c&i_report for vts
TRANSCRIPT
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C&I system at NTPC KAHALGAON
The control & instrumentation package of Kahalgaon project (4x210 MW) is
supplied by Russian with the Main package by M/s. TPE, USSR. In addition to the
original Russian supplied system there are Furnace Safeguard Supervisory System
(Make Forney, USA), Data Acquisition System (Make Westinghouse, USA), SteamWater Analysis System & uninterrupted Power Supply system (supplied by Keltron).
The C&I package can be broadly classified into the following categories.
1. Process Measurements
2. Process Protections
3. Interlock & Protections of Boiler and Turbine auxiliaries
4. Selective Control System & Short Sequence System
5. Auto Control system
6. Annunciation system.
7. Furnace safeguard supervisory system8. Data acquisition system
9. SWAS and its auxiliaries
1. PROCESS MEASUREMENT
The process parameter measurement is realized by means of Transmitters,
Thermocouples, RTDs and other primary instruments. The signals received from these
primary instruments are utilized for Control /Record /Indication of the process
parameter and protection of the process. In the process where mass monitoring is
required like Boiler metal temperatures, Turbine metal temperatures, Turbine bearing
temperatures and Generator slot temperatures in these cases either multipoint recorders
or indicators with a manual switch for point selection is provided. For remote
indications of level, pressure and flow, transmitters are providing. Explosion proof
Transmitters are provided for explosion prone areas like Fuel oil pump house and
Hydrogen plant. All transmitters are of strain gauge type, which gives an output of 4
20mA when the pressure across the diaphragm varies from minimum range to
maximum range.
For some process parameters the signal for DAS & Measurement is sharedfrom a single transmitter. This sharing is done through Zener diode isolation circuit.
Generally for Auto Control System dedicated transmitters are provided with 100%
redundancy.All the secondary instruments are powered from UPS including Recorders,
Indicators, TSI equipment & all process variation measuring transmitters.
Unit Control Board (UCB) is distinctly divided into two parts. One is operative
area which contain Desk panels, Annunciation panels, Recorder & Indicator panels,
Transmitter power supply panels & Mimic panels .The other is the Non- operative area
consisting of Interlock and Protection panels, Auto Control panels, Selective and Short
sequence panels, RC feeder & FSSS panels.
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There is facility to control the operation of all drives, valves & dampers from
operator desk panel. Status of the same is indicated through mimic just above the
operating panel. In the operator desk
The recorders & indicators are of three different types depending upon the
inputs i.e. milliampere, potentimetric and bridge type. These are utilised formeasurement of transmitter signal, thermocouple signal and resistance thermal detector
signal receptively.
For the measurement of excess Oxygen in flue gas, an insitu zirconia probe
(Make Westinghouse, supplied by I.L.Kota) is installed at 41 meter in second pass of
Boiler. The output of the probe is mv, which is converted to mA through converter. The
cell constant and cell slope is adjustable. Auto calibration facility is also available.
In Air preheater system, which is of tubular type, differential temperature of air & gas
is measured in a recorder. This gives annunciation when it crosses the alarm value. In
case of fire the differential temperature increases and when it crosses a pre-set value
alarm is obtained at UCB. For cleaning these tubular type
For Drum level protection as per the original design, level switches are provided at
different levels. However presently protection of drum level is of two out of three logic
rooted through Hydrastep (Keyston Make) both left and right side and the pressure
compensated signal from drum level compensation package (supplied by M/s Bells
control). Bearing temperature, winding temperature PA Fans & Mills are shared by
DAS and measurement from dual RTD. Coal pipe temperatures of furnace inlet are
exclusively provided in DAS only.
There are many important parameters, which are measured locally through
pressure gauges & switches. In Boiler Feed Pumps the bearing temperature recorders &
winding temperature indicators are located at local which helps the operator for easy
monitoring of the temp regularly.
For safe operation of Turbine the following Turbo Supervisory measurements
are carried out in continuous basis. .
1. Axial shift.
2. HPC / IPC differential expansion.
3. Eccentricity
4. HPC/IPC thermal expansion
5. Turbine speed measurement6. Turbine vibration of Bearing 1 to 7.
7. Seal Noise device for Bearing 1 to 7.
8. Control valve servo meter position measurement.
Axial Shift, HPC / IPC/ LPC differential expansion measurement are realised by a
instrument based on the principle of Linear voltage differential transducer principle.
Axial shift pick up is fixed near brg-2 i.e. the pivot point of the turbine rotor.
For Turbine speed measurement a permanent magnet pick up is mounted above a
wheel of 60 teeth attached to turbine shaft located at MOP. This pick up is having a coil
which is induces an A.C current which is processed by a pre amplifier to get a squarepulse. This square pulse is finally counted by the counter located in NOP area which
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gives three Analogue & three digital output used for local / UCB analogue / digital
measurement.
For Turbine vibration measurement in each bearing there are two pick-ups. One is
for vertical vibration & other one for axial & cross sectional vibration. Vibration signal
is measured by piezoelectric crystal, which induces a millivoltage as per the vibration,which is subsequently amplified by preamplifier at local. At UCB the signal is
processed & integrated to get velocity measurement output in the range of 0 12
mm/sec or 0 30mm/sec. The signal is converted into analogue output of 0 5 mA
who is shared DAS & measurement. In each pick up there is a facility of on line
checking of healthiness by injection of A.C voltage another piezoelectric crystal placed
near to the measuring crystal. There is a provision of two-alarm contact for alarm &
warning setting for the measurement of each vibration.
