Control & Operation Philosophy of Ac

Vivek
Kumar
Digitally signed by
Vivek Kumar
DN: cn=Vivek Kumar,
o=BHEL, ou=PEM,
email=vivekkumar@
bhelpem.co.in, c=US
Date: 2013.02.21
13:24:14 +05'30'
ESHA
16.01.13
09.11.12
Date
R-1
R-0
No
2nd Sub
1 St Sub
Revision
SC
SC
Prep By
25.02.2013
SC
SC
Checked
SC
SC
Approved
Project : (2x520 MW) HNPCL VIZAG TPS, A.P Project

Package
Air conditioning
CONTROL & OPERATION PHILOSOPHY OF AC
SYSTEM
Title
Customer
HINDUJA NATIONAL POWER CORPORATION LTD.
Principle Consultant
Main Contractor
Bharat Heavy Electricals Ltd.
Power Sector Project Engineering
Management, Noida
Sub Contractor
Sterling and Wilson Limited
Benfish IT Tower
31, GN Block
Sector-V, Salt Lake City
Kolkata-700 091
Job No:
BHEL Drawing No:
MOTT MACDONALD, NOIDA

Name
Sign
Date
Drawn
Checked
Approved
Prep By
Checked
Name
SC
SC
Date
09.11.12
09.11.12
Approved
SC
09.11.12
Scale-1:100
Sheet
1of 24
PE-V0-361-553-A105
PDF processed with CutePDF evaluation edition www.CutePDF.com
Submitted For
Approval
Rev No: 01
Compliance on Control Write Up A/C HNPCL

PAGE NO
DRG DESCRIPTION
Cover Sheet
MM's COMMENT MADE VIDE MAIL DTD. 03.01.2013
S&W/CSSAPL COMMENT dtd. 15.01.2013
BHEL to submit the P&ID for AC Plant-2, for reviewing the control philosophy
of AC plant-2
Noted and submitted on 2901013
BHEL to clarify whether a separate I/O has been considered in the PLC for
LOCAL/REMOTE selection.
Separate I/O not considered. Local/Remote selection will be in

HMI graphics as soft selection switch.
CPU's shall not be loaded more than 60% of the individual capacity even
under worst loading condition.
Noted & Agreed.Revised GA Drawings already submitted (PE-V9361-553-I917)
Speed of the communication bus shall be 100Mbps
PC - PLC communication bus is in ethernet 100Mbps
Bus and Data N/W loading shall in NO case be more than 60% of its capacity. Noted & Agreed.
1 os 22
6 of 22
Bus change over during failure shall be automatic and bump less.
BHEL to note that CPU, Communication Bus, I/O Modules, Power Supply etc
shall be redundant.
OWS/EOWS size shall be mentioned.
Noted & Agreed.

Noted & Agreed. Revised drawing submitted PE-V9-361-553I912, R-2
Revised drawing submitted.PE-V9-361-553-I912, R-2
BHEL to mention the type of interface with main plant DCS.
Ethernet. Revised drawing submitted.PE-V9-361-553-I912, R-2
BHEL to not that the OWS shall be 2 Nos and one shall be configured as
Operator Work Station and the other as Engineering workstation.
Noted but in your PLC Comments it is mentioned that both will

br EOWS, So we consider the same.
BHEL to mention the no and type of printers.
Revised drawing submitted.PE-V9-361-553-I912, R-2
ESP for Unit-4 to be corrected to ESP for Unit-2
Corrected in revised control Write-up
REMARKS
CONTRACTOR: STERLING & WILSON LIMITED

Project:
Package:
DOCUMENT:
DOC NO:
(2x520 MW) HNPCL VIZAG TPS, A.P

AIR-CONDITIONING & VENTILATION SYSTEM
CONTROL PHILOSOPHY FOR AIR CONDITIONG & VENTILATION
SYSTEM
PE-V0-361-553-A105 REV 01
15/01/2013
CONTROL WRITE-UP
SYSTEM DESCRIPTION FOR PLC CONTROLLED AIR CONDITIONING SYSTEM
A) PLC configuration
B) Details of Air-Conditioning system Equipments.
C) Operation Philosophy of Air-Conditioning Equipment
D) Operation Philosophy of Strip heater, Pan Humidifier & 3-way bypass valve.
A) PLC configuration:
For the operation & control of complete AC system dedicated PLC / PC System has been
envisaged. PLC with CPU, I/O panels (as required) shall be placed at different locations.
The PLC panel C01 (CPU Rack) located in the TG Building AC plant room consist of CPU &
I/O racks related to AC system.
OWS cum EWS consists of 1 no. PC, Monitor & Ethernet Switches, from this OWS the total
system can be operated, controlled & monitored based on the mode of operation selected.
1 nos. Remote I/O panels - C02 is located at Service building
1 no. Remote I/O panel C03 is provided at ESP- VFD 1
1 no. Remote I/O panel C04 is provided at ESP- VFD 2
Cable to be provided for PLC to remote I/O panels.
Complete operation can be carried through PLC OWS in Local (Auto and Manual) mode as
selected through Local (Auto and Manual) selector switch devised on the PLC OWS (HMI
Graphics) for respective equipments. Status / indications can be seen on PC monitor in both
Auto and manual mode.
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B) Details of Air conditioning system equipments:

1. Main Control Room (TG Building) (AC Plant 1)
a) UNIT 1
b) ESP VFD Control room of Unit 1
c) ESP VFD Control room of Unit 2
2. Service Building (AC Plant-2)
B.1) LIST OF AIR CONDITIONING SYSTEM EQUIPMENT FOR AC-1, MAIN CONTROL
ROOM
AC-1 plant consists of the following major items which are controlled through Panel C01
located at Main Control Room area. 3 Nos. Air Handling Units (AHU) : AHU 1/2 shall be located in the AHU Room at 17.0 M
Level, In case of failure of any of AHUs 1/2, AHU 3 will start automatically.
Motor driven Fan, Air filter & cooling coil comprises to Air handling unit. Each AHU is isolated
with, motorized isolation valve from chilled waterside & motorized non-return damper from
Airside, to isolate the unit if it is not operating.
2 Nos. Air Handling Units (AHU) : AHU 1 shall be located in the AHU Room at 8.5 M Level, In
case of failure of AHU No 1, AHU 2 will start automatically.
Motor driven Fan, Air filter & cooling coil comprises to Air handling unit. Each AHU is isolated
with, motorized isolation valve from chilled waterside & motorized non-return damper from
Airside, to isolate the unit if it is not operating.
5 Nos. Fan Coil Units (FCU) : 5 FCU shall be located at 0.0 M Level.
1 No. Fresh Air Fan (FAF) is provided in AHU room mentioned above.
standby fans.
Motorize Fire Damper for all supply and return air duct
There will be no
4 Nos. Cooling Towers (CT) are categorized in two following groups:Group#1 includes CT#1 & 2; both cooling tower fans can be selected in working OR standby
mode.
Group#2 includes CT#3 & 4, both cooling tower fans can be selected in working OR standby
mode.
Both groups are common for AC Plant-1; any of the groups can be selected as working.
Maximum two CT are required to run at a time during normal process.
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4 Nos. Condenser water pumps (CWP) are categorized as:Group#1 includes CWP#1 & 2; both pumps can be selected in working OR standby mode,
Group#2 includes CWP#3 & 4, both pumps can be selected in working OR standby mode.
Both groups are common for Plant-1; any of the groups can be selected.
Maximum two CWPs are required to run at a time during normal process.
4 Nos. Chilled water pumps (CHWP) are categorized in two following groups:Group#1 includes CHWP#1 & 2; both pumps can be selected in working OR standby mode,
Group#2 includes CHWP#3 & 4; both pumps can be selected in working OR standby mode.
Both groups are common for AC Plant-1; any of the groups can be selected.
Maximum two CHWPs are required to run at a time during normal process.
4 Nos. Chiller Machines (CHM) along with their individual isolation valves are categorized in
two groups;
Group#1 includes CHM#1 & 2; both CHM can be selected in working OR standby mode,
Group#2 includes CHM#3 & 4; both CHM can be selected in working OR standby mode.
Maximum two CHMs are required to run at a time during normal process.
The CHMs will be controlled from respective Microprocessor Panels located on each CHM.
AHU room of AC-1 system shall consist of following equipment
O
O
O
O
O
O
O
O
AHU
1 no. Isolation Valve in chilled water outlet line of each AHU
1 no. Isolation damper in AHU delivery duct of each AHU
3-way bypass Valve in inlet water line of each AHU and Isolation valve in bypass line.
1 no. Strip Heater & Fine Filter in conditioned air duct
1 no Fresh air fan, FAF
Other accessories like temperature & RH Sensors, etc.
Motorize Fire Damper For Supply & Return Air Duct etc.
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B.2) LIST OF AIR CONDITIONING SYSTEM EQUIPMENTS FOR AC-2, SERVICE BUILDING
AC-2 plant consists of the following major items that are controlled through Panel C02 located
at service building Room area: -
5 Nos. of Air Handling Units (AHU)

There are five elevations, one AHU is provided in each AHU room as below;
Elevation
Elevation
Elevation
Elevation
Elevation
0 meter1 no. AHU

