power plant automation

7/23/2019 Power Plant Automation

http://slidepdf.com/reader/full/power-plant-automation 1/96

Presented By- Pankaj TrivediDIL ,C& I

L



Thermal Power Stations employ a greatnumber of equipment performing numberof complex processes.

Ultimate aim being the conversion ofchemical energy into Electricity.

In order to have stable generatingconditions, always a balance is maintained.

I.e..Heat input = Electricity output + losses

Automation reduces the disturbance in

Balance06-10-2012 2DIL , C&I



The ba l a n ce i s f r eq u en t l y d i s t u r b edd u e t o

Grid troubles external to the process and

machines .

Troubles in the process itself .

Troubles in the equipment’s itself.

Troubles due to human intervention.

When the balance is disturbed, all the process

variables deviate from their normal values.

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To make the process stable by reducing

disturbances.To increase the efficiency of the unit.

To increase the reliability of the unit.

To increase the equipment & personal safety.To reduce the MTBF ie reducing down time of

equipment & Unit.

To reduce the MTTR .

To reduce the human intervention.

To assist the operator for Safe & efficient

operation .

To reduce the environmental hazards

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Role of C & I

1) Measurement

2) Indication

3) Recording

4) Control

5) Protection

6) Annunciation

7) Efficiency Monitoring

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The proportionate cost of instrumentationduring seventies was about 2.3 to 2.5% ofthe total cost of boiler, turbine and their

Auxiliaries for the unit sizes up to 60/100M.W.

This has become about 7 % for 210 M.W.and is reaching about 10-12% may even

higher in the near future.

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Increase in unit capacity, operating the unitat higher parameter for economic reasons.

New inventions, improvements,

modernization of instruments andequipment’s.

Expected change in the duty cycles of the

boiler and turbine facilitating two-shift

operation, quick run up etc. Improved awareness among the personnel

about the utility of the instruments.

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Mechanical

Pneumatic

hydraulic

Electrical

Electro-pneumatic

Electronics

µp based (controllers)

Computer based(PLC ,DDC ,DCS ,DDCMIS) )06-10-2012 10DIL , C&I



Traditional Instruments like thermocouples, RTDs,Gauges ,transmitters etc are being made more

and more intelligent.

New Instruments with better accuracy and noise

immunity are being invented. Use of computer technology lead to PLCs & DCS

for fast & accurate controlling of complex process.

Advancement of Information technology for better

& reliable communication & human machineinterfacing.

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1930s The discrete devices used for analogcontrol were governors and mechanicalcontrollers.

1940s direct connected pneumatic

controllers. 50s pneumatic Transmitters & controllers .

50s. discrete devices used for digitalcontrol were relays and stepping switches.

60s PLCs evolution.

70s onward computerized control.

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replacement of relays and pneumatic controllers

with their solid state equivalents, resulted in thedevelopment PLCs & PID controllers.

Realization of computer capabilities

first led to Data Acquisition, then to Supervisory

control and finally to Direct Digital-Control. With continued developments in technology, these

two streams have now merged into the present

day computer based control systems(distributed

digital control). With the advent of Information technology, DCS is

now became DDCMIS (Distributed digital control

& management information system)

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Pneum a t i c co n t r o l -

Simple ,hence less skilledperson can be utilized forservicing, Less expensiveon initial cost.

Reliable and more ruggedcomponents are available.

Higher motive force

actuator is readilyavailable. Flame proof, suitable for

hazardous surroundings. Operation is smooth, over

load proof due tocompressibility.

Requires large quantity ofclean compressedair(moisture & dirt free).

Permits wider ambienttemperature operations

E l ect r o n i c con t r o l -

High speed of signaltransmission hence lesstime lag.

Higher amplification ispossible

easily adaptable to

complex & integratedcontrol

greater accuracy

feed back from morenumber of variables

cheaper if the system is

adapted for large plants

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Instrumentation: To measure andindicate the amount of deviations.

Automatic Control: To correct the

deviation and bring back to normalcy. Annunciation : To warn about the

excessive deviations if any.

Protection: To isolate the equipment’s orprocess from dangerous operatingconditions caused due to such excessivedeviations

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Instrument:

A device used in performing an action.

Instrumentation:

provision of use of instruments to

perform different tasks in industry.Such as

measurement,control,protection,etc.

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1) Temperature

2) Pressure

3) Flow4) Level

5) Turbovisory

6) Analytical

7) Vibration

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Instrumentation as a whole is used toimprove /increase:

* safety of plant and personnel.

