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STATION: NTPC SIMHADRI

BHEL REF NO : PS-DC-186-500-NTPC REF NO: SIM/1/TS/ /

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PLANT AREA : CONTROL & INSTRUMENTATION

TESTING SCHEDULE : DDCMIS (OLCS,CLCS &IS)

LIST OF CONTENTS

1. PLANT DETAILS

2. TESTING OBJECTIVES

3. TESTING PROPOSALS

4. SERVICES REQUIRED

5. SAFETY PRECAUTIONS

6. EMERGENCY PROCEDURES

7. STATE OF THE PLANT

8. COMMISSIONING PROCEDURE

9. COMPLETION CRITERIA

10. APPENDICES



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1. PLANT DETAILS:

THIS SYSTEM CONSISTS OF OLCS,CLCS AND OTHER INTERFACE SYSTEM PANELS.

Each panel consists of Power supply module, Processor, Local Bus modules, Input and output modules (Analog and

Digital),Intra plant modules ,diagnostic modules and Interface modules either all or except one or two.

Sl. No. modules Cross reference1 Binary Input 70EBXX2 Analog Input 70EAXX3 Binary output 70ABXX4 Analog output 70AAXX5 Drive control 70AS04/066 Processor for text output 70KS017 Intra plant bus Access 70FA018 Intra plant Bus coupler 70FK019 IPB Coupler with address input XV771310 IPB Cable Power Supply XV771511 IPB cable input XV7717/812 IPB Traffic Director 70FV0113 Bus access 70BA0214 Bus circuit board 70BL0115 Bus coupler serial Interface 70BK0316 Bus isolation 70BT0117 Bus end 70BA0218 Cable for local bus extension 70BL0319 IPB Bus coupling 70BK0220 Bus traffic Director for extended Add range 70BV0521 Power supply XT37Y22 DC/DC convertor KH37023 Processor 70 PR 0524 IS between IPB & PC-AT PC42125 Diagnostic/SOE 70SK3Z

XX – 01,02,03,04 or 06 depending on versions/applications, it changes

Y – 3 for distribution,6 for buffer & 7 supervision for positive voltages

Z – 1 for video controller, 2 for RS232 interface for key board,3 for test memory ,4 for computer simulation memory

coupler, 5 for output voltage signal for trend,6 for EEPROM programming , 7 for local bus to computer buscoupler



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NAME PLATE DETAILS

MAKE:ELECTRONICS DIVISION,BHEL,BANGALORE

SYSTEM DESCRIPTION:

a) OLCS(CRB)Panels

These panels are used for operating single Drive in

open loop control system mode. In this outputs are not

controlled but monitored. Feedbacks, commands and other

parameters for drive are monitored through MMI. There are

22 such modules for NTPC Simhadri; CRB 01 to 22.

b) CLCS(CRA) Panels

These panels are used for operating Single drive in

CLCS mode i.e. the output is controlled by taking a

fraction of output as a controlling input to the system.

There are 15 such closed loop control system panels in NTPC

simhadri site. They are labeled as CRA 01 to 15.

c) IS Panels



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These panels are used for interfacing IPB with PC-AT.

There are such 6 modules in NTPC simhadri site; labeled as

CRC 01 to 06.

2.TESTING OBJECTIVE:

TO TEST THE DDCMIS PANELS AND TO MAKE THEM READY FOR SERVICE.



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3.TESTING PROPOSAL:

i) INTRA PLANT BUS COMMUNICATION TO BE ESTABLISHED

ii) POWER SUPPLY OF ALL PANELS ARE NOT BE MIXED UP

iii)POWER & CONTROL BUSES ARE TO BE ISOLATED FROM

EARTH.

iv) POTENTIAL ACROSS EARTH & NEUTRAL(ZERO) POINT OF

THE PANEL SHOULD BE WITHIN SOME MILLI VOLTS.

v) INPUT,OUTPUT,DRIVE CONTROL,PROCESSOR,COMMUNICATION &

DIAGNOSTIC STATION MODULES ARE TO BE TESTED AT FIRST.

vi) FIELD CONNECTIONS ARE TO BE TESTED THEREAFTER

vii) ALL LOGICS TO BE TESTED & FIND OUT EACH OUTPUTS ARE AS PER

THE GIVEN LOGICS

viii) CALIBRATION OF OUTPUT SYSTEMS SUCH AS CONTROL VALVES,SERVO

MOTORS ETC ARE TO BE CARRIED OUT.

ix) CHANGEOVER OPERATION OF INTRA PLANT BUS TRAFFIC DIRECTORS

(70FV01) & INDIVIDUAL BUSCOUPLERS OF EACH PANELS ARE TO BE CHECKED

AND FOUND OK.



