PLC INPUT OUTPUT LIST (SUGGESTED)

CLIENT : ULTRATECH CEMENT LTD. A/C AWARPUR CEMENT WORKS DOC. NO. : MB/C-758/28857
PROJECT : UPGRADATION OF FLY ASH HANDLING SYSTEM REV. (0) DATE / BY : 19.05.2007 / S.R

Macawber Beekay Limited, New Delhi

Digital Digital Interposing PC PC PC
Sl No. Input / Output Description Remarks
Input Output Relay Command Indication Alarm

A COMMON SYSTEM
1 AHS System Start/Stop - - - 1 1 -
2 Fault Alarm - - - - 1 1
3 Alarm Accept - - - 1 - -
4 Fly Ash Silo#1 Level High - - - - 1 1
5 Fly Ash Silo#1 Vent Filter Timer Unit - - - - 1
6 Fly Ash Silo#2 Level High - - - - 1 1
7 Fly Ash Silo#2 Vent Filter Timer Unit - - - - 1
FOR BOILER UNIT NO -1
B BOILER BANK & ECO.HOPPER (SYSTEM-11) (FIRING SEQUENCE - BOTH TOGETHER)
B-1 Boiler Bank Ash Vessel (Master) (V-111)
1 Surge Hopper Level High 1 - - - 1 -
2 Inlet Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Vessel Pressure Switch Low (PS-2) 1 - - - 1 -
4 Vessel Pressure Switch High (PS-3) 1 - - - 1 -
5 Convey Air Pressure Switch (PS-4) 1 - - - 1 -
6 System Probe Mode - - - 1 - -
7 System Timer Mode - - - 1 - -
8 System Start/Stop 1 - - 1 1 -
9 Probe Over ride Push Button 1 - - 1 - -
10 Purge Push Button 1 - - 1 - -
11 Inlet Dome Valve Open Solenoid - 1 1 - - -
12 Convey ON Solenoid - 1 1 - - -
13 Cycle On - - - - 1 -
14 Line Block - - - - 1 1
15 System Fault - - - - 1 1
16 Cycle Counter - - - - 1 -
17 Seal Fail - - - - 1 1
18 Cycle not starting - - - - 1 1
19 Convey Air Fail - - - - 1 1
B-2 ECO Ash Vessel (Slave) (V-112)
1 Surge Hopper Level High 1 - - - 1 -
2 Inlet Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Inlet Dome Valve Open Solenoid - * - - - - See Note
4 Seal Fail - - - - 1 1
NOTE: *Inlet dome valve solenoid of Slave Vessel shall also open from output of Master Vessel inlet dome valve open solenoid.
B-3 SWITCH VALVE (1/2 WAY) SV-1 (EXISTING)
1 Route -1 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
2 Route -2 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Route -1 Dome Valve Open Limit Switch 1 - - - 1 -
4 Route -2 Dome Valve Open Limit Switch 1 - - - 1 -
5 Route -1 Dome Valve Open Solenoid - 1 1 - - -
6 Route -2 Dome Valve Open Solenoid - 1 1 - - -
7 Route -1 Selected - - - 1 - -
8 Route -2 Selected - - - 1 - -
9 Switch Valve Fault - 1 - - 1 1
C APH HOPPERS (SYSTEM-12)
C-1 Denseveyor- (V-12)
1 Surge Hopper Level High 1 - - - 1 -
2 Inlet Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Vessel Pressure Switch Low (PS-2) 1 - - - 1 -
4 Convey Air Pressure Switch (PS-4) 1 - - - 1 -
5 System Probe Mode - - - 1 - -
6 System Timer Mode - - - 1 - -
7 System Start/Stop 1 - - 1 1 -
8 Probe Over ride Push Button 1 - - 1 - -
9 Purge Push Button 1 - - 1 - -
10 Inlet Dome Valve Open Solenoid - 1 1 - - -
11 Convey ON Solenoid - 1 1 - - -
12 Cycle On - - - - 1 -
13 Line Block - - - - 1 1
14 System Fault - - - - 1 1
15 Cycle Counter - - - - 1 -
16 Seal Fail - - - - 1 1
17 Cycle not starting - - - - 1 1
18 Convey Air Fail - - - - 1 1
C-2 SWITCH VALVE (1/2 WAY) SV-2
1 Route -1 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
2 Route -2 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Route -1 Dome Valve Open Limit Switch 1 - - - 1 -
4 Route -2 Dome Valve Open Limit Switch 1 - - - 1 -

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 Macawber Beekay Limited, New Delhi
Digital Digital Interposing PC PC PC
Sl No. Input / Output Description Remarks
Input Output Relay Command Indication Alarm

5 Route -1 Dome Valve Open Solenoid - 1 1 - - -

6 Route -2 Dome Valve Open Solenoid - 1 1 - - -
7 Route -1 Selection - - - 1 - -
8 Route -2 Selection - - - 1 - -
9 Switch Valve Fault - 1 - - 1 1
D ESP 1st FIELD (SYSTEM-13)
D-1 Denseveyor- (V-13)
1 Surge Hopper Level High 1 - - - 1 -
2 Inlet Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Vessel Pressure Switch Low (PS-2) 1 - - - 1 -
4 Convey Air Pressure Switch (PS-4) 1 - - - 1 -
5 System Probe Mode - - - 1 - -
6 System Timer Mode - - - 1 - -
7 System Start/Stop 1 - - 1 1 -
8 Probe Over ride Push Button 1 - - 1 - -
9 Purge Push Button 1 - - 1 - -
10 Inlet Dome Valve Open Solenoid - 1 1 - - -
11 Convey ON Solenoid - 1 1 - - -
12 Cycle On - - - - 1 -
13 Line Block - - - - 1 1
14 System Fault - - - - 1 1
15 Cycle Counter - - - - 1 -
16 Seal Fail - - - - 1 1
17 Cycle not starting - - - - 1 1
18 Convey Air Fail - - - - 1 1
D-2 SWITCH VALVE (1/2 WAY) SV-3
1 Route -1 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
2 Route -2 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Route -1 Dome Valve Open Limit Switch 1 - - - 1 -
4 Route -2 Dome Valve Open Limit Switch 1 - - - 1 -
5 Route -1 Dome Valve Open Solenoid - 1 1 - - -
6 Route -2 Dome Valve Open Solenoid - 1 1 - - -
7 Route -1 Selection - - - 1 - -
8 Route -2 Selection - - - 1 - -
9 Switch Valve Fault - 1 - - 1 1
E ESP 2nd FIELD (SYSTEM-14) (FIRING SEQUANCE 1+2)
E-1 Ash Vessel (Master) (V-141)
1 Surge Hopper Level High 1 - - - 1 -
2 Inlet Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Vessel Pressure Switch Low (PS-2) 1 - - - 1 -
4 Vessel Pressure Switch High (PS-3) 1 - - - 1 -
5 Convey Air Pressure Switch (PS-4) 1 - - - 1 -
6 System Probe Mode - - - 1 - -
7 System Timer Mode - - - 1 - -
8 System Start/Stop 1 - - 1 1 -
9 Probe Over ride Push Button 1 - - 1 - -
10 Purge Push Button 1 - - 1 - -
11 Inlet Dome Valve Open Solenoid - 1 1 - - -
12 Convey ON Solenoid - 1 1 - - -
13 Cycle On - - - - 1 -
14 Line Block - - - - 1 1
15 System Fault - - - - 1 1
16 Cycle Counter - - - - 1 -
17 Seal Fail - - - - 1 1
18 Cycle not starting - - - - 1 1
19 Convey Air Fail - - - - 1 1
ESP 3rd FIELD (EXISTING)
E-2 Ash Vessel (Slave-1) (V-142)
1 Surge Hopper Level High 1 - - - 1 -
2 Inlet Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Probe Over ride Push Button 1 - - 1 - -
4 Inlet Dome Valve Open Solenoid - 1 1 - - -
5 Cycle On - - - - 1 -
6 Cycle Counter - - - - 1 -
7 Seal Fail - - - - 1 1
8 Cycle not starting - - - - 1 1
ESP 4rd FIELD (EXISTING)
E-3 Ash Vessel (Slave-2) (V-143)
1 Inlet Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
2 Inlet Dome Valve Open Solenoid - * - - - - See Note
3 Seal Fail - - - - 1 1
NOTE: *Inlet dome valve solenoid of Slave Vessel-2 shall also open from output of Slave Vessel-1 inlet dome valve open Solenoid.
E-4 SWITCH VALVE (1/2 WAY) SV-4 (EXISTING)
1 Route -1 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
2 Route -2 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Route -1 Dome Valve Open Limit Switch 1 - - - 1 -