* availability of plant

* efficiency of plant and equipment.

* efficient use of process variables.* to alert the operator/engineer facilitating

them to take timely corrective actions.

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Process-

Sequence of interdependent and linkedprocedures which, at every stage, consume oneor more resources (employee , time, energy,machines, money) to convert inputs (data,material, parts, etc.) into outputs.

Process Parameters-

Flow, pressure,level,temperature,ph Etc are calledParameters of the Process , these parameters are

measured and then controlled to control theprocess , isolate the process & improve theprocess.

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Range of measurementRequired accuracy of measurement

The form of final data display required

Process mediaCost

Calibration & repair facilities available

Layout restrictions

Maintenance requirements/availability

availability of skill persons.

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M ea su r em en t :

is a comparison between known standard toun- known magnitude.

Measurement cycle-

Sensing

Transmitting Indicating/&recording /&controlling

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Pressu re –Bourdon tube , Diaphragm , capsule etc.

Tempe r a t u r e –

Thermometer , thermocouple , RTD etc.

L ev el –

Manometer , head pressure , float , resistance,ultrasonic etc.

F l ow – Primary elements , mechanical meters , mass

flow meters etc

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Signal conditioning suitable to next stage,i.e.:amplifying, converting, attenuating, etc.

Transmitting the desired signal to a remote

location in the form of Current (4-20 ma), Voltage ( 0-5 , 10 , 24 V) , pneumatic signal (3-15 PSI) for the purpose of Indicating recordingor controlling.

Pneumatic , electric ,electronic or smarttransmitters are used for transmitting.

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Indicating

Indicating & annunciation,/ protection.

Indicating & recording

recording & annunciation,/protection. Indicating/& controlling.

Controlling.

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Lo ca l : indicators are self-contained and self-operative and are mounted on the site.

Remote: used for telemetering purposes andmounted in the centralised control room orcontrol penal.

**The indicators both local and remote aresometimes provided with signaling contacts wherever required.

The remote indicators may be electrical,electronics, and pneumatic or hydraulic based for

their operation and accordingly they are named. The indicators can be classified as analogue or

digital on the basis of final reading. Indicators are available for single & multi point

measuring systems.

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Recorders are necessary wherever the

operating history is required for analyzingthe trends and for any future case studiesor efficiency purposes.*single point or multipoint Multipoint :multipoint continuousrecorders or multipoint dot recorders.(dot recorders select the point one after the

other in sequence)

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The intended use of the sensor.

Range : normal range over which thecontrolled variable might vary?.are there

extremes to this.?Resp on se t i m e: time required for a sensor

to respond,to a change in its input.

Accu r a c y : how close the sensor comes to

indicating the actual value of the measured value.

Sens i t i v i t y : how small change in thecontrolled variable the sensor can measure

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Prec i s i on : how consistent the sensor is inmeasuring the same value under the same

operating conditions over a period of time.D ead ba n d : how much of a change to the

process is required before the sensor respondsto the change?

Costs : what are the costs involved.(i.e. Purchase cost,installation cost, operating

cost,and calibrating etc.)

I n st a l l a t i on p r o b l em s : specialinstallations ( i.e.corrosive fluids,explosivemixtures,size and shape constraints,remotetransmission requirements etc.)

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T r a n s d u ce r :

Transducer converts one form of energyinto electrical energy

Ty pes o f T r an sdu cer s:

1)A ct i v e t r a n sdu cer s

These are self powered Transducers. Itconverts one form of energy into electricalenergy without need of any external energy.

2 )Passi v e T r an sdu cer s

These require external energy to convertone form of energy into electrical energy

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Should sense the desired input signal. Should be insensitive to other signals present

simultaneously in the measurand.

Should be amenable to modifications withappropriate processing and display devices.

It should not alter the event to be measured.

Should be able to with stand hostile environment

while maintaining the rated accuracy. Should be easily available and reasonably priced.

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Pressu re is actually the measurement offorce acting on unit area of surface.

Pressure measurement in a power plant

includes the measurement of steam pressure

feed water pressure

condenser pressure

lubricating oil pressure and many more

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Manometers for low pressure. Water filled

Mercury Filled

Bellows for medium pressureBourdon tube gauges for medium and high

pressure measurements

Capacitive type

LVDT type. Strain gauge type.

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Accurate continuous measurement of volume

of fluid in containers (closed or open vessels)can be done by using different types of Levelmeasuring instruments.