4.25 meter1 no. AHU
8.5 meter1 no. AHU
12.75 meter1 no. AHU
17.0 meter1 no. AHU
Motor driven Fan, Air filter & cooling coil comprises to Air handling unit. No stand by unit is
envisaged.
1 No. Fresh Air Fan (FAF) is provided per AHU room, Five AHU room comprises to 5 Fresh Air
Fans, and No stand by unit is envisaged.
2 Nos cooling towers (CT), 1W + 1S are provided;
Both the Cooling Tower Fans are facilitating to run in working as well as standby mode.
Any one CT can be selected as working & remaining one can be selected as standby. If one of
the running CT fails the standby CT will start automatically.
2 Nos condenser water pumps (CWP), 1W + 1S are provided;
Both the pumps are facilitate to run in working as well as standby mode.
Any one CWP can be selected as working pump & remaining one can be selected as standby
pump. If one of the running CWP fails the standby CWP will start automatically.
2 Nos chilled water pumps (CHWP), 1W + 1S are provided;
Both the pumps are facilitate to run in working as well as standby mode.
Any one CHWP can be selected as working pump & remaining one can be selected as standby
pump. If one of the running CHWP fails the standby CHWP will start automatically.
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2Nos. Chiller Machines (CHM), 1W+1S are provided along with their individual isolation valves.
Both the CHMs are facilitate to run in working as well as standby mode. Any one CHMs can
be selected as working chiller machine & remaining one can be selected as standby chiller
machine. If one of the running CHM fails the standby CHM will start automatically.
Maximum one CHMs are required to run at a time during normal process.
Individual AHU room of AC-2 shall consist of following equipments
o One no. AHU per room
o 3-way bypass Valve in inlet water line of each AHU and Isolation valve in bypass line.
o 1 no. Strip Heater & Fine Filter in conditioned air duct
o 1Nos Fresh air fan, FAF
o Other accessories like temperature & RH Sensors, etc
o Motorize Fire Damper For Supply & Return Air Duct etc.
B.3) LIST OF AIR CONDITIONING SYSTEM EQUIPMENT OF AC-1, ESP VFD CONTROL
ROOM
ESP plant consists of the following major items which are controlled through Panel C03 located
at ESP-3 Control Room area.
3 Nos. Air Handling Units (AHU) for ESP VFD 1: AHU 1/2 shall be started in the AHU Room
of unit 1, In case of failure of any of AHUs 1/2, AHU 3 will start automatically.
Motor driven Fan, Air filter & cooling coil comprises to
Air handling unit. Each AHU is
isolated with, motorized isolation valve from chilled water outlet side & motorized non-return
damper from Airside, to isolate the unit if it is not operating.
1 Nos. Fresh Air Fan (FAF) are provided in each AHU room for unit-1,
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ESP-VFD Control Room shall consist of following equipment

O
O
O
O
O
O
O
O
AHU
3-way bypass Valve between inlet & outlet chilled water line of each AHU
1 nos. Fresh air fan, FAF
B.4) LIST OF AIR CONDITIONING SYSTEM EQUIPMENT OF AC-2, ESP VFD-4 CONTROL
ROOM
ESP plant consists of the following major items which are controlled through Panel C04 located
at ESP-4 Control Room area. 3 Nos. Air Handling Units (AHU) for ESP VFD 2 : AHU 1/2 shall be Started in the AHU Room
of unit 2 , In case of failure of any of AHUs 1/2, AHU 3 will start automatically.
Motor driven Fan, Air filter & cooling coil comprises to
Air handling unit. Each AHU is
isolated with, motorized isolation valve from chilled water outlet side & motorized non-return
damper from Airside, to isolate the unit if it is not operating.
1 Nos. Fresh Air Fan (FAF) are provided in AHU room for unit-2,
ESP for unit-2 of ESP-VFD Control Room shall consist of following equipment
O
O
O
O
O
O
O
O
AHU
3-way bypass Valve between inlet & outlet chilled water line of each AHU
1 nos. Fresh air fan, FAF
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C) Operating philosophy for Air-Conditioning Equipment

C.1) AC-1 for unit-1 & 2:
Manual mode, START operation:
Step#1 (Local mode/Remote mode): Select the Fresh Air Fan (FAF) from OWS selection
button as working fan. If the breaker is OK, the Fan will start.
Step#2 (Local mode/Remote mode):
Out of 3 Nos. of Air Handling Units (AHU) 1/2/3), in AC -1, minimum 2 AHUs need to be
started. Select three AHUs from OWS as a working & remaining one as standby AHU.
Start the selected AHUs from OWS.
PLC will automatically check the interlock of either of FA fan of respective AHU room is
running.
In case of failure/trip of any of working AHUs, standby AHU will start automatically.
While starting the standby AHU, it will also cross check whether FAF is running or not.
Out of 2 Nos. of Air Handling Units (AHU- 1/2), in AC -1, minimum 1 AHUs need to be started.
Select one AHUs from OWS as a working & remaining one as standby AHU.
Start the selected AHUs from OWS.
running.
Out of 5 Nos. of Fan Coil Units (FCU-1/2/3/4/5), in AC -1, minimum 1 FCU need to be
started. Start the selected FCUs from OWS.
FAF is necessary to be running to operate the either of AHU.
Monitoring of supply and return air Motorize Fire Damper
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Check the level of water in cooling tower basin & the makeup water tank through level
switches. Level switches will give indication in case the water level is low in the respective
areas.
If the water level is o.k., then maximum two nos Cooling Tower Fan can
given time.
be operated, at any
CT#1 & 2; two cooling tower fans can be selected in working and other two as standby mode.
Cooling Towers are grouped in two; both groups are common for AC Plant 1
Group #1 comprise to: CT#1 & 2
Group #2 comprise to: CT#3 & 4
Maximum Two CTs can be operated to deliver the condenser water to AC Plant-1, at any given
time . Either of group can be selected from the OWS CRT, if group#1 is selected group#2
should remain as a Standby.
If group#1 is selected: start the CT#1 from OWS CRT, after some time delay start CT#2 start
from OWS CRT, if either of CT fans fails to start or trips in running, PLC will automatically
start the CT#3. If CT#3 & either of CT#1 or CT#2 is running & any one of the two is tripped,
PLC will automatically start the CT#4. At any given time logic will ensure that TWO CTs are
running.
If group#2 is selected: start the CT#3 from OWS CRT, after some time delay start CT#4 from
OWS CRT, if either of CT fails to start or trips in running, PLC will automatically start the
CT#1.
If CT#1 & either of CT#3 or CT#4 is running
& any one of the two is tripped, PLC will
automatically start the CT#2. At any given time logic will ensure that TWO CTs are running.
PLC will check the following safeties before starting the CT.
a) Minimum 1 AHU is running
b) Breaker fault/trip is not available.
If any one of the CT trips & standby CT starts, standby CT will
were complied for tripped CT.
also check the permits, which
All four CTs are common for Plant-1; Working & standby grouping is made to ensure the
uniform utilization of equipments.
CW pumps are grouped in two groups; both groups are common for Plant-1
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Group #1 comprise to: CWP#1 & 2

