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Presentation outline
Overview of Plant Controls Functions of ATRS Structure of ATRS
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MAN-MACHINEINTERFACE
OPERATOR
PLANT
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BOILER
TURBINE
GENERATOR
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MEASUREMENT
MONITORING
CLOSE-LOOP CONTROL
OPEN-LOOP CONTROL
PROTECTION
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ADVANTAGES OF AUTOMATION
OPERATING PERSONNEL FREED FROM ROUTINE TASKS. INCORRECT INTERVENTIONS IN THE PROCESS AVOIDED. STRESS ON EQUIPMENT REDUCED. PLANT OPERATIONS GEARED FOR MAXIMUM EFFICIENCY. INCIPIENT FAULTS RECOGNISED QUICKLY. ON FAULT OCCURRENCE, IMMEDIATE AND LOGICAL INTERVENTION POSSIBLE.
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A.
CONTROL SYSTEM:
ANALOG (CLOSE LOOP) - ELECTROHYDRAULIC CONTROLLER (EHC)
- TURBINE STRESS EVALUATOR (TSE) - LOW PRESSURE BYPASS CONTROLLER (LPBPC) - GLAND STEAM PRESSURE CONTROLLER (GSPC)
BINARY (OPEN LOOP) - AUTOMATIC TURBINE RUN UP SYSTEM (ATRS) - AUTOMATIC TURBINE TESTER (ATT)
B.
C.
PROTECTION SYSTEM
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HIERARCHY OF CONTROL
SUB-GROUP CONTRL-1
SUB-GROUP CONTRL-2
CONTROL INTERFACE
LOGS
CONTROL ROOM
UNIT CONTROL
AUTOMATION
CLOSED LOOP
FUNCTIONAL GROUP
PROTIVE
EQUIPMENT
CONTROL
SIGNAL CONDITIONING ALALOG, BINARY
CONTROL
LOGICS
ANNUNCIATION
PLANT INTERFACE EQUIPMENT
PLANT (FIELD)
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DRIVES
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FEATURES :
BASED ON FUNCTIONAL GROUP CONTROL PHILOSOPHY EACH FUNCTIONAL GROUP ORGANISED AND ARRANGED IN SUB-GROUP CONTROL, SUB-LOOP CONTROL, AND CONTROL INTERFACE OPERATING MODES AVAILABLE: - MANUAL MODE ( OPERATOR GUIDE) - AUTOMATIC MODE - STEP BY STEP MODE
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ATRS STRUCTURE
OIL SYSTEM, VACUUM SYSTEM, TURBINE etc.
GC
SGC SLC
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SGC SLC
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SGC
SLC CI
CI
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GROUP CONTROL: Decides WHEN, HOW MANY & WHICH SGC shall be operating and stopped. SUB GROUP CONTROL: Contains the sequential logics for switching drives ON and OFF. Perform sequence in STEPS, issue commands and get Checkbacks. SUB LOOP CONTROL: can be switched ON & OFF manually. Receive commands from GC, SGC and also Manual CONTROL INTERFACE: Standard Interface between the command transmitters and receivers in the plant, undertakes all necessary signal processing and monitoring.
ADVANTAGES OF ATRS
ELIMINATES HUMAN ERROR PROVIDES MAXIMUM PROTECTION AGAINST MALFUNCTIONS OPERATORS TASK LESS ARDUOUS ENABLES SAFE, SMOOTH, STRESS CONSISTANT AND OPTIMUM WARM-UP, ROLLING AND SYNCHRONISATION OF TURBINE IN LEAST POSSIBLE TIME INCREASES PLANT AVAILABILITY REDUCES STARTING TIME WITHOUT IMPAIRING LIFE MEETS EMERGENCIES AUTOMATICALLY ALL PLANT OPERATING CONDITIONS CATERED TO BY CRITERIA DEPENDANT PROGRAMMING INCREASED OPERATING FLEXIBILITY, SAFETY AND RELIABILITY
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ATRS
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STEP 01
START DRIVE A
DRIVE A ON
& MONITOR & BLOCKING TIME
STEP 02
OPEN DMPR A
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SGC executes commands to bring the equipment upto a particular defined status. The commands are executed in a predefined sequence in the form of steps. Desired number of criteria act as preconditions before the SGC can take off or execute its defined sequence. The functional group continues to function automatically all the time demanding enabling criteria based on the process requirements and from other FGs, if required. In case the desired criteria is not available, the system would automatically act in such a manner as to ensure the safety of the main equipment. The sequence is programmed in the processor. The process signals are acquired through the input modules and are available on the bus.