In offsite areas including Fly Ash, Bottom Ash, FOPH, UPH, H 2 & chlorine plant,
for easy monitoring and operation of the equipment in addition to local Pressure gauge,
pressure switch, Recorders and instruments indication the temperature & current etc.are also provided near the equipment itself. The ON/OFF status of the major offsite
drives are available in UCB # 1. In case of emergency i.e. when any local annunciation
is generated a parallel contact goes to UCB and control board faulty annunciation
appears. This helps the UCB personnel to maintain & monitor the offsite area.
In Fuel Oil Pump House their three receiving tanks, each consisting of two oil
transfer pumps. There are four oil storage tanks in which level and temperature are
measured. There are two sets of lift pumps. Each set consists of two stages. Suction and
discharge pressure is measured through local gauges. Fuel oil flow to boiler and return
oil flow from boiler is measured through transmitters.
There are two BottomAsh a pump house. Each Bottom Ash pump house consists of
three sets of pumps. In each set there are two pumps connected in series. This
arrangement is done to give more discharge Pressure to the slurry. In each pump
Bearing temperature is measured & dedicated recorders are provided in local panel.
Pneumatic valves are provided in the discharge of the pumps. Gland sealing is required
for each stage of pump. In Air Compressor house, there are four compressors common
to all four units. The Compressor has got two independent motors winding for two
independent speeds (Low speed and High speed). For each stage air temperature before
cooler is measured and independent tripping is initiated when it rises beyond the
alarmed value. Compressor trips when lubrication oil pressure falls below the set limitand cooling water flow is absent.
2. PROCESS PROTECTION
Protection intended to prevent the damage of the equipment under the alarm
conditions can be broadly divided into the following categories.
1. Unit protection.
2. Turbine protection
3. BFP protection
4. Boiler trip protection5. Boiler load drop protection
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6. QPRDS protection
7. Turbine local protection (HPH,LPH,D/A)
4. AUTO CONTROL SYSTEM
The Auto Control system is intended to maintain process variables within a
predetermined range and to ensure the reception of process data. The system produces
control instructions & actions which helps in achieving the predetermined state.
The system is based on a split architecture. Controllers comprises of two separate
units i.e regulating unit and operative unit.
The Controllers actions are processed through different blocks which are used
for different purposes .Some of the important blocks are mentioned below.
1.Signal input block.2.Signal converter block,
3.Integration block
4.Summator block
5.Pulse output block
6.Annunciation block
The input to the system is of 4 20 mA , millivolts or resistance depending upon
the type of transducer used which in-turn converted to 0 10v for block operation
through input signal block. This also optically isolates the input & output signals.
The pulse output block compare the process parameter set point , process
parameter measurements and control valve position and gives output accordingly for
the control valve.There is a signaling unit, which compares the parameter value with a
predetermined set point. Deviation beyond that gives alarm & changes the Auto
operation into Manual Mode. In the event of abrupt failure such as open circuit or short
circuit in transmitters controller trip action takes place through this block. Parallel
command goes to annunciation blocks also.
For some important controllers redundant transmitters are provided. Provisions
are there for manual change over to the standby in case of failure of the working
transmitter .Provisions are there for bumpless transfer of actuator from auto mode tomanual mode.
The main automatic controllers are as detailed below.
A. UNIT CAPACITY CONTROL
This controller is for maintaining a controlled TG power output and mainsteam
inlet pressure to turbine. This controller incorporate Load change limiter, Boiler capacity
control and Turbine capacity control. Boiler capacity controller will receive unit preset
capacity signals from unit load rate of change limiter and the actual power output. Itgenerates a demand signal to a coal flow controller & total air flow controller. Turbine
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capacity controller will receive signal from actual power output , rate of feed forward
signals of the preset output, the error signal representing the discrepancy between the
demand and actual main steam inlet pressure to for time . Turbine capacity control
initiates command to operate the speeder gear motor.
B. COMBUSTION CONTROL
Combustion control is done by means of Coal flow controller , Mill loading
controller, Total Air flow , Furnace draught controller & F.O pr. controller. Summation
of Coal flow & Fuel Oil flow are used for Total air flow controller which maintain a
predetermined value of free oxygen in flue gas. The loop actuates individual actuate of
FD fans dampers for maintaing the specified free oxygen in flue gas. Mill loading
controller regulates feeding of coal to the pulverizes. Furnace draught is controlled
through controlling the inlet vanes of ID fans.
5. ANNUNCIATION SYSTEM
The Annunciation system is intended to make available the information about
the equipment under control, deviation of measured parameters from the normal
(preset) value and interlock action. Alarm is provided with each annunciation block.
Visual status indication of equipment under control i.e Devices and Stop valves
Audio-visual alarm annunciation of emergency tripping and autostart of equipments
Audio-visual process annunciation.
Audio-visual preventive alarm annunciation of parameter deviation from normal
values.
There are three major section in the annunciation circuit. Section I controls
the Boiler & off site annunciations, section II controls the turbine related
annunciations and section III looks after the generator related annunciation. The
circuit is powered by 110v DC which is generated by 3 phase 415v AC rooted through
a transformer and diode rectifier circuit.
Operating status of important drives protection status and alarm conditions,
when arises actuate the annunciation system. Once the alarmed value is reached by any
signal, it flashes & hooter circuit is energizes. Flashing takes place till the resetting is
not done. If the alarmed condition stillexist then it glows steadily. Each annunciation
section will be provided with test push buttons to check the audio annunciation signaland with the panel switches for lamp healthiness checking.
6. FURNACE SAFEGUARD SUPERVISORY SYSTEM
The Furnace safeguard supervisory system supplied by Forney, USA i.e of
Model AFS 1000 is a 16 bit 80186 microprocessor based system. The main task of
FSSS is to control the fuel system equipments i.e. oil guns, igniters, PA Fans, Mills,
seal air fans and their associated dampers etc. so as to ensure safe operation of the
Boiler under start up, transient and normal conditions. