FUNDED BY THE
EUROPEAN UNION
High Pressure Cogeneration for Sugar Sector in Pakistan
Comprehensive Technical
Training
For Sugar Mills Staff on Operation & Maintenance of
Baggase Based HP Cogeneration System
Schedule: 10th July to 13th July, 2017
FUNDED BY THE
EUROPEAN UNION
High Pressure Cogeneration for Sugar Sector in Pakistan
Plant Control System
Purpose:
Plant Control System provides
necessary tools to enable the
operators to operate plant
safe reliable and efficiently.
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High Pressure Cogeneration for Sugar Sector in Pakistan
Purpose of Plant
Control System
1. Process monitoring, control and optimization
2. Plant and Unit performances analysis
3. Economical analysis of plant for optimization
4. Schedule optimization
5. Advanced control technologies
6. Equipment health management
7. Availability & Reliability
8. Ease of Trouble shouting & maintenance
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High Pressure Cogeneration for Sugar Sector in Pakistan
General Structure
of Plant DCS
Basic Structure
HMIsPrinters Historian
Plant Data Highway
Unit Data Highway
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High Pressure Cogeneration for Sugar Sector in Pakistan
Plant Control System
Basic Plant Control
Plant Data Highway - Ethernet
Plant Data Highway - Ethernet
Unit Data Highway - EGD
Unit Data Highway - EGD
OSM
HARD WIREDSIGNALS
DUPLICATE WORK STATIONS
SEPARATEENGINEERING
Station
SEPARATESPARE PARTS
DCS
NT
Subsystems
PrinterPrinter
Printer
Turbine Control
HMI Operator Interface
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Plant Control
System continue
• UDH, PDH and Data Connectivity
Plant Data Highway - Ethernet
Plant Data Highway - Ethernet
Unit Data Highway - EGD
Unit Data Highway - EGD
COMMON UNIT DATAHIGHWAY
BOP Control
Turbine Control
Plant Historian
HMI Operator Interface
Plant Data Highway
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DCS integrated
Systems
• Asset Management System
• Online PPMS
Sensors /
Instrumentation
Turbine Gen.
Controls
Sub-System
Integration
Plant Controls
Integrated
Systems
Plant Controls
Control Modules
BOP, TSI & Water Treatment
Asset Management
Sys
Field Instruments and Transducers
Plant Performance
Monitoring
Online PMS
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Control System
features
• Real-time Process data collection
• Real-time process statistics
• Real-time process monitoring
• Schematics visualization & analysis
• Reports Generation
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High Pressure Cogeneration for Sugar Sector in Pakistan
Online PMS (Plant
Performance Monitoring
System).
1. Plant Performance
2. Unit Performance
3. Mass and Energy Balance
4. Boiler
5. Turbine
6. Feed water Heater
7. Condenser
8. Cooling Tower
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Online PMS Continue
1. Air Pre heater
2. Feed water Pump
3. Condensing Pump
4. Circulating Pump
5. Induced Draft Fans
6. Force Draft Fans
7. Primary Air Fans
8. Burners & Combustion
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High Pressure Cogeneration for Sugar Sector in Pakistan
Targets &
Achievements
1. Minimized operations cost
2. Overall efficiency increase
3. Fuel cost savings
4. Emission Reduction
5. Reliability an availability of the system
6. Schedule for Preventive maintenance
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High Pressure Cogeneration for Sugar Sector in Pakistan
A comprehensive Intelligent Power
Plan is aimed to improve the overall
Energy Efficiency in following aspects
1. Improved Generation Efficiency.
2. Saved Auxiliary Energy Consumption.
3. Better Heat Rate.
4. Reduced Emission.
AIM
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High Pressure Cogeneration for Sugar Sector in Pakistan
Basic Control
Functions
• ON-OFF Control
• Modulating Control
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ON-OFF Control
(Discrete Control)
This Control is divided into following categories:
• Motor-driven rotating equipments such as pumps, fans, compressors and conveyors
• Motor-operated shutoff valves and dampers
• Solenoid-operated equipment such as pneumatic shutoff valves
The control action of an ON-OFF Control system maybe initiated manually by a command from an operator or initiated automatically by the system-based on the intelligence received from the process
The control logic will withhold the ‘start’ command if the seal water temperature, exhauster, discharge air temperature or lube-oil pressure of exhauster is not adequate for safe operation for exhauster
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High Pressure Cogeneration for Sugar Sector in Pakistan
Modulating
Control (Loops)
There are basically two types of control
loops:
• Open Loop
• Closed Loop
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Modulating Control
(Analog Control Loops)
The basic elements of the Modulating loop are as follows:
• Set point
• Process Variable / Controlled Variable
• Controller
• Manipulated Variable
• Final Control Element
The water temperature is controlled variable. The controlled valve is the final control element. The control loop is said to be “closed” in that the controlled variable is measured value is used to verify the result of the controlled action.
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Control Loops
• (A) Feed-Forward Control
• (B) Cascaded Control
• (C) Feed-Forward & Cascaded Control
Feed-back, feed-forward, and cascaded control techniques are the basic controlling functions used to build a control system that will maintain the plant parameters within designnormal operating conditions and keep the plant running safely and efficiently
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High Pressure Cogeneration for Sugar Sector in Pakistan
Modulating Control
Applications
Boiler Control System
Boiler-Follow Scheme: In thisscheme, the boiler controland turbine control aretwo separate controlsystems. The load demandsignal is sent directly tothe turbine controlsystems which positionsthe turbine valves inresponse to changes inload demands.
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Modulating Control
Applications
This scheme typically includes a Unit Development Program—it receives the load demand from load dispatcher and checks the demand signal from the load dispatcher & demand signal against allowable operating limits. The demand is subjected to maximum load that can be carried by boiler-turbine-generator (BTG) and minimum load desired.
Co-ordinated Control Scheme
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Modulating Control
Applications
1. This scheme provides a tight control on throttle pressure, but its response to load changes is very slow because the valves do not move until the firing rate has been adjusted to new demand level.
1. This scheme does not make use of any available stored energy from the boiler.
Turbine Follow Scheme
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Firing Rate Control
or Combustion Control
1. The firing rate control loop employs two closed loop controllers:
A. total fuel flow controller
B. total air flow controller
2. The firing rate demand serves as the fuel flow setpoint for fuel controller which uses the measured fuel flow as feedback signal to close the loop.
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Furnace Draft Control
It is a two-elementcontrol loop usinga furnace pressurecontroller plus afeed-forwardsignalrepresenting avariable, thatwhen changed –has an impact onfurnace draft suchas boiler air flowor the forced draftinlet control vaneposition.
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Superheat & Reheat Steam
Temperature Control
• Steam temperature control is carried out in all boilers to get a constant temperature within a range. Methods like de-superheating by water injection, flue gas flow diverting, burner tilting are few systems adopted. Main steam and reheat outlet temperature are controlled by these methods in boiler.
• All boilers used for both process and power generation plants have to maintain steam parameters within a particular range. The pressure and temperature of steam at superheater and reheateroutlets are to be maintained to achieve an optimum plant efficiency. In large capacity boilers, injection type de-superheating is more popular.
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Feed water
ControlMost boiler systems contain a de-
aerating tank which removes
dissolved gases from the feed
water (these gases can be
corrosive to the rest of the boiler
system). The de-aerating tank is
the source of feed water to the
pumps. Because feed water de-
aeration is achieved through
boiling, the water leaving the
tank may be very close to the
boiling point. It would be
undesirable for the water at the
pump suction to flash to steam,
so the de-aerating tank is located
at an elevation above the feed
water pumps. This elevation
should be chosen in order to
guarantee enough pressure at
the pump suction to prevent
flashing. The water pressure at
the pump suction is called net
positive suction head (NPSH).
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Super heater bypass
Control
• Feed water is supplied by the de-aerator, which also provides the necessary net positive suction head (NPSH) to the boiler feed pumps. The boiler feed pumps (BFP) must supply a constant flow necessary to replace water in the boilers that has been changed to steam. The boiler feed pumps (BFP) must also develop the required pressure to overcome head and drum pressure.
• The feed water system supplies proper feed water amount for the boiler at all the loads. The parameters of the feed water are temperature, pressure and quality. The feed water system consists of a feed water tank, feed water pump(s) and (if needed) high-pressure water pre-heaters.
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De-aerator Storage Tank &
Condenser Hot well Level
Control Loops
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High Pressure Cogeneration for Sugar Sector in Pakistan
Control System Hardware & Software.