Types of Level Measurement

Floats and liquid displacers

Head pressure measurement

DP type

Ultrasonic

Direct Viewing

Strain gauge

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Head type

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In closed pressurized vessels, Differential pressure

measurement is used to measure the level. One side condensate pot is used where constant level

is maintained. Other side is connected to the bottom ofthe vessel.

Difference between these two heads gives the level.

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Controlling the flow rate of fluids is a key control

mechanism for any process plant. There are many different types of devices

available to measure flow.

P r i n c i p l e

Flow rate is determined inferentially bymeasuring the liquid's velocity

Velocity depends on the pressure differential

Q = V x A

Q = liquid flow through the pipe V = average velocity of the flow

A = cross-sectional area of the pipe

Flow Q = ρ sqrt ( P1-P2)

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Head Type (DP)

Variable Area

Displacement

Electromagnetic

Ultrasonic

DP Ty pe (Flow Q = ρ sqrt ( P1-P2) )

Orifice

Venturi

Pitot Tube Dall Tube

Nozzle

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E = BVD , Electromagnetic principle

Ultrasonic principle

Variable area principle

Reflection ModeDiagonal Mode

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The degree of hotness or coldness of a piece

of plastic, wood, metal, or other materialdepends upon the molecular activity of thematerial. Kinetic energy is a measure of theactivity of the atoms which make up themolecules of any material. Therefore,temperature is a measure of the kinetic energyof the material.

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Expansion of Solids

Thermostats Expansion of Liquids

Temperature Gauges Expansion of gases

Temperature Gauges Thermal Electricity Thermocouples

Type K Chromel Alumel etc.

Change of Electric Resistance (RTD) Pt100 Cu53

Intensity of total radiation Optical Pyrometer

Radiation Pyrometer

Expansion of Liquids and gases are used for local gauges. Thermocouples and RTDs are used for most of the remote temperature

measurements and controls. RTDs are used for low temperature applications. Pyrometers are used for high temperature measurements. (NON Contact

type).

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To maintain the desired parameters with ina certain limit to optimize the plant efficiency ,smooth operation with equipment & personalsafety

Some Important parameters to be maintained inThermal Power Plant are –

Boiler drum level

Furnace pressure

Steam temperature at boiler outlet

Steam pressure , Condenser vacuum

Generator terminal voltage

Frequency & M.W load

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Based on human intelligence & experience , open loopsystem , simple , cheap, stable but inaccurate, affected by external disturbance

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.

A dev i c e i n w h i ch a s i g n a l f r om t h e det ect i n g el em en t i s

com pa r ed w i t h a si g n a l r ep r esen t i n g t h e set v a l u e a n dw h i c h o p er a t es i n su c h a w a y t o r ed u c e t h e d ev i a t i o n .

M o r e a ccu r a t e & p r eci se con t r o l , f a st r espon se bu t

com p l ex & v er y u n st a b l e u n d er f a u l t co n d i t i o n .

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W her e t h e o u t p u t co n d i t i o n i s m ea su r ed a n d i f d ev i t i o n co r r ect

a ct i o n i s t a k en a u t om a t i ca l l y t o co r r ect i t , i s ca l l ed cl o sed l o o p

co n t r o l .

I t co n t a i n s M o n i t o r i n g t h e o u t p u t p a r am et er & f eed b a ck e l em en t .

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No m o n i t o r i n g f eed b a ck t o t h e co n t r o l ler m a y b e m a n u a l o r

w i t h t h e h el p o f co n t r o l l er

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Steam pressure always called as Boiler

Master Control.Combustion control

Furnace draft control

Boiler feed regulation or drum level controlSuper heater/Re heater steam temperature

control

Auxiliary steam pressure control

Mill group control & coal feeder control.

Feed pump speed control –scoop control.

FSSS , BMS Control

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Condenser hot well level regulation

Drip level control in L.P. and H.P. heater.

Dearator level & pressure control.

Gland steam pressure control

Governor controls, speed & load control.

Automatic turbine run up systems.

Turbine Emergency trip system.

HP/LP bypass system.

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M

M

CENTRAL PROCESSING UNIT

M

M

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DCS is a open, integrated and distributed system for

industrial automation .

Heart of DCS is the powerful controller executing allthe control functions and the two communication links

Main Aspects of DCS automation Process Control

Operator Interaction

Engineering Information Management

Distributed Control

System

Functions distributedRedundancy possible

Risk distributed

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1st Generation: Use of relay technology in Control &

Protection Systems2nd Gen er a t i o n : Use of solid-state technology,

Digital modules & Integrated Circuit (IC)

3rd Generation: Use of hybrid technologies,

Microprocessor components4 t h Gen er a t i o n : Use of PLC-based computer

technologies, Software systems

5t h Gen er a t i o n : Use of advanced HMI

technologies, Digital computers, Software systems

…

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An a l o g co n t r o l

Very simple to construct Cheap & easy to maintain

Higher level functions are not possible

Limited operator interaction

DCS

Highly sophisticated & user friendly

Fine tuning, efficiency calculation &report generation are possible

Skilled maintenance engineers arerequired.

Spares are very costly and highly supplierdependent

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Control Architecture of CS-3000 DCS system



f 3 y

Controller

Operatorstation

Operatorstation

Operatorstation

Engineeringstation

Historianstation

MISstation

O-Net

Control-way

Network

I/O modules I/O modules

Controller

Control-way Network

C-Net

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F i f C i i k



CPU

Redundant Supervisory Network

This network connects thecontroller and high levelperipherals like Operator Station,Engineering Station, Historian

Node, Printers, ManagementInformation System.

Redundant Data network

Transfers the plant parameters between controller and I/O modulesto do the low level & high speedcontrol through communicationmodules.

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Functions of Communication networks



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Functionally and physically separate systems

connected with each other to share relevantinformation for optimum plant control Failure of a processor or a network will not result

in failure of another processors or networks of thesystem

Software acts as a filter Man-machine Interface Historisation Advanced Automation Supervisory Control Interface to Foreign Devices Sequence of Event recorder Master and slave clock system

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Automatic Data Acquisition System

Automatic Algorithm Processing

Drives

Third party connectivity (OPC)

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Manager’s PC’s

Plant-Wide

History

Advanced Appl ications

Gateway

Plant Intranet

SAP

Process Network

Foreign Device

Integration

WD

Gateway

PLC

Plant-WideHuman Interface

Controller

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Reduction in cabling in Control room Physically and functionally separate

modules

More uniform operations and tighter

controls Excellent information management

Better integration of plant controls

Considerable reduction over

maintenance efforts Supervisory and Advance control

strategy can be implemented

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Open L oop Con t r o l

Permissives

Interlock

ProtectionClo se L oop Con t r o l

Analog Single loop control Vs

Digital control

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M easu r em en t sy st em

Analog input(4-20ma,RTD,T/C, mv)Binary input

Pulse input

Redundant Transmitters a. Dual measurement sys

B. Triple measurement sys

Con t r o l l e r s

Pneumatic, Analog (Discrete & IC based) as well asµP based.

Proportional, Integral & Derivative Actions

Advanced Control Algorithms06-10-2012 71DIL , C&I



DIGITALDISTRIBUTED

CONTROLS ANDMANAMAGEMENT

INFORMATIONSYSTEMS

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I/O system, optionally, connected to Ethernet

ZCP270

FCP 270

Engineering workstationWorkstations

FoxC om

ICC/IACC/IEE

FoxViewFoxDraw

AIM/InSQL

ModbusSerial/E’net

RTU Master

OPC

Client

SOE

TDR

GPSFoxView

FF improvements:

•Redundant FBM

•Improved Diagnostics•Control Sync, improvements

APACS

FDSI

•Serial•Ethernet

•Simplex

•Redundant

© Invensys 8 October 2012Invensys proprietary & confidential73

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W ha t i s D AS ? -

Computerized intelligent system presenting data fromthe entire plant in desired and on as required basis tofacilitate easy monitoring, recording and to enableoperator to take quick decisions regarding operation.

NEED FOR A D AS

To collect process and present field data to operationand management For Efficient operation of Power Plant, close

monitoring of various plant equipment and theirparameters is required.

Indicating each of such parameters separately incontrol room requires lot of space.

DAS will solve many of the problems by displaying lotof analog as well as Digital points simultaneously inone Monitor.

To collect process and present field data to operationand management

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Displaying all the DATA in a systematicformat, so that the data can be used by theoperator in a efficient way.

Giving the operator alarms, in case of any

deviation of parameters from the normalrange.Storage of DATA for retrieval at a later

date.Generation of LOGs, for monitoring the

parameters and improving the efficiency.Generation of SOEs for analysing the cause

of unit Tripping/ any emergency etc.

