W.T. P PLC Specification: I.P.D.C. Project: Shirvan Gas Turbine Power Plant

IRAN POWER DEVELOPMENT COMPANY
MINISTRY OF ENERGY
I.P.D.C.
PROJECT: SHIRVAN GAS TURBINE POWER PLANT
W.T. P PLC SPECIFICATION
IN-HOUSE REVISIONS
D C B A 0 Second Issue The First Issue H.N.
22/05/05
DOCUMENT REVISIONS
D C B
H.N.
22/05/05
H.N. H.N.
22/05/05 12.Feb.05
A 0
Second Issue The First Issue
H.N. H.N.
22/05/05 06.Feb.05
H.N. H.N.
22/05/05 06.Feb.05
H.N. H.N.
22/05/05 12.Feb.05
H.N. 06.Feb.05 H.N. 06.Feb.05
Rev. Description Prep Date Chkd Date
App ro.
Date
Rev.
Description
Prep
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MAPNA Co.
(PRIVATE JOINT STOCK) IRAN POWER PLANT PROJECTS MANAGEMENT Co.
Doc. No.: MP-SVG-30IE-11-ZIP-001
Rev.A File No: 30IE11ZIP001
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Revisions 0 A X X X X X X X X X X X X X X
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CONTENTS
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Doc. No.: MP-SVG-30IE-11-ZIP-001 Rev.A File No: 30IE11ZIP001 MF Code: Page 2 of 14
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1. 2. 3. 4.
SCOPE STANDARDS AND CODES AMBIENT CONDITION EXTENT OF SUPPLY

4.1 4.2
4 4 4 4 4 4 5 5 5 5 6 7 7 9 9 10 11 11 11 12
EQUIPMENT SERVICES GENERAL HARDWARE REQUIREMENT

5.2.1
5. DESIGN AND CONSTRUCTION CHARACTERISTICS

5.1. 5.2.
HARDWARE GENERAL REQUIREMENT
5.3 5.4 5.5 5.6 5.7 5.8 5.9
PROCESSOR UNIT MEMORY UNIT I/O UNITS OPERATOR INTERFACE PROGRAMMING TERMINAL POWER SUPPLY UNIT DOCUMENTATION
5.9.1 5.9.2
HARDWARE DOCUM,ENTATION SOFTEWARE DOCUMENTATION SPARE PARTS 12 SPECIAL TOOLS 12
5.10
SPARE PARTS AND SPECIAL TOOLS

5.10.1
5.10.2
5.11
SHOP TESTS
5.11.1
12 FACTORY ACCEPTANCE TEST(FAT) 12 QUALITY ASSURANCE TEST 13 SYSTEM POWER-UP TESTS 13
5.11.2
5.11.3
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5.11.4
WITNESS TEST 13 DETAIL FINAL ACCEPTANCE TEST 13 TEST DOCUMENTS REQUIREMENT 14 FINAL REPORT 14
5.11.5
5.11.6
5.11.7
SCOPE
This specification covers design, construction, general requirement characteristics, inspection, tests and technical documents for PLC (programmable logic controller) of Water Supply of Shirvan power plant
STANDARDS AND CODES

PLC system design shall be in compliance to the latest revision of IEC 1131.3 standard.
AMBLENT CONDITION
Site Location Road Site Elevation Max. Ambient Air Temperature Min. Ambient Air Temperature Design Ambient Temperature Relative Humidity Design wind velocity 9 km east of Shirvan in the Ghotbabad 1115 m above sea level 42.3C - 30C 15C 56% 144 km/hr
EXTENT OF SUPPLY
1.1 EQUIPMENT The supply consists of the following: Programmable logic controller (PLC) I/O interface modules Power supplies Programmer 1.2 SERVICES
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The supply includes: Inspection and tests Complete documentation including: installation drawings, Operation manual, maintenance manual, catalogs and certificates.
DESIGN AND CONSTRUCTION CHARACTERISTICS

