Design of Control & Click to edit Master subtitle style Instrumentation Systems For Thermal Power Plant

Presented by: Group B4

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CONTENT

DCS

PLC Generators Turbines Bolier CHP Plant

and its auxiliaries

& AHP water systems

SCADA CCTV
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Distributed Control System

Several

processors operate together tasks are dedicated to different

Different

machines
The

plant's information and control systems are determined based on requirements of mechanical and electrical engineering system functions:
Acquisition & Processing of process data. Open loop and closed loop control.
Open loop system is a non feedback type system relying

Control

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on the current and the model of the system

A Typical DCS Configuration

Central Cabinet house the processors that execute the control functions. These cubicles also contain the attendant interface and input/output (I/O) cards and the necessary power supply units (PSUs). The latter will usually be duplicated or triplicated, with automatic changeover from one to another in the event of the first failing.

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This automatic changeover is often referred to as diode auctioneering because silicon diodes are used to feed power from each unit onto a common bus-main In the event of the operational power-supply unit failing, its diode prevents a power reversal while the back-up power unit takes over. They may also allow limited control to be performed, but all this will function for only a short period (typically 30 min) and it is therefore usual to provide an external uninterruptable power supply (UPS) system which can allow the plant to be operated for a longer time

Instead, it is common to provide a battery capacity 8/17/12 will allow the plant to be safely shut down in the that

Operator Workstations

The operator workstations consist of screens on which plant information can be observed, plus keyboards, trackballs or 'mouse' devices allowing the operator to send commands to the system Also comprise printers for operational records, logging of events Screen update time: This is the time between the occurrence of an event and its appearance on the screen. As system loading is increased, this time can become extended

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Operator Work Station

Alarm

Monitoring display Display guidance display and diagnostic

Mimic/graphic Trend

Operator System

display
Control Bar
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chart display

Sequence

Benefits of DCS/PLC
High

reliability response time operator interfaces to plant accessibility of Plant data to storages and retrieval system

Improved Improve Improve

engineering & management personal

Historical

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DCS Components

The typical DCS system shown in above figure can consists of one or more of the following elements:

Local Control Unit (LCU) Data Acquisition Unit Batch Sequencing Unit Local Display Bulk Memory Unit General Purpose Computer Central Operator Display
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Programmable Logic Controller

A

programmable logic controller (PLC) or programmable controller is a digital computer used for automation of electromechanical processes PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact or discrete signals behave as binary switches, yielding simply an On or Off signal signals are like volume controls, with a

the

Digital

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Generator Voltage Regulation

To maintain the output voltage of a generator at a desired value As load on an AC generator changes, the voltage will also tend to change.
The main reason for this change in voltage is the change

in the voltage drop across the armature winding caused by a change in load current

Because of changes in voltage, due to changes in load and changes in power factor, AC generators require some auxiliary means of regulating output voltage

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Generator Protection Circuitry and Relaying

Protective relays are designed to cause the prompt removal of any part of a power system that might cause damage or interfere with the effective and continuous operation of the rest of the system. The relays can be designed to protect generating equipment and electrical circuits from any undesirable condition, such as under voltage, under frequency, or interlocking system lineups.

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There are only two operating principles for protective relays:

electromagnetic attraction and electromagnetic induction.

Electromagnetic attraction relays operate by a plunger being drawn up into a solenoid or an armature that is attracted to the poles of an electromagnet. This type of relay can be actuated by either DC or AC systems. Electromagnetic induction relays operate on the induction motor principle whereby torque is developed by induction in a rotor. This type of relay can be used only in AC circuits.

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Need for C&I of turbines

Modern control platforms provide better control of the steam turbine, the flexibility to meet the demands of the market can be obtained. The control system design is critical to optimize availability and reliability while minimizing impact on maintenance and capital budgets. Recent developments in digital processing faster processing speeds, lower cost, and smaller sizes Maintenance of old systems required a certain degree of familiarity and knowledge of the instrumentation of its era

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Turbine control system (TCS)

TCS is designed to control the main steam flow to the steam turbine in all operational conditions by means of the turbine throttle, governor, admission, and or extraction control valves. The control functions are conducted through the use of simplex or redundant electronic functions incorporated within the TCS software and hardware Master controllers automatically engage when required to ensure the appropriate rates of change match the mode of operation of the turbine.