Soft wares
1. Operating System.
2. Applications Software.
3. Third Party Software & Drivers.
4. Anti Virus.
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Control System
Hardware
1. Large Screen.
2. HMIs.
3. Computers.
4. Servers.
5. HSR and Media / dedicated Rack of HDD.
6. HUB and Switches.
7. Dot Matrix Printers.
8. Color Platters/Printers.
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Microprocessor based
Control Systems
Any instrumentation systems centered around a microprocessor are known as microprocessor based system. The logical and computing power of microprocessor has extended the capabilities of many basic instruments, improving accuracy and efficiency of use. The microprocessor is a versatile device for use in any instrumentation system.
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High Pressure Cogeneration for Sugar Sector in Pakistan
Network
Topologies
Hybrid Topology Tree Topology
Star Topology Ring Topology
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RS232C Interface
RS232C interface is widely used standard for direct point-to-point data transmission between two digital equipments.
It is the recommended standard of Electronics Industry Association.
This interface specifies interconnection & signal exchange.
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Programmable
Logic Controller
Basically PLC consists of:
1. Input Module
2. Processor
3. Output Module
Other accessory systems are power supply & interconnecting wires.
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Layout of PLC
Schematic Diagram
Ladder Diagram
Relay Ladder Logic Diagram is used for PLC Programming. The ladder diagram is derived from the schematic wiring diagram (elementary wiring diagram).
The two types of PLC programming devices are:
Hand-held programming devices
Stand-alone programming devices
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DCS Basic
Configuration
DCS has been categorized into:
• Control Module –performs control & PID(proportional & integral & derivative), binary logic and arithmetic functions.
• Data-processing Module –manipulates data, performing functions as data table, graphic display, variable trending, report generation, and long-term data storage and retrieval.
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Distributed Control
System
1. Large Screen Display.
2. Operator Interface HMIs.
3. Alarm Display.
4. SOE & Event Logging.
5. GPS Time Synch System.
6. Historian.
7. Engineering Station & Printer.
8. Weather Monitoring System.
9. Online Performance Monitoring System.
10. Asset Management System.
11. Alarm, Event and Report Printers.
12. Web-Server.
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High Pressure Cogeneration for Sugar Sector in Pakistan
Distributed Control System Continue
13. UPS
14. Cyber Security.
15. Remote Monitoring Server.
16. SCADA & AGC connectivity with DCS.
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High Pressure Cogeneration for Sugar Sector in Pakistan
Controllers & their Status
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DCS Specs
1. Redundancy of Controllers.
2. Redundancy in critical field devices (Controls)
3. Number of I/O Points (Digital & Analog).
4. Signal Processing Speed.
5. Connectivity features.
6. Security Provisions.
7. Third Party integrations.
8. User friendly.
9. Built in Libraries for Programming.
10.Time Synch & Redundancy.
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High Pressure Cogeneration for Sugar Sector in Pakistan
DCS Management
Essential Tasks of System Manager (I&C Engr.)
1. System Backup.
2. System Crash Recovery Preparation.
3. System Diagnostics & troubleshooting software on dedicated laptop.
4. Reference Commissioning Data preservation.
5. Daily Messages & Events Review of System.
6. DCS Software & hardware related messages.
7. Archiving.
8. System health checks.
9. Power Source including the UPS (batteries & inverter).
10. Standard UPS time & Safe shutdown.
11. Memory card Battery Backups & replacement.
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High Pressure Cogeneration for Sugar Sector in Pakistan
DCS Management Continue
1. System Password Protection.
2. Limited Access to users.
3. Effect of USB/External HDD.
4. Running Virus Scanners.
5. Adding the Programs & Precautions.
6. System Limitations.
1. Memory Review.
2. HDD space review.
3. Program Cycle Execution Time.
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High Pressure Cogeneration for Sugar Sector in Pakistan
Present Control
Systems Different OEMs are making Control Systems out of which following are the best known, these are different in many features but very commonly used systems are.
