AO4 AO5 AO6 AO7 AO8 1 1 1 1 1 1 SPARE RTD Channel Spare RTD12 Summary SPARE I/Os Used I/Os Supplied Modules SPARE I/Os SPARE I/Os ( % ) TBRTD-34,35,36 3MDL RTD3-4 TBAO-7,8 TBAO-9,10 TBAO-11,12 TBAO-13,14 TBAO-15,16 3MDL2 3MDL2 3MDL2 3MDL2 3MDL2 AO1-4 AO1-5 AO1-6 AO1-7 AO1-8 R33 R34 R35 R36 R37 R38 R39 R40 R41 R42 R43 R44 R45 R46 R47 R48 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 42 V V V V V V V V V V V V V V V V DC DC DC DC DC DC DC DC DC DC DC DC DC DC DC DC SPARE AI AI17 AI18 AI19 AI20 AI21 AI22 AI23 AI24 AI25 AI26 AI27 AI28 AI29 AI30 TBAI-33,34 TBAI-35,36 TBAI-37,38 TBAI-39,40 TBAI-41,42 TBAI-43,44 TBAI-45,46 TBAI-47,48 TBAI-49,50 TBAI-51,52 TBAI-53,54 TBAI-55,56 TBAI-57,58 TBAI-59,60 3MDL AI2-2 3MDL AI2-3 3MDL AI2-4 3MDL AI2-5 3MDL AI2-6 3MDL AI2-7 3MDL AI2-8 3MDL AI2-9 3MDL AI2-10 3MDL AI2-11 3MDL AI2-12 3MDL AI2-13 3MDL AI2-14 3MDL AI2-15 TBDO1-65,66 TBDO1-67,68 TBDO1-69,70 TBDO1-71,72 TBDO1-73,74 TBDO1-75,76 TBDO1-77,78 TBDO1-79,80 TBDO1-81,82 TBDO1-83,84 TBDO1-85,86 TBDO1-87,88 TBDO1-89,90 TBDO1-91,92 TBDO1-93,94 TBDO1-95,96 3MDL DO3-1 3MDL DO3-2 3MDL DO3-3 3MDL DO3-4 3MDL DO3-5 3MDL DO3-6 3MDL DO3-7 3MDL DO3-8 3MDL DO3-9 3MDL DO3-10 3MDL DO3-11 3MDL DO3-12 3MDL DO3-13 3MDL DO3-14 3MDL DO3-15 3MDL DO3-16 DO AI RTD AO Relay RELAY 24V DC NO. CONTACT TYPE Signal Level ZENER No. Terminal No +Ve,-Ve TBDI2-23,24 TBDI2-25,26 TBDI2-27,28 TBDI2-29,30 TBDI2-31,32 Interconnections PLC MODULE NO. 3MDL DI4-12 3MDL DI4-13 3MDL DI4-14 3MDL DI4-15 3MDL DI4-16 From to Tag Type PLC Core Remarks

53 64 4 11 17%

32 48 3 16 33%

16 30 2 14 47%

11 3 12 8 3 1 1 5 8% 63%

CABLE SCHEDULE REMOTE IO

Page 3