Group #2 comprise to: CWP#3 & 4
Maximum Two pumps can be operated to deliver the condenser water to Plant-1, at any
given time . Either of group can be selected from the OWS CRT, if group#1 is selected group#2
should remain as a Standby.
If group#1 is selected: start the CWP#1 from OWS CRT, after some time delay start CWP#2
start from OWS CRT, if
either of pump fails to start or trips in running, PLC will
automatically start the CWP#3.
If CWP#3 & either of CWP#1 or CWP#2 is running & any one of the two is tripped, PLC will
automatically start the CWP#4. At any given time logic will ensure that TWO CWPs are
running.
If group#2 is selected: start the CWP#3 from OWS CRT, after some time delay start CWP#4
from OWS CRT, if either of pump fails to start or trips in running, PLC will automatically
start the CWP#1.
If pump#1 & either of CWP#3 or CWP#4 is running & any one of the two is tripped, PLC will
automatically start the CWP#2. At any given time logic will
ensure that TWO CWPs are
running.
PLC will check the following safeties before starting the CWP.
a) Minimum 1 CT Fan is running
If any one of the CWP trips & standby CWP starts, standby CWP will
which were complied for tripped CWP.
also check the permits,
All four CWPs are common for Plant-1; grouping is made to ensure the uniform
utilization of equipments.
CHW pumps are grouped in two groups; both groups are common for unit-3 & unit-4
Group #1 comprise to: CHWP#1&2
Group #2 comprise to: CHWP#3&4
Maximum two pumps can be operated to deliver the chilled water to Plant-1 AHUs, at any
given time
Either of group can be selected from the OWS CRT, if group#1 is selected group#2 should
remain as a Standby.
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If group#1 is selected: start the CHWP#1 from OWS CRT, after some time delay start CHWP#2
start from OWS CRT, if
automatically start the CHWP#3.
If CHWP#3 & either of CHWP#1 or CHWP#2 is running & any one of the two is tripped,
PLC will automatically start the CHWP#4. At any given time logic will ensure that TWO
CHWPs are running.
If group#2 is selected: start the CHWP#3 from OWS CRT, after
some time delay start
CHWP#4 from OWS CRT, if
automatically start the CHWP#1.
If pump#1 & either of CHWP#3 or CHWP#4 is running & any one of the two is tripped, PLC
will automatically start the CHWP#2. At any given time logic will ensure that TWO CHWPs are
running.
PLC will check the following safeties before starting the CHWP.
a) Minimum 1 CWP is running
If any one of the CHWP trips & standby CHWP starts, standby CHWP will
permits, which were complied for tripped CHWP.
also check the
All four CHWPs are common for both units; grouping is made to ensure the uniform
utilization of equipments.
Step# 6 (Local mode/Remote mode):
4 no. Chiller machines are grouped in two groups, both groups are common for Plant-1,
individual isolation valve at discharge of CHM are considered as an integral part of CHM.
Group #2 comprise to: CHM#3 & 4, along with their isolation valves.
Maximum Two CHMs
any given time.
can be operated to chill the water, so as to cater it to Plant-1 AHUs, at
Maximum Two CHW pump running to be ensured to operate the chiller machines & their
isolation valves.
Either of group can be selected, if group#1 is selected group#2 should
remain as a Standby.
If group#1 is selected: Open the isolation valve of CHM#1, after a delay of some time, &
isolation valve opening is ensured, start the CHM#1 from PLC.
Similarly, open the isolation valve of CHM#2, after a delay of some time, & isolation valve
opening is ensured, start the CHM#2. PLC will ensure that, the respective isolation valve
is open before starting the Chiller.
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If either of Chiller Machine fails to start or trips in running, PLC will automatically
open the isolation valve of CHM#3 & start the CHM#3.
If CHM#3 & either of CHM#1 or CHM#2 is running & any one of the two is tripped,
PLC will automatically open the isolation valve of CHM#4 & start the CHM #4 . At any
given time logic will ensure that TWO CHMs are running.
If group#2 is selected : Open the isolation valve of CHM#3 from PLC, after a delay of
some time , & isolation valve opening is ensured, start the CHM#3 from PLC.
Similarly, open the isolation valve of CHM#4 from PLC, after a delay of some time, &
isolation valve opening is ensured, start the CHM#4 from PLC. PLC will ensure that, the
respective isolation valve is open before starting the Chiller.
If either of Chiller Machine fails to start or trips in running, PLC will automatically
open the isolation valve of CHM#1 & start the CHM#1.
If CHM#1 & either of CHM#3 or CHM#4 is running & any one of the two is tripped,
PLC will automatically open the isolation valve of CHM#2 & start the CHM #2. At any
given time logic will ensure that TWO CHMs are running.
Isolation valve is considered as a part of chiller machine, once the isolation valve is
opened & open limit switch feedback is acknowledged by PLC, then only PLC can permit
to start the respective chiller machine.
Group selection of isolation valve & respective CHM is strictly same.
PLC will check the following safeties before opening the isolation valves of chiller machines
& starting the chiller machines:
a) Minimum 1 CHWPs are running
b) Chiller panel fault/trip is not available.
c) Group safety fault is not available.
If any one of the Chiller machine/isolation valve
trips & standby chiller
machine/isolation valve starts, standby Chiller machine/isolation valve will also check the
permits which were complied for tripped Chiller machine/isolation valve.
All four chiller machines along with their isolation valves are common for both
units, grouping is made to ensure the uniform utilization of equipments.
Selection/De-selection
applications.
of
standby
is
through
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toggle
function
for
all
standby