1. GE.
2. Siemens.
3. Emerson.
4. Yokogawa.
5. Honeywell
6. ABB.
7. Alstom.
8. Invensys.
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High Pressure Cogeneration for Sugar Sector in Pakistan
Major controls of Boilerfor power plant
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High Pressure Cogeneration for Sugar Sector in Pakistan47
PID’s bagasse
fuel feeding system
E
E
E
E
Plate slide Plate slide
E
VSD
VSD
Fixed speed
VSD
Fixed speed
Signal load control4- 20 mA-
E
E
PI
PS
Spreader air fans
MCCAutomatic
start standby
Sight glassSight glass
Sight glassSight glass
peepholes
2 inch connections
3inch
inch
inchinch
Rotary air damper
Rotary air damper
Spreader fans
3 more
Bagasse feeding and spreading system
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PID of Air system
FGAP2grate
FGAP2 overf
FGAP1grate
GFAP1overf
Right side wall
left side wall
Overfiring nozzles
2 * 5 dumping grates
5 air dampersPut air on and it will closeNormally open by spring
Raw water 1 inch
overflow
Push button for operation at each grate
E
VSD
E
VSD
StapOFA
Stapgrat
e
FT
FT
TT
TT
TT
TT
PT
E
VSD
o/c
o/c
E
VSDo/c
o/c
Load controlAir fuel ratio
E
Damper fan close directly automatic when fan stops.
PT
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49
PID’s Flue gas
system
Dumping grate
PT
TP
TP
TP
TP
TP
TP= testpoint of 1 inch
Fly ash arrestor
PI
TT
Pressure control
PS
PS
H L
E
FGAP2grate
FGAP2 overf
FGAP1grate
GFAP1overf
sup2
sup1B
sup1A
evap
2 *
eco
E 2 * E 2 *
XT
O2
E
VSD
E
VSD
o/c
o/c
pT
TP
TP
TP
TP
TP
TP
TP
TP
TT
drain
Damper fan close directly automatic when fan stops.
Trip boiler
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High Pressure Cogeneration for Sugar Sector in Pakistan50
Sup 1 BDeaerator
LT
LIC
PT
PI
LS
LG
LIC
To sample cooler ¼ inch
Dosing hydrazine½ inch
Dosing ammonia½ inch
Design pressure deaeratorat 2 barg, saturated and 100% vacuum
2 inch drain
Condensate And demi water return
??inch
From LP header? inch
Into demi water tank1 inch
? inch
1/2 inch
Steam air preheater
1 inch drain
To pressure/temperature reducing station
?? inch
BFW pumps
Capacity?
To BFW pumps
L
HTo cond pumps
E
? inch
PI
PI
?? inch? inch
Second pump
2nd
2nd
To boiler
2nd
PT
Start 2nd
pump
L
PID feed water
system
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condensate
Condensate vesselDiam 1000 and 1500 mm highOn 4 m level
2 inch balancing line
?? tph LP steam from outlet steam turbine at 1,2 barg
To condensate clean tank
LT
LG
12 inch
? inch? inch
? inch
? inch
? inch
3 inch
System Steam air preheater
8 inch
? inch globe
Condensate vessel
Installed near vessel
Water level control valve
TIC
At 8 m level
Design 3 barg 150 C
PID steam air
preheater system
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PID Water system
boiler
2 inch
2 inch
LS
LG
LL
LT
1 in
ch
1 in
ch
2 inch
2 inch
LS
LG
LL
LT
1 in
ch
1 in
ch
Steam drum
eco
1 in
chTri phosphate dosing
??inch
FT
1 inch
From BFW pumps
FIC
LIC
1 in
ch 1 in
ch
To de-superheater
Parabolic valve for manual control
1 i
nch
1,5 inch
1,5 inch
1,5 inch
1,5 inch
Sample cooler
Trip boiler ( stop feeder and air supply)After stop air fans then stop ID fan
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PID Steam system
boiler
Steam drum
sup1
sup2
Sample cooler
1 in
ch
4 * 4 inch
?? inch
TT
TT
Steam to sootblowers
PI
TI
1 inch
1 inch
1 inch
FT
TI
?? inch
FT
TT
TI
PT
PS
Trip boiler
LIC
Feed forward signal on steam flow
To 3 comp water control
Feed forward for fuel control
Load control
silencer
PID Water system
boiler
Continued..
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PID Soot blowing
system
Fly ash arrestor
FGAP2grate
FGAP2 overf
FGAP1grate
GFAP1overf
sup2
sup1B
sup1A
eco
2 *
E
E
E
E
E
eco
E
E
E
E
E
E
2 *
2 *
2 *
3 *
evap
evap
E
2 *
3 *
3 *
3 *
3 *3 *
3 *
3 *
2 inch
PT
PI
From de-superheating line at inlet superheater2
1,5 inch
1,5 inch
1,5 inch
Blow down vessel
TT
TT
2 inch
Design pressure 25 bargDesign temp. 400 C
Design pressure 124 bargDesign temp. 450 C
Pressure control
Automatic sequence control
Signal to start/stop sootblowers
Signals from sootblowers
temperature control