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 Macawber Beekay Limited, New Delhi
Digital Digital Interposing PC PC PC
Sl No. Input / Output Description Remarks
Input Output Relay Command Indication Alarm

4 Route -2 Dome Valve Open Limit Switch 1 - - - 1 -

5 Route -1 Dome Valve Open Solenoid - 1 1 - - -
6 Route -2 Dome Valve Open Solenoid - 1 1 - - -
7 Route -1 Selected - - - 1 - -
8 Route -2 Selected - - - 1 - -
9 Switch Valve Fault - 1 - - 1 1
F AIR RECEIVER
1 Pressure Switch 1 - - - 1 -
FOR BOILER UNIT NO-2
G BOILER BANK & ECO.HOPPER (SYSTEM-21) (BOTH TOGETHER)
G-1 Boiler Bank Ash Vessel (Master) (V-211)
1 Surge Hopper Level High 1 - - - 1 -
2 Inlet Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Vessel Pressure Switch Low (PS-2) 1 - - - 1 -
4 Vessel Pressure Switch High (PS-3) 1 - - - 1 -
5 Convey Air Pressure Switch (PS-4) 1 - - - 1 -
6 System Probe Mode - - - 1 - -
7 System Timer Mode - - - 1 - -
8 System Start/Stop 1 - - 1 1 -
9 Probe Over ride Push Button 1 - - 1 - -
10 Purge Push Button 1 - - 1 - -
11 Inlet Dome Valve Open Solenoid - 1 1 - - -
12 Convey ON Solenoid - 1 1 - - -
13 Cycle On - - - - 1 -
14 Line Block - - - - 1 1
15 System Fault - - - - 1 1
16 Cycle Counter - - - - 1 -
17 Seal Fail - - - - 1 1
18 Cycle not starting - - - - 1 1
19 Convey Air Fail - - - - 1 1
G-2 ECO Ash Vessel (Slave) (V-212)
1 Surge Hopper Level High 1 - - - 1 -
2 Inlet Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Inlet Dome Valve Open Solenoid - * - - - - See Note
4 Seal Fail - - - - 1 1
NOTE: *Inlet dome valve solenoid of Slave Vessel shall also open from output of Master Vessel inlet dome valve open solenoid.
G-3 SWITCH VALVE (1/2 WAY) SV-5 (EXISTING)
1 Route -1 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
2 Route -2 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Route -1 Dome Valve Open Limit Switch 1 - - - 1 -
4 Route -2 Dome Valve Open Limit Switch 1 - - - 1 -
5 Route -1 Dome Valve Open Solenoid - 1 1 - - -
6 Route -2 Dome Valve Open Solenoid - 1 1 - - -
7 Route -1 Selected - - - 1 - -
8 Route -2 Selected - - - 1 - -
9 Switch Valve Fault - 1 - - 1 1
H APH HOPPERS (SYSTEM-22)
H-1 Denseveyor- (V-22)
1 Surge Hopper Level High 1 - - - 1 -
2 Inlet Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Vessel Pressure Switch Low (PS-2) 1 - - - 1 -
4 Convey Air Pressure Switch (PS-4) 1 - - - 1 -
5 System Probe Mode - - - 1 - -
6 System Timer Mode - - - 1 - -
7 System Start/Stop 1 - - 1 1 -
8 Probe Over ride Push Button 1 - - 1 - -
9 Purge Push Button 1 - - 1 - -
10 Inlet Dome Valve Open Solenoid - 1 1 - - -
11 Convey ON Solenoid - 1 1 - - -
12 Cycle On - - - - 1 -
13 Line Block - - - - 1 1
14 System Fault - - - - 1 1
15 Cycle Counter - - - - 1 -
16 Seal Fail - - - - 1 1
17 Cycle not starting - - - - 1 1
18 Convey Air Fail - - - - 1 1
H-2 SWITCH VALVE (1/2 WAY) SV-6
1 Route -1 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
2 Route -2 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Route -1 Dome Valve Open Limit Switch 1 - - - 1 -
4 Route -2 Dome Valve Open Limit Switch 1 - - - 1 -
5 Route -1 Dome Valve Open Solenoid - 1 1 - - -
6 Route -2 Dome Valve Open Solenoid - 1 1 - - -
7 Route -1 Selected - - - 1 - -
8 Route -2 Selected - - - 1 - -
9 Switch Valve Fault - 1 - - 1 1