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Manual mode STOP operation (Local mode/Remote mode):

a)
b)
c)
d)
e)
f)
g)
h)
Stop the Chiller machines

Close the isolation valves
Stop the Chiller water pumps
Stop the Condenser water pumps
Stop the Cooling Tower Fans
Close the isolation valves & isolation dampers of AHUs
Stop the running AHUs
Stop the Running Fresh Air fans
Stop operation is done from PLC OWS in Local mode.

START
operation in Auto mode (Local /Auto):
A common Auto button is envisaged on OWS screen of PLC, if this

entire system for Plant-1 will turn into Auto mode operation.
button is pressed,
Select working Fresh air fan

Select either of two working AHUs & one standby AHU for Plant-1
Select either of CT group as working & another group as standby
Select either of CWP group as working & another group as standby
Select either of CHWP group as working & another group as standby
Select either of CHM group (along with their isolation valve) as working & remaining
group as standby
Once the operator gives common Auto start command, following operation will takes place
If the breaker is OK, the Fan will start.
PLC will automatically check the

running & will start the selected
working AHUs, standby AHU will
While starting the standby AHU, it
interlock of either of FA fan from AHU room is

working AHUS, In case of failure/trip of any of
start automatically.
will also cross check the FAF is running.

If the operation of minimum one AHU is ensured, PLC will start the first CT in
working group, after a delay of 6 seconds, PLC will start another working CT.
If the operation of minimum one CT is ensured, PLC will start the first CWP in
working group, after a delay of 6 seconds, PLC will start another working CWP.
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If the operation of minimum one CWP is ensured, PLC will start the first CHWP in
working group, after a delay of 6 seconds, PLC will start another working CHWP.
If the operation of minimum one CHWP running is ensured, the isolation valves on
running chiller machine will open. (Time delay of 6 second is provided between
CHWP start & isolation valve opening)
Once the opening of isolation valves of CHM is ensured by its limit switch
feedback from PLC in sequential operation.
The standby operation of AHUs for Plant-1, Cooling Tower Group ,CWP group,CHWP
per group & Chiler machine per group along with their isolation valves is taken
care by PLC & the operation will remain same as explained in manual mode
operation.
STOP operation in Auto mode (Local /Remote):

A common Auto-stop button is envisaged on OWS CRT screen of PLC, if this
button is
pressed, entire system for unit-3 & unit-4 will turn into Auto-stop mode operation & PLC
will take following actions;
a)
b)
c)
d)
e)
f)
g)
h)
Stop both the Chiller machines

Close both the isolation valves of chiller machines
Stop the Chiller water pump
Stop the Condenser water pump
Stop Cooling Tower Fan
Close both the isolation valves & isolation dampers of running AHUs
Stop all the running AHUs
Stop all the Running Fresh Air fans
C.2) AC-2 for Service Building:

Step#1 (Local/Remote):
There are five separate AHU rooms considered in AC-2, each AHU room consists of one
AHU. Common CT, CWP, CHWP & CHM provides chilled water for all five AHUs.
Depends on requirement, an individual AHU can be taken into operation.
A selection button is provided on OWS CRT to select or deselect the particular AHU.
Select the Fresh Air Fan (FAF) as working, from OWS selection button. Start the FAF from
OWS CRT. If the breaker is OK, the Fan will start.
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Step#2 (Local /Remote):

