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Syed Ijlal Haider EE-038 (group leader) Naeem ullah khan EE-054 Mohd.

Ahmed EE-052 Zeeshan EE-318

Present day power plants are being controlled using a large number of open loop and closed loop control systems. The closed loop controls are still being predominantly implemented through PID controllers. However other control philosophies like state variable controllers, fuzzy controllers etc have started making way into some of the control loops. Understanding how these loops operate or function and the implication of failures of these loops is very important for the C&I executives who are involved in maintaining and tuning of control loops. The aim of this project is to give people a fairly good exposure to the various open and closed loop controls implemented in todays power plants. It will also provide exposure to the latest trends, developments and advances in the power plant control philosophy. At the end of project, we shall able to State the various types of control loops implemented on the boiler, turbine and unit C&I systems. Describe the functioning of PID controllers. Define the various parameters to be modified and monitored during tuning of control loops. Analyze the impact changing the parameters on performance of the plant. State the latest developments and treads in power plant control philosophy

We have considered steam power plants as a basis of studies on controlling of generation machine to understand what kind of auxiliaries have to be controlled and in what order.

These are the basic auxiliaries in a steam power plant


Vacuum to main condenser LP exhaust temperature Lube oil pressure Shaft pump discharge Lube oil tank level Hydraulic fluid tank level Hydraulic fluid pressure EHC malfunction Bearing vibration Bearing temperature Mechanical over speed Manual mechanical trip ETS fluid pressure Generator temperature

Boiler temperature Turbine temperature Electrical over speed Generator trip Drum level Thrust bearing position detector Thrust bearing metal temperature

These are only few of the general auxiliaries to be monitored Information cutesy of FFBL.

Typical diagram of a coal-fired thermal power station

1. 10. 19. 2. 11. 20. 3. 12. 21. 4. 13. 22. 5. 14. 23. 6. 15. 24. 7. 16. 25. 8. 17. 26. 9. 18. 27.

Cooling tower Steam Control valve Superheater Cooling water pump High pressure steam turbine Forced draught (draft) transmission line (3-phase) Derator Reheater Step-up transformer (3-phase) Feedwater heater Combustion air intake Electrical generator (3-phase) Coal conveyor Economiser Low pressure steam turbine Coal hopper Air preheater Condensate pump Coal pulverizer Precipitator Surface condenser Boiler steam drum Induced draught (draft) Intermediate pressure steam turbine Bottom ash hopper Flue gas stack

These power plant operation depends on steam. The fuel heats up water in the boiler, producing steam which turns the turbine. This process generates electricity which is transmitted as out put of the generator. The power reaches the common man and industries through power grids all over pakistan. The four main circuits of thermal power plants are Coal & Ash Circuit, Air & Gas Circuit, Feed Water & Steam Circuit and Cooling Water Circuit. The initial stages of Coal fired power plant operation start with the combustion in the Coal & Ash Circuit. The Coal & Ash Circuit handles the filling of coal, manages the ash generated during the combustion process and takes care of coal and ash transfer and storage. Air, the main element in combustion process of thermal power plant operation, is utilized by the Air & Gas Circuit during its function. Feed Water & Steam Circuit handles steam transmission from the boiler to the turbine during thermal power plant operation. The water cooling process of thermal power plant operation is done by the Cooling Water Circuit of thermal power plants.

1. Boiler A boiler is an enclosed vessel that provides a means for combustion heat to be transferred into water until it becomes heated water or steam. The hot water or steam under pressure is then usable for transferring the heat to a process. Water is a useful and cheap medium for transferring heat to a process. When water is boiled into steam its volume increases about 1,600 times, producing a force that is almost as explosive as gunpowder. This causes the boiler to be extremely dangerous equipment that must be treated with utmost care.

2. Turbine Turbine, rotary engine that converts the energy of a moving stream of water, steam, or gas into mechanical energy. The basic element in a turbine is a wheel or rotor with paddles, propellers, blades, or buckets arranged on its circumference in such a fashion that the moving fluid exerts a tangential force that turns the wheel and imparts energy to it. This mechanical energy is then transferred through a drive shaft to operate a machine, compressor, electric generator, or propeller. Turbines are classified as hydraulic, or water, turbines, steam turbines, or gas turbines. Today turbine-powered generators produce most of the world's electrical energy. Windmills that generate electricity are known as wind turbines.

3.A deaerator is a device that is widely used for the removal of air and other dissolved gases from the feed water to steam generating boilers. In particular, dissolved oxygen in boiler feedwaters will cause serious corrosion damage in steam systems by attaching to the walls of metal piping and other metallic equipment and forming oxides (rust). It also combines with any dissolved carbon dioxide to form carbonic acid that causes further corrosion. Most deaerators are designed to remove oxygen down to levels of 7 ppb by weight (0.0005 cm/L) or less.