1.3 GENERAL The water treatment plant control system will be equipped with one PLC unit to monitor equipment status for their operating limits and release contact inputs, to perform functions such as, permissive operational conditions, sequential logic for start-up and shutdown the affected equipment. The PLC will be modular design with easy maintenance and operation. The PLC will be capable to be programmed by ladder diagram symbols as well as, any other industrial standard symbols (According to IEC 1131.3 standard): 20% spare shall be considered for I/O's. A microprocessor based portable programming terminal will make it possible to configure, send and receive data to and from the input /output modules, display alphanumeric messages and either Boolean or ladder type diagrams on the screen, and drive printers. 1.4 HARDWARE REQUIREMENTS The PLC's hardware will be generally of highly modular electronics (microprocessor based) using the state of the art technology. The following separate modules are considered as the structure of the PLC; CPU, memory, I/O interface, power supplies. 1.4.1 HARDWARE GENERAL REQUIREMENTS The CPU will be capable to be expanded animatingly. Such a feature will be for I/O increase in future by means of adding further CPU'S and interface cards between CPU'S:
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Provisions will be made in the system, to program the PLC directly by means of Programming terminal, as inserting memory modules (EPROA or EEPROM modules.) The controller will be for of rack-mounted type to be mounted inside industrial enclosures. The PLC system will provide adequate self-diagnostic capability for system hard ware and software. Necessary standard hardware will be provided for PLC system, which has been field proven on previous similar projects. All hardware will be interchangeable by new versions of modules without requirements for internal or external field modifications. Card files will be readily accessible. Any single fault shall not prevent a shutdown on a genuine input single demand nor initiate a spurious shut -down.
1.5 PROCESSOR UNIT The central processing unit (CPU) will continuously scan the application program stored in memory, along with status of all inputs, and execute the programmed commands to the appropriate outputs. The logic controller will be preferably manufactured by commercially available microprocessor chips and shall be of standard manufacturer product. The CPU will have the following capabilities, as a minimum: Logic functions Timing functions. Counting functions Sequence functions Arithmetic functions Data transfer to other components of the PLC system Failure diagnostics Data manipulation A key-operated mode-selector switch will be provided to select the CPU mode
These modes will include: Program load / debug: In this mode, outputs will be disabled to allow alteration of memory by the programming terminal or computer Run: In this mode application programs will be executed and all outputs are enabled.
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The selected CPU operating mode will be visually indicated on the PLC front pane.
The CPU will be capable to be connected to a computer device or similar programming terminal for program entry and debugging of existing programs.
The CPU will be capable to be connected to a printer documentation of the application programs stored in the PLC's memory (e.g. loading diagrams or logic functions, I/O reference and memory listing). 1.6 MEMORY UNIT
The internal memory of the PLC will be so sized that, at least 30% spare memory to be available after definition of the I/O tables and entry of the application programs. The central controller memory capacity will be sufficient for all control and monitoring function plus enough spare space with to be expanded for handling future expansions. A power failure or power - off condition will not change the data loaded to the memory, it shall reside in it unit deliberately changed. Memory will be available in static RAM, EPROM or EEPROM. Volatile memory, if provide, will have a battery backup system capable of retaining all memory for a minimum of six (6) months. This battery will not require any special venting, the backup battery will be capable of being replaced with no interruption of memory integrity. The application memory will be available in sizes suitable for the given application, memories must be expandable in the field by card exchange. The entire application memory will be available for storing the operational control or application program, considering that executive or "housekeeping" programs has not been counted in memory size rating. All logic words will be checked for parity when read from memory. A parity error shall cause an immediate shutdown with alarm and visual indication. A memory protect key lock switch will be provided to prevent unauthorized program changes. 1.7 I/O UNITS
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The input / output (I/O) hardware is the equipment required to interface the central processor with the plant equipment. I/O hardware will be mounted in the same PLC cabinet that contains the central processor. The following I/O quantities has been considered for PLC unit:
-
15 No's Input module , each equipped with 16 7 No's output module , each equipped with 16
Inputs
-
Outputs The I/O modules for the PLC system will accommodate the following minimum requirements: The I/O modules will be clearly identified as to their function and shall be "keyed " to prevent incorrect location. LED indicator lights will be provided for each input / output cards. I/O modules will be easily removed and replaced without disturbing external wiring. Field wiring terminals will be clearly identified. I/O modules will accept Discrete I/O, but not be limited to the other inputs or outputs.
All filed instruments and equipment external to the PLC will terminate in terminal trips located at bottom half of the cabinets. The top half of the cabinets will be equipped with rack chassis to accommodate the I/O modules and cards, connection between different I/O cabinet will be made by means of cord and sockets. The detail arrangement of the cabinets and pertinent connectors will be submitted by the bid proposal. The I/O units meet the following requirements, as minimum:
The I/O interface will be modular in design, installed in heavy duty, I/O chassis. Termination shall not be to the I/O modules, but to the rack plug- in connectors. 20% spare will be considered for I/O's. The I/O termination will be made by means of screw terminals suitable for wires. It will be possible to install the I/O modules in any configuration within each I/O chassis, regardless of signal voltage level. The I/O, as well as PLC cabinets, will be provided with suitable heat dissipation Fans. The heat dissipation of the I/O chassis will be adequate when all I/O modules are inserted (all spare locations are in use) and carrying their maximum design current. All I/O modules will be plug- in type and will permit insertion or removal from the chassis without disturbing the external wiring
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The power supply unit of the I/O cabinets shall be installed at top section of the cabinets mounted to a sub- panel with suitable indication of the status of operation of the power supplies. The status of all inputs and outputs along with the I/O card, Fault status will be indicated on the visible front edge of I/O modules. Status and alarm contact inputs will be sensed by the I/O system. The system will accommodate both normally open and normally closes contacts. Normally closed contacts will be used for alarm or shutdown inputs normally open contacts will be used for equipment status input. Contact input modules will include circuitry to ensure elimination of "chatter" or bounce ", during contact closure. If necessary, interposing relays will be provided for contact outputs. Relay contacts shall be free of voltage, and the contacts shall be independent of each other. Discrete output modules will be capable of handling on /off signals to the field devices with contacts closed at normal process conditions. Contact outputs will be fail safe in order to drive the equipment to a safe position on power failure, i.e. contacts will be closed to start on equipment or stroke a motor operated valve to the opposite, and vice versa. Each I/O circuit will be designed to have insulation withstanding of 1000 VAC / VDC for on unlimited time. The I/O module cabinetry, will be engineered and implemented in a manner that the logically related function for each process area to be physically grouped together in the same cabinet. The I/O chassis will be capable to be installed remote from the PLC's processor unit with shielded / twisted, coaxial, or twin axial cable interconnecting them. Remote I/O chassis, if used, will have their own power supply with status indicators and fault monitor to identify the transmission faults.
1.8 OPERATOR INTERFACE Operation of the various plant processes will generally be from panel mounted pushbuttons and indicating lights, which may be located on a local panel. 1.9 PROGRAMING TERMINAL Programming facilities will be provided for the engineering and/or maintenance interface to the PLC. The programming device will provide the following functions: Monitor user programs Alter/ edit user, programs Commission and test user program
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Control all PLC information It shall be possible to connect the programming device either directly to a particular PLC system, or to the PLC data highway where such is provided. Mass storage device will be provided for the user programs that will provide fast reload capability. The saving and reload procedure will be provided with either a key lock or software security function to ensure access by authorized personnel only. Provisions will be made to transfer the contents of a PLC processor memory to a hard copy printer via an RS-232C or ASCII port. The programming terminal will provide capability to define all logic elements in a ladder diagram by a reference code number. The programmer will be equipped with application software's to enable the operation to define all logic elements in standardized logic symbols as ISA-S52, VDE-4019 and IEC-617-12. The PLC application programs and I/O configuration will be provided removable diskettes as well as the terminal's hard disk media. It will possible to store the PLC application programs and I/O configuration removable diskettes/CD for backup purpose which in the event memory deletion purposely or accidentally, memory will be reloaded the back -up diskettes /CDs. on be on of by
Application programs will be furnished with programming terminal to provide Comprehensive aid for PLC program debugging and off-line program developments The programmer system will provide a menu-oriented display for configuring and operating the adder logic, as well as, all other logic loading languages. The programmer system will provide on-line help screen and prompt messages for assistance, during inter- active logic system development and maintenance. System will contain a logic test mode that allows the user the to force the contacts and coils programmed, as well as assigning present reset values for the timers / counters for dynamic verification of program operations 1.10
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POWER SUPPLY UNIT (S)