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 Macawber Beekay Limited, New Delhi
Digital Digital Interposing PC PC PC
Sl No. Input / Output Description Remarks
Input Output Relay Command Indication Alarm

I ESP 1st FIELD (SYSTEM-23)

I-1 Denseveyor- (V-23)
1 Surge Hopper Level High 1 - - - 1 -
2 Inlet Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Vessel Pressure Switch Low (PS-2) 1 - - - 1 -
4 Convey Air Pressure Switch (PS-4) 1 - - - 1 -
5 System Probe Mode - - - 1 - -
6 System Timer Mode - - - 1 - -
7 System Start/Stop 1 - - 1 1 -
8 Probe Over ride Push Button 1 - - 1 - -
9 Purge Push Button 1 - - 1 - -
10 Inlet Dome Valve Open Solenoid - 1 1 - - -
11 Convey ON Solenoid - 1 1 - - -
12 Cycle On - - - - 1 -
13 Line Block - - - - 1 1
14 System Fault - - - - 1 1
15 Cycle Counter - - - - 1 -
16 Seal Fail - - - - 1 1
17 Cycle not starting - - - - 1 1
18 Convey Air Fail - - - - 1 1
I-2 SWITCH VALVE (1/2 WAY) SV-7
1 Route -1 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
2 Route -2 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Route -1 Dome Valve Open Limit Switch 1 - - - 1 -
4 Route -2 Dome Valve Open Limit Switch 1 - - - 1 -
5 Route -1 Dome Valve Open Solenoid - 1 1 - - -
6 Route -2 Dome Valve Open Solenoid - 1 1 - - -
7 Route -1 Selected - - - 1 - -
8 Route -2 Selected - - - 1 - -
9 Switch Valve Fault - 1 - - 1 1

J ESP 2nd FIELD (SYSTEM-24) (FIRING SEQUANCE 1+2)