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4.SERVICES REQUIRED:

500 V DC MEGGER

230 V 1 PHASE 50 Hz AC SUPPLY

24V DC SUPPLY

DIGITAL MULTIMETER



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5.0 SAFETY PRECAUTIONS:

GENERAL:

5.1 FUSES OF DIFFERENT RATINGS ARE PROVIDED IN EACH CARDS TO

PROTECT ITSELF FROM OVERCURRENT, SHORT AT OUTPUT SIDE OR

ANY OTHER INTERNAL FAULT.

5.2 CIRCUIT BREAKERS ARE PROVIDED TO PROTECT MAIN EQUIPMENTS

FROM SHORT, EARTHING OF INPUT POWER SUPPLIES

PERSONNEL :

5.3.1 ALL MEMBERS OF THE TEST TEAM AND ALL OTHER PERSONS

INVOLVED IN THIS TESTING SCHEDULE MUST BE MADE

FAMILIAR WITH THE CONTENTS OF THE TESTING SCHEDULE.

5.3.2 SAFE ACCESSES TO AND ADEQUATE ESCAPE ROUTES FROM

CONFINED AREAS MUST BE MAINTAINED.

5.3.3 SAFETY CLEARANCE CERTIFICATE WILL BE IN FORCE.

5.2 PLANT :

5.2.1 WHILE INSERTING MODULES IN DDCMIS, ENSURE THAT

THEY ARE NOT INSERTED UPSIDE DOWN, WHICH CAN BE

DISASTROUS.

5.2.2 ENSURE THAT WHILE CARRYING OUT THE

MEASUREMENTS/OBSERVATIONS OF THE POWER SUPPLIES, NO

ACCIDENTAL SHORTING OF WIRES OCCURS.



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5.2.3 CABLE USED FOR RTDS & OTHER TRANSMITTER MEASUREMENTS SHOULD

NOT HAVE ANY JOINTS

5.2.4 DO NOT USE HIGH VOLTAGE SOLDERING IRON FOR REMOVING OR

FIXING ANY COMPONENT IN THE ELECTRONIC MODULE, THIS MAY

DAMAGE PRINTED CIRCUITS. USE 6V, 30V, SOLDERING IRON FOR

THIS PURPOSE.

5.2.5 VARIOUS ELECTRONIC MODULES NEED CERTAIN JUMPERS TO BE

CLOSED BY LINKS AND SOME JUMPERS ARE TO REMAIN OPEN. IN

SOME CASES, A FEW RESISTORS ARE TO BE MOUNTED BEFORE

TESTING. THIS INFORMATION IS GIVEN IN RELEVANT TEST

PROCEDURES OF THE MODULES. IT IS IMPORTANT TO CROSS CHECK

THAT ALL SUCH LINKS AND RESISTORS ARE MOUNTED BEFORE

CONDUCTING TESTS.

5.2.6 ZERO POTENTIAL AND EARTH POTENTIAL SHOULD HAVE BEEN

CONNECTED AT ONE POINT IN THE WORKS. ENSURE THAT THE SAME

HAS BEEN DONE.

5.2.7 WHILE MEGGERING, ENSURE THAT ALL ELECTRONICS MODULES AND

SUBASSEMBLIES ARE REMOVED / SHORT CIRCUITED.

5.2.8 BEFORE CONDUCTING TESTS ON ELECTRONIC MODULE, CHECK

AVAILABILITY OF RELEVANT POWER SUPPLY (IF ANY) AT THE TEST

SOCKET OF MODULE OR RACK.

5.2.9 THE EARTH CONNECTIONS AT THE SUPPLY TERMINALS OF THE CRO

SHOULD BE REMOVED AND ISOLATED. ALTERNATIVELY IT WOULD BE

PREFERABLE TO FEED THROUGH AN ISOLATING TRANSFORMER.



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6. EMERGENCY PROCEDURE:

6.1 EMERGENCY PUT OFF PB IS AVAILABLE AS AN OPTION AND MAINLY

SERVES TO DISCONNECT THE POWER SUPPLY TO THE PROCESSORS AND

OTHER CIRCUITS.

6.2 EMERGENCY TELEPHONE NUMBERS FOR HOSPITAL & FIRE STATIONS SHALL

BE PREDOMINANTLY DISPLAYED.

6.3 A TELEPHONE MUST BE AVAILABLE NEARBY

6.4 FIRST AID CHARTS FOR ELECTRICAL SHOCKS MUST BE AVAILABLE



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7. STATE OF THE PLANT:

7.1 PANELS ARE ERECTED.

7.2 IP BUS CABLES ARE INTERCONNECTED & TERMINATED WITH RC NETWORKS

AT THE ENDS.

7.3 APPLICATION EPROMS ARE LOADED WITH CORRECT PROGRAMS.

7.4 NO CABLE CONDUCTOR STRANDS ARE BENT INADVERTENTLY & TOUCH THE

GROUND POINTS DIRECTLY;BUT GROUNDED THROUGH CAPACITOR.

7.5 POWER SUPPLY CABLES ARE CONNECTED.



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8.COMMISSIONING PROCEDURE:

i) ENSURE IPB CABLE IS TERMINATED AS PER SEC 2.0 OF IPB

CHECKLIST

ii) IN BK02/FV01 MODULES,CHECK S104 & S105 OF AKA/SKA &AKB/SKB

JUMPERS ARE IN POSITION 2 RESPECTIVELY TO ENABLE SWITCHOVER

TO REDUNDANT LINE IN CASE OF A FAULT IN THE WORKING LINE.

IF IN THE SAME IPB, ONE 70FV01a &70FV01b ARE USED IN

REDUNDANT MODE, THE PLUG IN JUMPER AKB/EKB(S105) MUST BE IN

POSITION 1 IN 70FV01b.

iii) DATA COMMUNICATION CHECKS

CHECK ALL DATAS ARE RECEIVED IN END MODULE THROUGH

BK02 OVER IPB; OTHERWISE FOLLOW THE PROCEDURE MENTIONED IN

THE PAGE 04,05& 06 OF 11 OF IPB CHECK LISTS

ENSURE THE FOLLOWING

a) THE MAXITERMI,70BL02/70BL03, MODULE CONNECTIONS ARE

FIRM AND OK.

b) COOLING FAN DIRECTION IS SUCH THAT IT DRAWS AIR FROM

BOTTOM AND EXHAUSTS OUT AT THE TOP

c) PROTECTIVE DIODES IN THE BACK PLANE PCB(DN,DI,CK,ADR&

Z) ARE HEALTHY.



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d) PROPER DISTRIBUTION OF POWER SUPPLIES TO INDIVIDUAL

RACKS IN TF,TQ,TL,SOE INTER PANEL CONNECTIONS &

SYNCHRONISATION SIGNAL WIRING TO FV01s FROM

DIAGNOSTIC STATION AS PER RELEVANT DOCUMENTS

iv) INPUT MODULES

a) ALARM SIGNAL SHOULD NOT APPEAR IN HEALTHY STATE

b) ENSURE DIAGNOSTIC IS WORKING UNDER THE CONDITIONS OF WIRE

BREAK, SHORT CIRCUIT, SUPPLY FAILURE ETC

c) APPROPRIATE COMPENSATING RESISTORS ARE TO BE SUED BETWEEN

PIN 17 & 19 IN EA04 MODULES

d) INPUT SIGNALS MUST BE POTENTIAL AS WELL AS ELECTRO MAGNETIC

INTERFERENCE FREE AND FIXED CONTACTS

v)OUTPUT MODULES

a) ALARM SIGNAL SHOULD NOT APPEAR IN HEALTHY STATE b)

DIAGNOSTIC RESPONSES LIKE MODULE FAILURE, MISSING

PCB ARE TO BE CHECKED.

v) DRIVE CONTROL MODULES

a) ENSURE THAT CORRECT APPLICATION EPROM IS PUT PROPERLY WITH

CORRECT POLARITY.