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Measurement Analog, Binary and Pulse Signal Conditioning

Data Display( Video Trend , bar chart, mimic, periodic) Alarm monitoring and Printing L o g g i n g

- Daily Logs- Sequence of Events Log

- Post Trip Log- Boiler Start-up & Shutdown Log

H i st o r i ca l St o r a g e Performance Calculations

- Heat rate of Boiler , Turbine ,

Unit etc.D i a g no s t i c s

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Group review displays

Graphic mimics

Bar charts

Alarm DisplaysHistorical Storage

Real Time Trends

Operator Guidance MessagesLogs

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Used for Displaying DATA in a group.

All the DATA relating to a particular Auxiliary

DATA relating to a System (Feed water etc)

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Displaying the DATA on the Plant mimics

Better understanding of the Process

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Displays all the alarms in the order of their occurrence

Useful for analysing the cause of the major failures. All digital DATA and Analog values crossing the limits will be

displayed in this window in the order of their occurrence.

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All important DATA can be stored in the Storage

Devises available and can be retrieved later foranalysis.

SOEs

LOGs

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Operator can configure the required points for

real time trending purpose and can see thereal time trend and in case of any deviation(abnormal change) can react quickly.

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Operator Guidance messages can be displayed

on the DAS monitors when rolling or anyimportant activity is going on.

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Even t A ct i v a t ed l o g s SOE

Post Trip Log

Start-Up Log

T im e A ct i v a t ed L o g s Daily Log

Shift Log

M a i n t en a n ce Da t a L o g

On D em a n d L o gs

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Report

Package


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System

Management


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integrated plant control for SteamGenerator (SG), Turbo Generator (TG)and balance of plant to control it

may be remembered that historically the term

DDCMIS used to be referred for the so-called“BOP-c& i ” . the SG-c&i, i.e. FSSS etc. TG-c&ii.e. TRS, turbine protection etc. originally werenot considered under DDCMIS or DCS as permany suppliers. only recently the type ofsystems for all the systems have becomesimilar (with some difference ).

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integrated plant operation through fully interchangeableopertaor work stations (ows) for sg, tg and balance ofplan (sometimes this may not be possible due topackaging concept).

provision of extensive self-diagnostics

use of large video screens for projections of various plantmimics etc.

provision of fault alarm analysis to guide the operator tothe most likely event

provision of trend alarms

provision of safety hardware for burner managementsystems

provision of fail-safe hardware for turbine protectionsystem

provision of adequate reliability and availability withproper redundancy in sensor, i/o and controller.

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sequence of event (SOE ) and annunciationsystem functions

system programming facility

a) tuning & configuration for control system

b) modification & program development formmipis

master & slave clock system

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CONTROL SYSTEM

PROGRAMMING & MMIPIS M & S

CONFIGURATION SYSTEM CLOCK

SG- C&I BOP- C&I TG- C&I

SYSTEM SYSTEM SYSTEM

DCS

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consists of Furnace supervisory safeguard system

(FSSS), soot blower control system (SBC),secondary air damper control system (SADC),auxiliary PRDS controls (APRDS), Seal Gap control,Hot spot detection system

For FSSS “safety system” hardware is specified, i.e.

the hardware , which meets the requirement ofrelevant NFPA and VDE standards` triple redundant configuration for the furnace

protection (MFT) portion of burner managementsystem (FSSS)

for SBC, SADC, APRDS, mill & oil elev. sequence,interlock and protection, configuration similar toOLCS/CLCS

for mill & oil elev. logics, safety system hardware shall be used

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consists of turbine protection system (ETS),

automatic turbine run-up system ( ATRS),automatic turbine testing system (ATT), electro-hydraulic turbine control system (EHTC/DEH)for main & BFP turbine, turbine stress controlsystem (TSCS), gland steam pressure control

generator seal oil, primary water & hydrogencontrol system (recent addition).

triple redundant or 2 x 100 % repeated twiceconfiguration for the turbine protection system(TPS). for this, safety system hardware / fail-safe

hardware shall be used for others, configuration similar to olcs/clcs

(described later) to be used

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consists of open loop control system (OLCS)and closed loop control system (CLCS)

OLCS -the sequence control, interlock of of allthe plant systems which are not covered in the

SG-c&i and TG-c&i. this includes majorauxiliaries like FD/ID/PA FANS, AIR-PREHEATER,BFP/CEP/CWP/ BCWP ,DMCWP/CLCWP and Electrical breakers(CLCS) –

the modulating control for various importantplant parameters, like FW flow (drum level),furnace draft, combustion control (fuel flowand air flow), PA hdr pressure control,deaerator/hotwell/heater level controls etc.

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Anyquestion ?

Thanks……………

….

power plant automation

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