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The principle features of the TCS system

Speed Control
Inlet/Admission Pressure Control Load Control Turbine Stress Influence Frequency Influence ADS (Automatic Dispatch System) Influence Valve Lift Control Other functions

The TCS system ensures stable operation throughout all 8/17/12 operational phases, i.e. during unit start up, shutdown, parallel

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The TCS should provide automatic and manual shutdown. In automatic shutdown, the system must lower the load until the generator breaker opens on reverse current. On manual shutdown, the operator will open the generator breaker manually once the turbine is at minimum load.

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Speed Control

Provides the operational control involving the speed limiting and acceleration functions of the unit over the entire operating speed range Depending on the particulars of the steam turbine itself and its application use, the unit can be configured to open the governor valve(s), and modulate the stop valve in order to warm the unit without breaking turning gear speed For eg. The speed control function is designed to receive up to three speed inputs. These inputs feed a 1 of 2, 2 of 3, and or 2 of 4 voting algorithm which issue an over speed trip command. If one of the channels fail, that channel is automatically deselected, an alarm is issued alerting the operator of the malfunction, and the unit shifts to the next available comparison algorithm In the event the speed channel is repaired (the operator found a loose wire connection in the junction box on the ST), then the unit automatically detects the correction, and shifts back automatically into the pre-configured algorithm.
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Inlet/Admission Pressure Controller

The inlet/admission pressure control provides two channel selection which facilitates initial pressure (boiler follow mode) and limit pressure (turbine follow mode) functions. This automatic control function is activated when the inlet-steam pressure drops to a pre-determined configurable set point.

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Load Control

Once the turbine is on the grid, the TCS can either be transferred automatically or manually into the load control mode of operation. The load control function produces steam flow demand signals via the position controller of the associated servo valve actuators. Logic signals derived from the units load control system (ULCS) indicate operating conditions, such as power load imbalance. Standard turbine runback features designed within the system are Loss of boiler feed water pump Loss of condenser vacuum

Loss of primary coolant/pump (generator H2 coolant circulating water pump

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Turbine Stress Influence

Limiting the acceleration and load ramp gradients This value would limit the acceleration and or deceleration limit applied to the turbine via the master controllers

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Frequency Influence

When the generator is on the grid and the turbine controller is in the load control mode, the speed control function continues to provide a speed error (influence) input for use in frequency regulation. Comparing the speed reference with the actual speed derives the speed error signal. The frequency detection accuracy is within 10 MHz, with tunable variables controlling dead band and droop characteristics.

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ADS (Automatic Dispatch System) Influence

The TCS system is designed to accept influencing from an ADS controller, facilitating the remote dispatch loading and unloading of the machine along predetermined ramp gradients. The load limit gradients are configurable through the entire range of operation

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Valve Lift Control

The valve lift controller integrates the min-gated valve demand reference versus valve actual (setpoint) functions. Rates of greater than 20 samples per cyclic event throughout the stroke of the valve to achieve the fastest possible response time.

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Field Device Parameter Sensing Assemblies

The following items are installed in place of the trip block assembly and provide inputs to the TPS.

Vacuum Pressure Bearing Lube Oil Pressure. Turbine Thrust Pressure Sensing. Turbine Trip Solenoids.

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Electrical Auxiliaries

Vibration monitoring equipment should be added or upgraded to monitor the health of the rotor and associated bearings. Adding more sensors to monitor bearing lube oil and metal temperatures, valve metal temperatures, steam chest temperatures and any other temperatures as applicable should enhance temperature monitoring. These indications should be added to the TCS graphics.

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Boiler and its Auxiliaries

Instrumentation and controls in a boiler plant encompass an enormous range of equipment from simple in the small industrial plant to the complex in the large utility station. It consists of several control loops to control various systems related to a boiler. The main control of boilers include combination control and feed-water control. Virtually any boiler-old or new, industrial or utility can benefit from or several control system modifications available today either by introducing advanced control schemes adding to existing control schemes The boiler control system is the means by which the balance of energy & mass into and out of the boiler are achieved. Inputs are fuel, combustion air, atomizing air or steam &feed water. Of these, fuel is the major energy input. air is the major mass input, outputs are steam, flue gas,

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CONTROL LOOPS
Boiler control systems contain several variable with interaction occurring among the control loops for fuel, combustion air, & feed-water . The overall system generally can be treated as a series of basic control loops connected together. for safety purposes, fuel addition should be limited by the amount of combustion air and it may need minimum limiting for flame stability.

Combustion controls
Amounts of fuel and air must be carefully
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Block Diagram

The output from the boiler i.e., the steam outputs and the level of water is given to transmitters. The output of transmitter is given to the controller which act as level indicator controller and flow indicator controller. If there is any error corresponding to desired set point, the signal from 8/17/12

BOILER DRUM TRANSMITTER CONTROLLER CONVERTER VALVE

COMBUSTION CONTROL
A combustion control system is broken down into

(a) Fuel control (b) Combustion air control subsystems.

The interrelationship between these two subsystems necessitate the use of fuel air ration controls. The primary boiler fuels are coal, oil and gas. The control of gas and oil fuels requires simplest controls- i.e., a control valve in the fuel line. The steam drum pressure is an indication of balance between the inflow and outflow of heat. Therefore by controlling the steam supply one can establish balance between the demand for steam (process load ) and supply of water.

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DIFFERENT TYPES OF COMBUSTION CONTROLS

There are three general types of combustion control schemes used today:

Series,
In series control, variations in steam header pressure(the master control

signal) cause a change in combustion air flow which in turn results in a sequential change in fuel flow. This type of control is limited to small boilers having relatively constant steam load & burning fuel.

Parallel
In parallel control, variation in steam pressure simultaneously adjusts

both fuel & air flows. This method is common to any size boilers.

Series-parallel
In series-parallel, variation in steam pressure set points are used to

adjust the fuel. Flow to the above boiler since steam flow is directly related to heat release of the fuel and hence the air flow, the steam flow can be used as an index of the required combustion air.

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The control hardware used to carryout the above schemes include: ON/OFF controls:

HARDWARES USED IN COMBUSTION CONTROL

Are still used in many industries but are generally used in small water tube

boilers. When the pressure drops to a present value, fuel & air are automatically fed into the boiler at predetermined rate until pressure has risen to its upper limit.

Positioning systems:
Respond to changes in header pressure by simultaneously positioning the forced

draft damper and fuel valve to a predetermined alignment. This is not used in liquid , gaseous fuel fired boilers.

Metering control system:

In this system control is regulated in accordance with the measured fuel and air

flows. This maintains combustion efficiency over a wide load ranges & over long period of time. Both metering & positioning control systems use steam header pressure as their primary measured variable & as a basis for firing rate demand. A master pressure controller responds to changes on header pressure & positions the dampers to control air flow and fuel valve to regulate fuel supply 8/17/12

FEED-WATER CONTROL

Feed-water control is the regulation of water to the boiler drum. It provide a mass accounting system for steam leading and feed-water entering the boiler. Proper boiler operation requires that the level of water in the steam drum should be maintained within certain band. It is important to made that the water level in the boiler drum must be above 50% all the time. The water level in the boiler drum is related to, but is not a direct indicator of , the quantity of water in the drum. At each boiler load, there is different volume in the water that is occupied by steam bubbles. So if load is increased there are more steam bubbles and this cause water to rise, rather than fall because of added water usage 8/17/12

Control system complexity is based on number of measured variables used to initiate control action and include single element ,two element,3 element and advanced control schemes to improve accuracy of final control action.

SINGLE ELEMENT CONTROL SYSTEMS

Used for small boilers having relatively high storage volumes and slow

changing loads ,single element control system is used

Controls feed water flow based on drum level. Response is very slow

TWO ELEMENT CONTROL SYSTEMS

Uses steam flow changes as a feed forward signal Used in intermediate boilers as well as large boilers Flow and level transmitters are summed by a computing relay and will be

the set 8/17/12 point for feed-water

Three Element Control

Required for wide and rapid load changes Similar to two element except for the closed water flow loop Control action, the third element based on feed-water flow. The level and steam flow signals are summed and used as an index or set point to the feed-water flow. The feed-water flow measurement provides corrective action for variation in feed-water pressure.

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Advanced Element Controls

Additional elements can be added to a feed-water control system to improve response accuracy

Five Element Control

Steam flow measurement is temperature compensated Drum level measurement is pressure compensated

Five Element Control

Transmitters for blow down flow Soot-blower flow could be added
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ADVANTAGES

Multiple element feed-water control can help:

Faster response of systems. More accurate control. Maximum system stability.