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Waiting Time : It implies that the subsequent step will not be executed unless the specified time elapses. If no waiting time is specified, the next step gets executed as soon as the enabling criteria are fulfilled. Monitoring Time : It is the time required for executing the command of any step as well as the time required for appearance of criteria for the next step. Under healthy conditions it should happen within the specified time, otherwise an alarm is initiated. Whenever there is uncertainty regarding the time required for completing a particular task, such as warming-up, pulling vacuum etc., the monitoring time is blocked.
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&
BYPASS CRITERION
EXAMPLE
1
&
02
PROGRAM LOOP
WAIT
50s
MO TIME
20s
COMMAND
1 2
&
STEP 2 ( START UP PROGRAM) WITH 2 STEP CRITERIA, 2 COMMAND OUTPUTS AND A MONITORING & WAITING TIME . WITH ADDITIONAL PROGRAM LOOP CONTROL AND A BYPASS CRITERIA FOR STEP 1 WAITING OR MO TIME CAN BE PROGRAMMED FOR 0.1 SEC TO 999 MIN. NOS. 1-49 USED FOR START-UP, PMI Revision 00 51 TO 99 FOR SHUTDOWN PROGRAM.
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ATRS can be switched on at any stage after completing certain tasks manually, if so desired. In such cases, the SGC program quickly scans through the steps and starts executing from the stage upto which the tasks have been completed manually. This is achieved by incorporating suitable overflow /bypass conditions in the logic.
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1. ATRS is organised in the following four Sub-Groups : Oil supply Evacuation Turbine HP CONTROL FLUID
2. SGC issues commands either to the SLC or directly to the drive through the Control Interface.
3. Each of these SGCs has its subordinate SLCs and CI modules. These SGCs in conjunction with the turbine governing system , TSE and the auto-synchroniser accomplish the function of start-up of the TG set.
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1. SGC-TURBINE :
Sub-loop Control (SLC) Drains. Warm up Controller. Starting Device of turbine governing system. Speed & Load Setpoint devices of turbine governing system. Auto-synchroniser.
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Sub-loop control (SLC) turning gear. SLC auxiliary oil pump 1. SLC auxiliary oil pump 2. SLC emergency oil pump. SLC jacking oil pump.
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Sub-loop Control (SLC) condensate extraction pumps. Starting ejector, if provided. Main ejectors / vacuum pumps (as applicable). Vacuum breaker.
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Sub-loop Control (SLC) HPCF SLC HPCF pumps HPCF pumps HPCF re-circulation pumps LPCF temp control valve
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LP WATER INJECTION
AUTOMATIC SYNCHRONIZER
MANUAL OPEN/CLOSE
MANUAL ON/OFF
DRAIN VALVES
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SGC-DISPLAY
4 6 8 7 5
1. PUSHBUTTON SHUTDOWN 2.PUSHBUTTON STARTUP OR OPERATION 3.PUSHBUTTON AUTOMATIC ON/OFF 4.LAMP SHUTDOWN PROGRAM 5.LAMP STARTUP OR OPERATION PROGRAM 6.LAMP AUTOMATIC OFF 7.LAMP AUTOMATIC ON 8.LAMP FAULT
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SLC-DISPLAY
2 3 4
1
1. PUSHBUTTON MANUAL ON/OFF 2.LAMP SLC OFF 3.LAMP FAULT 4.LAMP SLC ON
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DRIVE INTERFACE-DISPLAY
3 4 5
1. PUSHBUTTON OFF (CLOSE) 2. PUSHBUTTON ON (OPEN) 3. LAMP OFF (CLOSE) 4. LAMP FAULT 5. LAMP ON (OPEN)
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1
NAAANN 1MAJ15
2
AANNN AP001
3
AANN XB01
SIGNAL IDENTIFICATION
CONSECUTIVE NO. OF EQUIPMENT
TYPE OF EQUIPMENT NO. OF SUBGROUP PLANT GROUP (FUNCTIONAL GROUP) NO. OF UNIT
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HYDRAULIC
ELECTRICAL
EXTENDED
PROT. CRITERIA
TRIP SYSTEM
- OVER SPEED TRIP DEVICE 1/2 - VACUUM TRIP DEVICE - HAND TRIP LEVER(LOCAL) 1/2
TRIP SYSTEM
- MANUAL REMOTE TRIP ( UCB) - LOW VACUUM TRIP - LOW LUBE OIL - FIRE PROT. TRIP -BRG METAL TEMP -AXIAL SHIFT -HP/IP TOP/BOT DIFF TEMP HI
TURBINE PROT.
- LP EXH. STM. TEMP. > MAX
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i)
Fire protection switch, either in unit control room or in machine hall, operated. ii) Level in main oil tank falls to a very low value, indicating substantial leakage of oil from the system.
The command signal under condition (ii) is initiated from three level transmitters in 2-out-of-3 logic cofiguration.
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6. TRIP COMMAND INITIATED FROM ATRS : The protection acts when the trip command signal is initiated from the Automatic Turbine Run-up System .
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THANK YOU
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