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Power supply units will be used for the CPU's and the internal memory in the same enclosure. The following articles define the minimum requirements to be met by power supply units:
Main voltage monitoring circuit will be provided in the power supply units. This circuit will transmit under voltage signal to the CPU to stop communication with the I/O interface before loss of logic- level power of the CPU occurs. The circuit will detect any line voltage drop below minimum rated value for time duration more than one- half cycle. The power supplies will be mounted on the top side of the cabinets using a sub-panel section. Power supply status will be indicated on this sub-panel section, as well as, on the front side of power supply unit. Power supply unit will have current limiting circuit breaker device on the primary side, as well as, diode polarity isolation, current limiting circuitry and over-voltage protection against their primary voltage transients. Power supplies will have their individual alarms, hardwired to suitable terminals for external alarm connection. Power to the output drivers will not be applied before power to the logic circuits and all circuits will be reset when main power to the system is supplied or restored. DOCUMENTATION
1.11
Documentation with respect to programmable controller systems is defined as an orderly collection of record information, concerning both the hard ware and software components of the system. The information will allow the client without reference to the supplier, to properly test check. Operate, troubleshoot and repair, add/delete maintain or modify the system. 1.11.1 HARDWARE DOCUMENTATION
Maintenance manuals-these binders will typically contain a copy of each service and / or technical manual schematics for all elements. These manuals shall also contain a listing of diagnostics for each device plus instructions of loading and running these testing aids. A system manual that defines all interface connections between system components, provides details on any modification to standard components, describes overall system operation and special programming, and lists all major components to the module level.
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Complete literature for all specific portions of the system including logic diagrams, schematics, and wiring lists. Operators manuals-this document typically contains operator oriented data and information such as CPU operation, terminal operation, etc. Additional reference material on such areas as theory of operation on all elements of the system, general architecture of the system a listing of all components and subassemblies for the system, factory testing data all hard ware modifications or changes during factory test, etc. Listing of all ROM and firmware components. 1.11.2 SOFTWARE DOCUMENTATION
APPLICATION PROGRAM
Program listing for the real time operating system executive and all application software. Real time operating system support and installation manuals. Application programs, specifications, descriptions, and flow charts. Memory organization (i.e. data base layout and program partition). Diagnostic software listing, flow charts and descriptions. Listings, operating procedures and documentation of all support and development software. SPARE PARTS AND SPECIAL TOOLS SPARE PARTS
1.12 1.12.1
a) Construction pre-commissioning and commissioning spare parts will be provided together with the PLC supply. b) Five years spare parts The parts necessary for five years operation will be proposed separately to the client. 1.12.2 SPECIAL TOOLS
All special tools necessary for the main and auxiliary equipment for erection, pre-commissioning, commissioning and maintenance will be supplied. 1.13 SHOP TESTS
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The following articles specify the general requirement for inspection, testing and factory acceptance test for PLC equipment modules and system. The final shop test will be carried out according to final mutually agreed procedure. 1.13.1 GENERAL The test shall demonstrate the functional integrity of the system software and hardware. Client assigned inspectors shall inspect the performance of all tests and they shall have right of access to all facilities involved in manufacture process of the equipment purchased under this specification. The vendor will maintain and / or replace any hardware or modify the software, if the specified functions are not performed satisfactorily in (FAT) period on client inspector judgment. A detailed, scheduled factory test (FAT) procedure will be prepared considering all requirements set forward here-in, and be submitted to the client as per PLC supplier proposal. Also all necessary personnel and test equipment to perform the test will be provided. 1.13.2 QUALUTY ASSURANCE TESTS Quality control tests will be as per manufactures- quality control in the system. The sampling procedure for the tests will be defined by clients assigned inspectors. All workmanship will be checked and all this routine test on the system prior to power-up of the system will be performed. 1.13.3 SYSTEM POWER-UP TESTS FACTORY ACCEPTANCE TEST (FAT)
All functions of the PLC hard ware and software including diagnostic routines will be checked at system and sub-system level by simulating the inputs. 1.13.4 WITNESS TEST
For performing the witness test, all system components will be interconnected as per the required configuration at job site, in a manner to form totally integrated system. The entire logic circuit test be performed as per the final logic diagram in the contract. The inputs will be simulated at input terminals by means of a switch bank and the outputs will be observed in some dummy inductive loads. 1.13.5
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DETAIL FINAL ACCEPTANCE TEST:

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Following are details of testing to be performed by the supplier and witnessed by the client assigned inspectors. The clients inspectors will have the right to perform the required tests, or ask for additional testes, as included in the vendor test procedure proposal. a) Visual and mechanical testing: Client inspectors will carry out visual and mechanical checking of the system in principle to assure correct, proper and good workmanship of the equipment. b) Hardware testing: The testing shall include the following: Central processor unit (CPU) Input system Out put system Programming equipment Program storage unit Correct operation within the voltage variations specified Correct operation within the voltage variations specified Fault detection and diagnostic capabilities Correct operation in the presence of electrical transients and electromagnetic fields.
c) Functional testing Functional tests will include simulation of Inputs and outputs to verity proper response and operation of I/O signals. These tests include the following as a minimum: d) Complete loading off logic configuration Demonstration of all processor functions Scan time checking for all configurations Date base checking for all configurations Checking the system diagnostic routine and switchover function. Checking of spare capabilities terminals I/O memory, etc. Checking the arrangement of the cubicles to meet the job specifications. Performance test
After completion of above mentioned testing, the complete system will be kept energized for 72 hours continuously without any repair or
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maintenance. The system performance will be observed for given simulated Inputs. Any malfunction or alarm condition during the test will be recorded as "observations" in the final FAT report without any adjustment of any final fault permitted during this test. 1.13.6 TEST DOCUMENTS REQUIREMENT
All the test latest logic diagrams loaded in the system during FAT will be transferred on the CDs and will be shipped / transported with the PLC. 1.13.7 FINAL REPORT
On completion of factory acceptance test (FAT), the client assigned inspectors will issue a test certificate to be the permission for shipment. No shipment / transportation may be allowed without a test certificate. After the test certificate issuance, the equipment will be packed according to companies specification and inspections and forward it to the job-site.
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W.T. P PLC Specification: I.P.D.C. Project: Shirvan Gas Turbine Power Plant

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IRAN POWER DEVELOPMENT COMPANY

PROJECT: SHIRVAN GAS TURBINE POWER PLANT