Metering control system maintains combustion efficiency over wide. load changes and over long period of time. Parallel combustion control can be used in any size of boilers

DISADVANTAGES

Boilers require quick responding controls. Level of the water in the boiler must be kept above 50% of height.
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CONTROLOF COAL HANDLING PLANT

Control & instrumentation through microprocessor based PLC system for the entire Coal handling plant It should cover the total functional requirement of sequence control, interlock and protection, monitoring, alarm , data logging etc. Design of the control system shall adhere to the principle of Fail safe operation of all system levels The system shall provide an integrated control & monitoring of coal handling plant equipment from a Main CHP Control Room. The control Room operator shall be provided with color graphic displays of the Coal handling plant and with sufficient details to allow proper control and monitoring of the plant function.
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The entire Coal handling plant will be controlled from the following control points

The overall operation and control of the entire Coal Handling Plant, with a control desk and suitable control panel will be provided at the Main CHP Control Room . The traveling Tippler and its associated drives shall be controlled from local panel located near the bunker floor MCC room Similarly Coal unloading operation for wagon rakes near track hopper area shall be controlled from control panel located in the control room with in building near track hopper. Stacker reclaimer shall be provided with PLC system.

Following Equipment will come under sequential interlock scheme and can be started / stopped from control desk in the main CHP control room :

All belt conveyors. Vibrating feeders. Screens Crushers Flap Gates.

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Following equipment will not generally come under interlock scheme and can be started / stopped / controlled from its local

Belt Weigher Bunker Level Indicator Paddle Feeder Stacker/Reclaimer Coal Sampling System Mobile Tippler Magnetic Separator in line Ventilation system Dust extraction System Dust suppression System Vibration monitoring system( for coal crushers)
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Following equipment will be operated from its local panels without any indication in control desk Electric Hoist. Sump pump Suspended magnets All equipment systems and accessories supplied shall be from the latest proven product range of a manufacturer

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CONTROL PHILOSPHY OF ASH HANDLING SYSTEM

The control & instrumentation shall be through microprocessor based PLC system for the entire Ash handling plant covering the total functional requirement of sequence control, interlock & protection, monitoring, alarm data logging etc. The entire Ash Handling plant will be controlled from the following control points: For overall operation and control of entire Ash Handling Plant with fly ash system, bottom ash system, ash water and slurry pumping system and ash disposal system, a control desk along with control panels mimic will be provided at the Main AHP Control Room. System cabinet associated with local controls shall be located near the local control panels. Suitable alarm system will be provided to warn any mal-functioning of ash handling system

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Following Equipment will come under interlock scheme and can be started/stopped from control desk with indication on CRT and mimic panel with fault correction facility:
All Pumps/Blowers and Compressors . Bottom Ash system. Fly ash system, comprising of ash extraction from ESPs & duct hopper to buffer

hopper located near ESPs and fly ash transportation system from buffer hopper to storage silos.
Ash slurry disposal system. Bottom ash over flow system comprising of bottom ash over flow water storage

tanks, settling tank, ash over flow water pumps, sludge pumps etc.
Silo system. All Motorized valves All pneumatic operated valves.

For local operation in the Bottom Ash area one Bottom ash control panel/cubical is provided for each unit .this panel shall provide control for clinker grinders, bottom ash discharge valves, jet pumps for ash slurry transport etc. A control panel/cubicle shall also be provided in MCC room near silo area for fly ash collection system. The panel shall provide control for dry pneumatic ash 8/17/12 extraction transportation and unloading system.

Plant Water system

C&I shall be through microprocessor based PLC system for the entire Plant water system covering the total functional requirement of sequence control, interlock & protection, monitoring, alarm data logging. Overall operation and control of entire Plant water system i.e. raw water system, Chlorination plant for raw water system and DM plant system, a control desk along with control panels mimic will be provided at the DM plant Control Room.

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The following local control panels are envisaged which are located near their associated system

Raw water system local control panel Chlorination plant local control panel for raw water treatment and CW water treatment Chlorination plant local control panel for potable water system. CW treatment plant local control panel Transfer of acid/Alkali local control panel for DM plant Any other control recommended by contractor

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SCADA System

Supervisory control and data acquisition systems (SCADA) are widely used in industry for supervisory control and data acquisition of industrial processes. A Man-Machine Interface (MMI) is the apparatus which presents process data to a human operator, and through this, the human operator, monitors and controls the process. A supervisory system, acquiring data on the process and sending commands to the process. Remote Terminal Units (RTUs) connecting to sensors in the process, converting sensor signals to digital data and sending digital data to the supervisory system. Communication infrastructure connecting the supervisory system to the RTUs.
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The SCADA system usually consists of the following subsystems:

In fact, most control actions are performed automatically by RTU or by programmable logic controllers (PLC). Host control functions are usually restricted to basic overriding or supervisory level intervention. Example: a PLC may control the flow of cooling water through part of an industrial process, but the SCADA system may allow operators to change the set points for the flow, and enable alarm conditions, such as loss of flow and high temperature, to be displayed and recorded. The feedback control loop passes through the RTU or PLC, while the SCADA system monitors the overall performance of the loop

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Components of SCADA system:

Field data interface devices Communication networks Central host computers Operator station and software components
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Field Data Interface Devices:

Form the "eyes and ears" of a SCADA system Devices such as reservoir level meters, water flow meters, valve position transmitters, temperature transmitters, power consumption meters, and ressure meters all provide information that can tell an experienced operator how well a water distribution system is performing. In addition, equipment such as electric valve actuators, motor control switchboards, and electronic chemical dosing facilities can be used to form the "hands" of the SCADA system and assist in automating the process of distributing water. Information from data interface devices must be converted to a form that is compatible with the language of the SCADA system So electronic field data interface is required and RTUs (Remote Telemetry Units) provide this interface They are primarily used to convert electronic signals received from field interface devices into the language (known as the communication protocol) used to transmit the data over a communication channel. 8/17/12

Communications Network

Provide the means by which data can be transferred between the central host computer servers and the field-based RTUs The Communication Network refers to the equipment needed to transfer data to and from different sites. The medium used can either be cable, telephone or radio. The use of telephone lines (leased or dial-up) is a more economical solution for systems with large coverage. Remote sites are usually not accessible by telephone lines. The use of radio offers an economical solution. Radio modems are used to connect the remote sites to the host.

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Central Host Computer

Most often a single computer or a network of computer servers that provide a man-machine operator interface to the SCADA system. It processes the information received from and sent to the RTU sites and present it to human operators in a form that the operators can work with. Operator terminals are connected to the central host computer by a LAN/WAN so that the viewing screens and associated data can be displayed for the operators Recent SCADA systems are able to offer high resolution computer graphics to display a graphical user interface With the increased use of the personal computer, computer networking has become commonplace in the office and as a result, SCADA systems are now available that can network with office-based personal computers

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Operator Workstations and Software Components

Operator workstations are most often computer terminals that are networked with the SCADA central host computer The central host computer acts as a server for the SCADA application, and the operator terminals are clients that request and send information to the central host computer based on the request and action of the operators. The most obvious software component is the operator interface or Man Machine Interface/Human Machine Interface (MMI/HMI) package Depending on the size and nature of the SCADA application, software can be a significant cost item when developing, maintaining, and expanding a SCADA system When software is well defined, designed, written, checked, 8/17/12

CCTV

CCTV equipment can provide instant alerts when problematic trouble occurs ensuring crime against people, theft and vandalism are all substantially reduced and covered These systems can facilitate round-the-clock monitoring of the power plant CCTV system security technology can be used in both internal and external environment to watch over and protect people, property vehicles and valuables

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Energy Storage systems in thermal power plants

An electrical battery is a combination of one or more electrochemical cells, used to convert stored chemical energy into electrical energy The prime function of the Battery Energy Storage System (BESS) is to provide spinning reserve in the event of power plant or transmission line equipment failure. For these systems rechargeable batteries are used to store electricity in the form of chemical energy. These systems can take energy from the grid when either the frequency or voltage is too high and return that energy to the grid when the frequency or voltage begins to sag. Much like a hybrid electric vehicle incorporates a battery component to improve efficiency; combining battery storage with a traditional power plant allows the plant to more effectively use its own generated power while continuing to provide essential spinning reserve
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Reference

http://specinstrumentationbop.wordpress.com/2008/10/30/154controlphilosphy/ http://www.avantgarde-india.com/techpapers/Essential%20Boiler %20Instrumentation%20and%20Controls.pdf http://provecta.com.au/liddell-coal-handling-plant-systems-controls-andinstrumentation-upgrade/ http://www05.abb.com/global/scot/scot244.nsf/veritydisplay/18ef94c51a254 8d1c1257958002ef13e/$file/abb_optimized_coal_handling_article.pdf www.wikipedia.com http://www.heinzmann.com/heinzmannuk/steamturbines.php? getfile=Steam_Turbine_Controls_e.pdf

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