Start Air Handling Units (AHU) from OWS for individual AHU room. PLC will automatically
cross check the interlock of either of FA fan of respective AHU room is running.
Similar operation can be followed for all three elevations like:
Elevation 0 meter1 no. AHU
Elevation 4.25 meter1 no. AHU
FAF is necessary to be running to operate the AHU.
Check the level of water in cooling tower basin & the makeup water tank through level
switches. Level switches will give indication in case the water level is low in the respective
areas.
If the water level is o.k., then maximum one Cooling Tower Fan can be operated. , at any given
time.
Out of two CTs, maximum one CT can be running at any time, any one CTs can be
selected as working & the other one is necessarily to be selected as standby.
Start working selected CT-1 & 2 from OWS,
If the running CTs, either one fails, the standby CT will start automatically.
PLC will check the following safeties before starting the CT Fan :
a) Minimum 1 AHU is running
If any one of the CT trips & standby CT starts, standby CT will
permits which were complied for tripped CT Fan.
Both CTs are common for all five elevations , standby logic
the uniform utilization of equipments.
also check the
is developed to ensure
Selection/De selection of standby is through toggle function for all standby applications.
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Out of two CWPs, maximum one CWP can be running at any time, Either one CWP can be
selected as working & the other one is necessarily to be selected as standby.
Start working selected CWP-1/2 from OWS CRT,
If the running CWP fails, either one, the standby CWP will start automatically.
PLC will check the following safeties before starting the CWP:
a) CT Fan is running
If any one of the CWP trips & standby CWP starts, standby CWP will
permits which were complied for tripped CWP.
Both CWPs are common for all five elevations , standby logic
ensure the uniform utilization of equipments.
is
also check the

developed
to
Out of two CHWP, maximum one CHWP can be running at any time, Either one CHWP
can be selected as working & the other one is necessarily to be selected as standby.
Start working selected CHWP-1 /2 from OWS
If the running CHWP fails, either one the standby CHWP will start automatically.
PLC will check the following safeties before starting the CHWP :
a)Minimum 1 CWP is running
b)Breaker fault/trip is not available.
If any one of the CHWP trips & standby CHWP starts, standby CHWP will
the permits which were complied for tripped CHWP.
Both CHWPS are common for all five elevations , standby logic
ensure the uniform utilization of equipments.
also check
is developed to
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Step# 6 (Local /Remote):

Maximum one CHM can
AHUs, at any given time.
be operated to chill the
water, so as to cater it to all five
Out of two chiller machines along with their isolation valves, maximum one chiller
machine can be operated to chill the water , at any time. Either one chiller machine
along with its isolation valves can be selected as working & the remaining is necessarily
to be selected as standby.
Open the isolation valve of as working selected chiller machine from PLC,
Start the working selected chiller machine from PLC, so as to pass on the command at
chiller local panel for sequential operation.
If the running CHM is failed, the standby CHM along with its isolation
automatically.
PLC will check the following safeties before
machines & starting the chiller machines:
opening
the
valve will start
isolation valves
of chiller
a) 1 CHWP is running
b) Chiller panel fault/trip is not available.
c) Group safety fault is not available
If any one of the Chiller machine/isolation valve trips & standby chiller machine/isolation
valve starts, standby Chiller machine/isolation valve will also check the permits which
were complied for tripped Chiller machine/isolation valve.
Manual mode STOP operation (Local mode/Remote mode):
a) Stop the Chiller machines from PLC
b) Close the isolation valves from the PLC
c) Stop the Chiller water pumps from OWS CRT
d) Stop the Condenser water pumps from OWS CRT
e) Stop the Cooling Tower from OWS CRT
f) Stop the running AHUs
g) Stop the Running Fresh Air fans
Stop operation is done from PLC OWS CRT in Local mode.
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operation in Auto mode (Local /Auto):
A common Auto button is envisaged on OWS CRT screen of PLC, if this

button is
pressed, entire system for below mentioned elevation will turn into Auto mode operation.
Elevation 0 meter, Elevation 4.25 meter, Elevation 8.5 meter, Elevation 12.75,AHU
Elevation 17.0
Select working Fresh air fan for all five elevations

Select the AHUs those are required to be operated, per elevation
Select one CTs as working & remaining one as standby.
Select one CWs pumps as working & remaining one as standby
Select one CHWs pump as working & remaining one as standby
Select one CHM (along with their isolation valve) as working & remaining
standby.
one as
Once the operator gives common Auto start command, following operation will takes
place;
If the breaker is OK, the selected Fresh air Fan of AHU will start.
PLC will automatically check the interlock of either of FA fan from AHU room is
running & will start the selected working AHU.
FAF is necessary to be running to operate the
AHU.
Monitoring of supply and return air Motorize Fire Damper.
If the operation of minimum one AHU is ensured, PLC will start the first working
selected CT Fan , then one no CWP, Then one CHWP
If one CHWP running is ensured, the isolation valves on the working selected chiller
machine will open. (Time delay of 6 second is provided between CHWP start &
isolation valve opening)
Once the opening of isolation valves of CHM is ensured by its limit switch
feedback from PLC, a command is issued by PLC to Chiller panel to start the
chiller machine in sequential operation.
The standby operation of CHWP & Chiler machine along with their isolation valves
is taken care by PLC & the operation will remain same as explained in manual
mode operation.
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Selection/De-selection of standby is through toggle function for all

applications.
standby
STOP operation in Auto mode(Local /Remote):

A common Auto-stop button is envisaged on OWS CRT screen of PLC, if this
button is
pressed, entire system for AC-2 will turn into Auto-stop mode operation & PLC will take
following actions;
a) Stop both the Chiller machine
b) Close both the isolation valves of chiller machine
c) Stop both the Chiller water pump
d) Stop both the Condenser water pump
e) Stop both the Cooling Tower Fan
f) Stop all the running AHU
g) Stop all the Running Fresh Air fan
C.3) ESP-1, VFD -3 control room Building:
Select the Fresh Air Fan (FAF) from OWS
OK, the Fan will start.
selection button as working fan. If the breaker is

Out of 3 Nos. of Air Handling Units (AHU) 1/2/3, in ESP-1, maximum 2 AHUs need to be
started. Select two AHUs from OWS CRT as a working & remaining one as standby AHU.
Start the selected AHUs from OWS CRT.
running.
STOP operation in manual mode(Local /Remote):
a) Stop the running Air Handling Units
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b) Stop the Running Fresh Air fan

Select the UAF Pumps from OWS
breaker is OK, the Pump will start.
Select the UAF Fans from OWS
will start.
selection button as working and rest as stand by. If the
selection button as working. If the breaker is OK, the Fan

Out of 2 Nos. of Pumps, in unit-3, minimum 1 Pump need to be started & remaining one as
standby Pump.
Start the selected Pumps from OWS.
In case of failure/trip of any of working Pump, standby Pump will start automatically.
1 No. of UAF Fan, in unit-3, minimum 1 Pump needs to be started.
C.4) ESP-VFD-4 control room Building:
Select the Fresh Air Fan (FAF) from OWS
OK, the Fan will start.
selection button as working fan. If the breaker is

Out of 3 Nos. of Air Handling Units (AHU) 1/2/3, in ESP-1, maximum 2 AHUs need to be
started. Select two AHUs from OWS CRT as a working & remaining one as standby AHU.
Start the selected AHUs from OWS CRT.
running.
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STOP operation in manual mode(Local /Remote):

a) Stop the running Air Handling Units
b) Stop the Running Fresh Air fan
Select the UAF Pumps from OWS
breaker is OK, the Pump will start.
selection button as working and rest as stand by. If the

Out of 2 Nos. of Pumps, in unit-3, minimum 1 Pump need to be started & remaining one as
standby Pump.
Start the selected Pumps from OWS.
In case of failure/trip of any of working Pump, standby Pump will start automatically.
1 No. of UAF Fan, in unit-3, minimum 1 Pump need to be started.
D) Operation Philosophy of Strip heater, Pan humidifier , 3-way bypass valve & Fire
Damper.
3 way bypass valve:- It is fixed in the return chilled water line of the AHU circuit and having a
bypass connection with the supply line bypassing the chilled water coil of AHU. It consist of a
3 way valve, a actuator and a controller. It operates against the input received from
temperature (TS) located in return air Path at AHU room. When TS indicates that temp. of
return is lower than the designed temp. then 3 way bypass valve start bypassing proportionate
amount of chilled water from supply line to directly to return line of AHU chilled water circuit.
Thus not allowing full chilled water flow in the AHU coil. Then when TS indicates that
temperature of return is higher that than the designed temp. then 3 way bypass valve allows
the required chilled water to flow to AHU coil and minimize the bypass of chilled water
proportionately. Thus 3 ways mixing vale always modulates the chilled water flow as per the
feedback of TS.
Strip heater: - Strip heaters are required to add sensible heat at monsoon season. These are
fixed at the supply duct of AHU or common plenum. These are having banks of heaters. It will
be operative as per the signal received from R H Sensor. RH sensor senses the relative
humidity (RH) of the return air at the AHU room. If the RH is more than designed RH then it
gives signal, on command to strip heater. When the RH sensor have a reading that RH of
return air is within range of designed temperature it then gives input to heater contactors i.e.,
off command to strip heater.
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Pan humidifier: - Pan humidifiers are required to add humidity at supply air at winter season.
It consists of few heater coils immersed at a confined tank . When these heaters get operated
the water starts boiling and the vapor from the tank get delivered to supply duct with the help
of a probe. It will be operative as per the signal received from R H Sensor. R H Sensor will
generate on/off signal . RH sensor senses the relative humidity (RH) of the return air at the
AHU room. If the RH is less than designed RH then it gives signal to pan humidifier. It will
start generating vapor and will supply it to supply air duct. When the RH sensor have a
reading that RH of return air is within range of designed temperature it then gives off
command to pan humidifier.
AHU Fans and other related equipment as per requirement of process will trip in case of fire on
receiving signal from Fire Panel. Fire Damper position will be monitored in PLC. Fire Dampers
will be operated (power feeding) from Fire Damper Control panel based on fire signal.
E) Details of Air Washer Ventilation Equipment