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b) ENSURE POWER SUPPLY AT A/M STATIONS, PUSH BUTTONS/LAMPS IN

CONTROL ROOM ETC

c) INTERFACE SIGNALS (TORQUE/LIMIT SWITCH/POSITION

FEEDBACKS, COMMAND OUTPUTS THROUGH RELAYS,E/P

CONVERTOR, ACTUATOR) ARE TO BE CHECKED

d) ENSURE THE MODULE IS IN NOT SIMULATOR MODE.

e) PROTECTION LOGIC IS IN ORDER FOR ALL THE O/PS

f) THE OUTPUT TELEGRAMS ARE ALL OK

g) DIAGNOSTIC INFORMATION IS PROPER FOR VARIOUS FAULT

CONDITIONS

h) ENSURE CORRECT DRIVE CONTROL STANDARD FUNCTIONS ARE

PROGRAMMED

i) ENSURE FEEDBACK TRANSMITTER IS PROPERLY TERMINATED,

GROUNDING OF THE VALVE POSITION, FEEDBACK CABLE ARE NOT

PRESENT IN CASE OF 70AS06 & ITS CALIBRATION WITH LOAD IS

PROPER

j) CHECK HARD WIRED PROTECTION IS PROPERLY TERMINATED

vii) PROCESSOR MODULE

ENSURE THE FOLLOWING

a) CORRECT VERSION OF FIRMWARE IS USED



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b) APPLICATION EPROMS WITH CORRECT APPLICATION PROGRAM

NUMBERS ARE USED

c) PARAMETERS ARE SET ACCORDING TO THE SCHEME USING 70SK06 OR

DIAGNOSTIC STATION

d) FAULT ANNUNCIATIONS ARE ALL RIGHT UNDER ALL FAULT

CONDITIONS

e) DIAGNOSTIC EPROM READING FACILITY IS ENABLED

f) PROCESSOR NUMBERS ARE CORRECTLY SET WHEN MORE THAN ONE

PROCESSOR MODULE IN A LOCAL BUS IS PRESENT

g) PROGRAM END STATEMENT IS PROGRAMMED AFTER THE USER PROGRAM

IN ALL PROCESSOR MODULES

h) THE INTERPROCESSOR DATA TRANSFER ADDRESS RANGE IS BEYOND

THE LAST SERVICE ADDRESS USED IN 70BK02 MODULE IN CASE OF

70PR05 MODULES CONFIGURED IN HOT STANDBY MODE.

vi) COMMUNICATION MODULE

a) ENSURE WIRING IS OK BETWEEN 70BK02,70FV01 & XV7713/ 70FA01

b) ALL MODULES INSIDE XV7713/70FA01 ARE PROPERLY PLACED

c) RC CIRCUIT IS SOLDERED & PLACED PROPERLY AT THE BEGINNING

& AT THE END OF IP BUS CABLE (XV/FA BOXES)



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d) IP BUS IS TERMINATED IN ALL PANELS WITH PROPER LUGS.

ENSURE COAXIAL CABLE CONNECTIONS

e) TO REDUCE DISTURBANCES ENSURE THAT THE IPB CABLE IS

EARTHED AT MORE POINTS(MULTIPLE EARTHING)

f) IN CASE 70BK02b IS USED WITH 70FV01a,ENSURE C80 CAPACITOR

OF 70FV01a IS CHANGED FROM 47nf TO 147nf

g) ALARM SIGNAL SHOULD NOT APPEAR IN ANY OF THE 70BK02 &

70FV01

h) IN 70BK02 MODULES, ENSURE THAT

1. LINE NUMBERS 016 & 017 ARE PROGRAMMED WITH DF02 & 03FF

RESPECTIVELY TO ENABLE EPROM READING FACILITY FROM

DIAGNOSTIC STATION

2. IN WORD MARSHALL PROGRAMMING,STARTING FROM LINE NUMBER

0400,THE BK NUMBERS ARE CALLED IN THE ASCENDING ORDER,AS

OTHERWISE THE MODULE WON’T FUNCTION

i) ENSURE EARTH LINK IS SOLDERED IN ALL XV MODULES

j) AFTER IPB IS COMMISSIONED, CHECK THE CHANGEOVER OPERATION

OF REDUNDANT IPB TRAFFIC DIRECTORS(70FV01)



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ix) DIAGNOSTIC STATION

a) ENSURE THAT THE CORRECT VERSION OF FIRMWARE IS LOADED IN

70SK33 MODULE IN PROPER LOCATION

b) APPLICATION PROGRAM IS LOADED & NO RAMS PRESENT IN 70SK33

c) NO OTHER EPROM, RAMS ARE IN 70SK33

d) OPERATION OF DC/DC CONVERTOR MODULES ARE OK & THE OUTPUTS

ARE WITHIN PERMISSIBLE LIMITS

e) CHECK THE INTERCONNECTION CABLES/FKB FOR SOE OPERATION

f) ENSURE THAT NO DIAGNOSTIC/SOE STATION MODULES ARE

INSERTED/PULLED OUT IN POWER-ON CONDITION

g) ENSURE THAT THE WORD 02 IS MARSHALLED TO 01 IN DIAGNOSTIC

STATION AS THIS SYCHRONISATION WORD IS USED IN ALL THE P13

LOCAL BUSES

h) ENSURE THAT A 70AB01 MODULE IS PROVIDED IN DIAGNOSTIC

STATION WITH ADDRESS 01 & THE PIN 13 OF THIS MODULE IS

HARDWIRED TO ALL 70FV01 MODULES(PIN 95) TO ENABLE ALL

70FV01 MODULES TO FLOAT A ADDRESS & AT THE SAME TO HAVE

SYNCHRONISM IN FLASHING OF LAMPS ON THE DESK. PIN 95 OF

70BK02 MODULES IS HARDWIRED TO ALL 70EB10 MODULES (IF OUB

61 EXIST) TO ENABLE THEM TO START THE MILLISECOND COUNTER

AT THE SAME TIME.



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i) ENSURE THAT THE 70BV05 MODULE CYCLE TIME IS SELECTED AS 20

ms IN BOTH DIAGNOSTIC STATION & THE SOE STATION AND SOE AS

MASTER, DIAGNOSTIC STATION AS SLAVE

j) MARSHALL THE WORDS 02,03,FE FROM SOE STATION INTO

DIAGNOSTIC STATION

k) ENSURE THAT SOE COMMAND WORD IS TRANSMITTED TO ALL

STATIONS WHEREVER 70EB10 MODULES ARE LOCATED

l) CHECK JUMPER SETTINGS AND CORRECT INSTALLATION OF

RAM,EPROM, APPLICATION EPROMS,FIRMWARE EPROMS AS PER

ANNEXURE I

x)FIELD CONNECTIONS

a) ENSURE SIGNAL/SHIELD ARE PROPERLY TERMINATED

b) FERRULES TO B E PROVIDED FOR ALL USED CABLE CORES IN

JUNCTION BOXES AND UNSIGNED CABLE ENTRIES USED TO BE

PLUGGED

xi)FLAME SCANNER

a) ENSURE THAT PROPER JUMPER SELECTIONS ARE MADE IN THE

POWER SUPPLY MODULE BEFORE PUTTING INTO SERVICE.

b) DO NOT REMOVE OR INSERT ANY MODULE UNDER POWER-ON

CONDITION



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9.COMPLETION CRITERIA:

DDCMIS IS COMMISSIONED. ALL PARAMETERS AS PER SCHEME ARE

MONITORED & CONTROLLED FROM OPERATING STATIONS. SEQUENCE OF EVENTS IN

CASE OF TRIP ON FAULT, CHANGEOVER, PROCESS CHANGES AND

STARTING/STOPPING OF MAIN EQUIPMENTS ARE FOUND AVAILABLE IN THE

WORKSTATION MONITORS. CHANGEOVER OF PROCESSORS, IP BUS LINES ARE

FOUND OK WHEN FAULT OCCURS & NO DISTURBANCE IN THE DATA TRANSFER



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10. APPENDICES:

DRAWINGS: EARTHING PRACTICE - ED 046 28 02/REV 01

( 19 SHEETS)

PRECOMMISSIONING OF P13/42 - EC 00001 /REV 01

( 17 SHEETS)

IPB CHECKLIST - SK 676 410 0105 REV01

( 11 SHEETS)

FV & BK LISTS FOR IPBs - 1-50-1638-01REV01(15.8.2001)

1-50-1639-01REV01(15.8.2001)

LOG SHEETS : I) INDIVIDUAL TERMINAL RESISTANCE OF IP BUS

AT VARIOUS PANEL

II)LIST OF JUMPER SETTINGS,VERSIONS OF

APPILICATION PROGRAMS USED

III) LIST OF SOEs CONFIGURED

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