4. Heat Exchangers Heat exchangers are equipment that transfers heat from one medium to another. The proper design, operation and maintenance of heat exchangers will make the process energy efficient and minimize energy losses. Heat exchanger performance can deteriorate with time, off design operations and other interferences such as fouling, scaling etc. It is necessary to assess periodically the heat exchanger performance in order to maintain them at a high efficiency level. Heat

5. Super Heater A super heater is a device in a steam engine that heats the steam generated by the boiler again, increasing its thermal energy and decreasing the likelihood that it will condense inside the engine. Super heaters increase the efficiency of the steam engine, and were widely adopted. Steam which has been superheated is logically known as superheated steam; non-superheated steam is called saturated steam or wet steam. 6.The surface condenser is a shell and tube heat exchanger in which cooling water is circulated through the tubes. The exhaust steam from the low pressure turbine enters the shell where it is cooled and converted to condensate (water) by flowing over the tubes as shown in the adjacent diagram. Such condensers use steam ejectors or rotary motor-driven exhausters for continuous removal of air and gases from the steam side to maintain vacuum.

7.Economizers, or in British English economisers, are mechanical devices intended to reduce energy consumption, or to perform another useful function like preheating a fluid. The term economizer is used for other purposes as well. In simple terms, an economizer is a heat exchanger.

8.Feed water heaters In the case of a conventional steam-electric power plant utilizing a drum boiler, the surface condenser removes the latent heat of vaporization from the steam as it changes states from vapour to liquid. The heat content (btu) in the steam is referred to as Enthalpy. The condensate pump then pumps the condensate water through a feed water heater. The feed water heating equipment then raises the temperature of the water by utilizing extraction steam from various stages of the turbine.

9.In electricity generation, an electrical generator is a device that converts mechanical energy to electrical energy, generally using electromagnetic induction. The reverse conversion of electrical energy into mechanical energy is done by a motor, and motors and generators have many similarities.

A control system is a device or set of devices to manage, command, direct or regulate the behavior of other devices or systems. There are two common classes of control systems, with many variations and combinations: logic or sequential controls, and feedback or linear controls. There is also fuzzy logic, which attempts to combine some of the design simplicity of logic with the utility of linear control. Some devices or systems are inherently not controllable.
In a Steam power plant controlling is used for maximum efficency and for a sort of protection of the system from causing any sort of damage to it self.

Vacuum to main condenser LP exhaust temperature Lube oil pressure Shaft pump discharge Lube oil tank level Hydraulic fluid tank level Hydraulic fluid pressure Emergency Hydraulic malfunction Bearing vibration Bearing temperature Mechanical over speed Manual mechanical trip ETS fluid pressure Generator temperature Boiler temperature Manual Turbine trip Electrical over speed trip Generator trip Drum level Thrust bearing position detector Thrust bearing metal temperature

when high when low when low when low when low when low when high when high at 110% 86R

when low when high

The Automatic Turbine Startup (ATS) function will govern the steam turbine startup sequence through the phases of startup. This includes rolling the unit from turning gear to rated speed, synchronization, initial loading, and HP Flow mode transfer. The ATS sequence is considered complete once Inlet Pressure Control is selected.

The turbine has essentially two control modes. In the first mode the control system will be capable of controlling speed (frequency) or load. This mode is referred to as Speed/Load Control. In the second mode the control system will be capable of controlling inlet steam pressure, assuming that the frequency is controlled by the power grid or another machine. This mode is referred to as Inlet Pressure Control. Speed control will always override the current control mode in an overspeed condition.

A speed setpoint is set at the operator interface, and the speed reference is automatically ramped toward the speed setpoint at a pre-determined rate. A speed error signal is the result when speed is subtracted from the speed reference.

There are a number of inputs, internal and external, such as those that will be required to adjust speed and phase for synchronization, that will have the net effect of changing the load setpoint.

Inlet Pressure Control (IPC) is closed loop control on inlet pressure. The inlet pressure is subtracted from the inlet pressure signal and the net error is multiplied by the appropriate gain, a function of regulation and the pressure control range, to produce the control signal.

The main control valve responds to the Speed/Load demand signal. A variable gain is also applied using a proportional plus integral controller to further fine-tune the flow signal to the MCV.

The control system will automatically calculate the HP flow required for a successful HP Flow mode transfer. The steam flow required for the transfer is dependent on hot reheat pressure and main steam temperature, and the turbine control system will automatically transfer to HP Flow mode when proper conditions are met. During a shutdown, the turbine control system will also automatically transfer out of HP Flow mode.

An automatic turbine shutdown can be selected at anytime during unit operation. If the unit is operating in Inlet Pressure Control, selecting SHUTDOWN will automatically transfer from IPC to Speed/Load control and will begin unloading the unit. The HP Bypass Valves and LP Bypass Valves must be ready to control steam pressures. The unit will automatic TRIP when the turbine has fully unloaded.

Steam seals are used on condensing steam turbines for the dual purpose of preventing air from entering the steam turbine and preventing steam from escaping from the turbine ends into areas where personnel may be working. The system consists of a pressure transmitter measuring steam seal header pressure, a dump valve which controls flow from the steam seal header to a lower pressure section of the turbine, one or more feed valves which control steam coming from an auxiliary source(s) into the steam seal header, and the turbine control system, which reads the transmitter and controls the feed valve(s) and dump valve. The turbine control system uses a proportional plus integral control loop for steam seal pressure control.

A lube oil system is provided to lubricate and cool the turbine generator bearings. The lube oil temperature control system consists of a temperature control valve, lube oil coolers, and thermocouple(s). The turbine control system uses a proportional plus integral control loop for lube oil temperature control, so the lube oil temperature should equal the lube oil temperature setpoint except during transients.

PROTECTIVE SUBSYSTEMS A. Operation Under Controlled Overspeed Conditions If, in the course of normal operation, a load rejection or other upset should occur, it is possible that an overspeed condition could develop momentarily. The normal Speed/Load control subsystem defined as the turbine's first line of defense will be capable of accepting the upset and controlling speed at a new level at or above the original operating speed. For example, if a load rejection should occur, with the turbine suddenly isolated at no load, the transient speed may rise to just below the trip setting for overspeed, but the settled speed on normal Speed/Load control should be approximately 105% with 5% regulation for 100% load change.

B. Operation Under Uncontrolled Overspeed Conditions If, in the course of normal operation, an upset should occur such that the normal speed control subsystem fails to bring turbine speed under control, the primary overspeed trip system will trip the turbine to prevent any mechanical damage to the turbine. This system is commonly referred to as the second line of defense. If for some reason the primary overspeed trip system does not trip the turbine, the emergency overspeed trip system, which acts as a third line of defense against uncontrolled overspeed, will trip the turbine. After a trip, the turbine will coast to zero speed. The trip system can be reset anywhere between rated speed and zero speed. If an overspeed trip occurs, the cause of the overspeed should be determined and necessary actions should be taken prior to restarting the turbine.

C. Primary Overspeed Trip Two-out-of-three voting logic is used with speed signals obtained from the three primary speed probes to determine primary trip speed. The primary trip signal is used to de-energize redundant primary trip relays. Contacts on these relays are used to de-energize the 125 Vdc electrical trip devices. The speed and load setpoints are all run back to 0% in response to a primary overspeed trip. D. Emergency Overspeed Trip Three separate probes are used to obtain emergency speed signals. Two-out-of-three voting logic is used with the speed signals obtained from the emergency speed sensing circuitry to determine emergency trip speed. The emergency trip signal is used to de-energize redundant emergency trip relays. Contacts on these relays are used to de-energize the 125 Vdc electrical trip devices. A closing signal is applied directly to all of the control valve servo valves in response to an emergency overspeed trip. This will hold the control valve closed until the emergency overspeed condition no longer exists and the emergency trip is reset by the operator at the operator interface.

E. Electrical Trip Various turbine-related problems such as low lube oil pressure, low hydraulic pressure, high vibration, etc., are capable of tripping the turbine through the primary trip relays. Refer to A14 Steam Turbine Operation Guidelines . These trips rely on the turbine control system processors, which drive the primary trip relays. Manual trips can be initiated from the push-button on the turbine control cabinet door, from the push-button at the DCS, from the push-button near the turbine control system operator interface, or from the push-button on the turbine front standard. These are hardware trips, which are independent of any processors. Trip header pressure feedback will indicate to the turbine control system that the unit has indeed tripped, and the status of the manual trip switches are monitored by the processors to indicate where the trip originated. All trip signals de-energize the electrical trip devices, which trip the turbine. F. Functional Tests Functional tests can be initiated and performed at the operator interface. These functional tests include on-line primary overspeed trip test, on-line emergency overspeed trip test, on-line main stop valve test, on-line combined reheat stop valve and intercept valve tests, off-line test of each electrical trip device (ETD), off-line primary overspeed trip test, and off-line emergency overspeed trip test. Refer to separate publications on how to perform each of these functional tests.

EMERGENCY SHUTDOWN When it is necessary to shut the unit down immediately, press one of the TRIP pushbuttons. Avoid removing the electrical load (opening the generator or tie breaker) prior to tripping the turbine. Some situations require that the breaker be opened simultaneously with the turbine trip. This is usually accomplished with automatic protective relaying and should not be attempted manually. For further discussion on this and related subjects, refer to the publication Protective Relaying and Electrical Circuit Protection. The turbine TRIP will immediately close all turbine steam valves. Refer to the A14 Steam Turbine Operation Guidelines for further actions.

THANK YOU

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