F) Operation Philosophy of Air Washer Ventilation Equipment
E) Air Washer Ventilation Equipment

Ventilation system plant is located at following areas:
E.1) Air Washer Ventilation System Equipment a, TG BLDG UNIT-3
Equipment list:
16 nos. Air washer Fan (8W +8 SB)
16 no. Pumps (8W +8 SB)
E.2) UAF for Ventilation System Equipment at ESP-1

Equipment list :
1 no. UAF Fan
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E.3) UAF for Ventilation System Equipment at ESP-2

Equipment list :
1 no. UAF Fan
F.) Operation Philosophy for Air Washer Ventilation Systems:

Local mode /Remote mode:
a) Fan operation :
Air washing Fan can be started from the Local Control Panel in local mode. If breaker is in
healthy condition the Fan will start.
During running condition, if fan trips, the RUN status on LCP will change to TRIP status
along with annunciation in the control room.
b) Wash water pump operation :

Pumps are facilitate to run in working as well as standby mode. Any one wash water
pump can be selected as working pump & remaining one can be selected as standby
pump from LCP.
Selected pump can be started & stoped from LCP. If running wash water pump fails the
standby pump will start automatically.
If, water level of the air washer tank is low then all the pumps will trip.
And if the pressure at common discharge of the pump falls below 2.5 Kg/cm2 then the
working pump will automatically change over to stand by pump and the stand by pump will
turn to working pump and the same will be controlled and monitored in PLC.
Selection/Deselction of standby is through toggle function for all standby
Same philosophy is applicable for all Air washer fans & air washer pumps.
Page 22 of 22
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Vivek

Project : (2x520 MW) HNPCL VIZAG TPS, A.P Project

HINDUJA NATIONAL POWER CORPORATION LTD.

MOTT MACDONALD, NOIDA

PDF processed with CutePDF evaluation edition www.CutePDF.com

Compliance on Control Write Up A/C HNPCL

MM's COMMENT MADE VIDE MAIL DTD. 03.01.2013

S&W/CSSAPL COMMENT dtd. 15.01.2013

Noted and submitted on 2901013

Separate I/O not considered. Local/Remote selection will be in

Noted & Agreed.Revised GA Drawings already submitted (PE-V9361-553-I917)

Speed of the communication bus shall be 100Mbps

PC - PLC communication bus is in ethernet 100Mbps

Noted & Agreed.

BHEL to mention the type of interface with main plant DCS.

Ethernet. Revised drawing submitted.PE-V9-361-553-I912, R-2

Noted but in your PLC Comments it is mentioned that both will

BHEL to mention the no and type of printers.

Revised drawing submitted.PE-V9-361-553-I912, R-2

ESP for Unit-4 to be corrected to ESP for Unit-2

Corrected in revised control Write-up

CONTRACTOR: STERLING & WILSON LIMITED

(2x520 MW) HNPCL VIZAG TPS, A.P

CONTRACTOR: STERLING & WILSON LIMITED

(2x520 MW) HNPCL VIZAG TPS, A.P

B) Details of Air conditioning system equipments:

CONTRACTOR: STERLING & WILSON LIMITED

(2x520 MW) HNPCL VIZAG TPS, A.P

CONTRACTOR: STERLING & WILSON LIMITED

(2x520 MW) HNPCL VIZAG TPS, A.P

5 Nos. of Air Handling Units (AHU)

0 meter1 no. AHU

CONTRACTOR: STERLING & WILSON LIMITED

(2x520 MW) HNPCL VIZAG TPS, A.P

CONTRACTOR: STERLING & WILSON LIMITED

(2x520 MW) HNPCL VIZAG TPS, A.P

ESP-VFD Control Room shall consist of following equipment

CONTRACTOR: STERLING & WILSON LIMITED

(2x520 MW) HNPCL VIZAG TPS, A.P

C) Operating philosophy for Air-Conditioning Equipment

CONTRACTOR: STERLING & WILSON LIMITED

(2x520 MW) HNPCL VIZAG TPS, A.P

Step#3 (Local mode/Remote mode):

also check the permits, which

CONTRACTOR: STERLING & WILSON LIMITED

(2x520 MW) HNPCL VIZAG TPS, A.P

Group #1 comprise to: CWP#1 & 2

also check the permits,

CONTRACTOR: STERLING & WILSON LIMITED

(2x520 MW) HNPCL VIZAG TPS, A.P

also check the

can be operated to chill the water, so as to cater it to Plant-1 AHUs, at

CONTRACTOR: STERLING & WILSON LIMITED

(2x520 MW) HNPCL VIZAG TPS, A.P

CONTRACTOR: STERLING & WILSON LIMITED

(2x520 MW) HNPCL VIZAG TPS, A.P

Manual mode STOP operation (Local mode/Remote mode):

Stop the Chiller machines

Stop operation is done from PLC OWS in Local mode.

operation in Auto mode (Local /Auto):

A common Auto button is envisaged on OWS screen of PLC, if this

Select working Fresh air fan

If the breaker is OK, the Fan will start.

PLC will automatically check the

Control & Operation Philosophy of Ac

Control & Operation Philosophy of Ac