J-1 Ash Vessel (Master) (V-241)
1 Surge Hopper Level High 1 - - - 1 -
2 Inlet Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Vessel Pressure Switch Low (PS-2) 1 - - - 1 -
4 Vessel Pressure Switch High (PS-3) 1 - - - 1 -
5 Convey Air Pressure Switch (PS-4) 1 - - - 1 -
6 System Probe Mode - - - 1 - -
7 System Timer Mode - - - 1 - -
8 System Start/Stop 1 - - 1 1 -
9 Probe Over ride Push Button 1 - - 1 - -
10 Purge Push Button 1 - - 1 - -
11 Inlet Dome Valve Open Solenoid - 1 1 - - -
12 Convey ON Solenoid - 1 1 - - -
13 Cycle On - - - - 1 -
14 Line Block - - - - 1 1
15 System Fault - - - - 1 1
16 Cycle Counter - - - - 1 -
17 Seal Fail - - - - 1 1
18 Cycle not starting - - - - 1 1
19 Convey Air Fail - - - - 1 1
ESP 3rd FIELD (SYSTEM-24) (EXISTING)
J-2 Ash Vessel (Slave-1) (V-242)
1 Surge Hopper Level High 1 - - - 1 -
2 Inlet Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Probe Over ride Push Button 1 - - 1 - -
4 Inlet Dome Valve Open Solenoid - 1 1 - - -
5 Cycle On - - - - 1 -
6 Cycle Counter - - - - 1 -
7 Seal Fail - - - - 1 1
8 Cycle not starting - - - - 1 1
ESP 4rd FIELD (SYSTEM-4) (EXISTING)
J-3 Ash Vessel (Slave-2) (V-243)
1 Inlet Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
2 Inlet Dome Valve Open Solenoid - * - - - - See Note
3 Seal Fail - - - - 1 1
NOTE: *Inlet dome valve solenoid of Slave Vessel-2 shall also open from output of Slave Vessel-1 inlet dome valve open Solenoid.
J-4 SWITCH VALVE (1/2 WAY) SV-8 (EXISTING)
1 Route -1 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
2 Route -2 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Route -1 Dome Valve Open Limit Switch 1 - - - 1 -
4 Route -2 Dome Valve Open Limit Switch 1 - - - 1 -
5 Route -1 Dome Valve Open Solenoid - 1 1 - - -
6 Route -2 Dome Valve Open Solenoid - 1 1 - - -
7 Route -1 Selected - - - 1 - -

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 Macawber Beekay Limited, New Delhi
Digital Digital Interposing PC PC PC
Sl No. Input / Output Description Remarks
Input Output Relay Command Indication Alarm

8 Route -2 Selected - - - 1 - -
9 Switch Valve Fault - 1 - - 1 1
K AIR RECEIVER
1 Pressure Switch 1 - - - 1 -
L STACK HOPPER (SYSTEM-31) (EXISTING)
L-1 Densveyor- (V-5)
1 Inlet Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
2 Vessel Pressure Switch Low (PS-2) 1 - - - 1 -
3 Convey Air Pressure Switch (PS-4) 1 - - - 1 -
4 System Probe Mode - - - 1 - -
5 System Timer Mode - - - 1 - -
6 System Start/Stop 1 - - 1 1 -
7 Probe Over ride Push Button 1 - - 1 - -
8 Purge Push Button 1 - - 1 - -
9 Inlet Dome Valve Open Solenoid - 1 1 - - -
10 Convey ON Solenoid - 1 1 - - -
11 Cycle On - - - - 1 -
12 Line Block - - - - 1 1
13 System Fault - - - - 1 1
14 Cycle Counter - - - - 1 -
15 Seal Fail - - - - 1 1
16 Cycle not starting - - - - 1 1
17 Convey Air Fail - - - - 1 1
L-2 SWITCH VALVE (1/2 WAY) SV-9 (EXISTING)
1 Route -1 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
2 Route -2 Dome Valve Seal Pressure Switch (PS-1) 1 - - - 1 -
3 Route -1 Dome Valve Open Limit Switch 1 - - - 1 -
4 Route -2 Dome Valve Open Limit Switch 1 - - - 1 -
5 Route -1 Dome Valve Open Solenoid - 1 1 - - -
6 Route -2 Dome Valve Open Solenoid - 1 1 - - -
7 Route -1 Selected - - - 1 - -
8 Route -2 Selected - - - 1 - -
9 Switch Valve Fault - 1 - - 1 1
Notes:
1 All I/O's are in Purchacer's scope of supply.
2 This I/O's list is for complete Ash handling system including the existing system. Purchaser to varify the existing system I/Os at their end.
3 Complete Pneumatic Conveying System shall be Controlled & Monitored through Purchaser's PLC / PC System.
4 Control voltage for solenoid valves and level probes : 110V AC & PLC Interrogation voltage for I/O's 24V DC.
5 Any I/O's requirement of Purhaser's compressors are not indicated in this schedule.

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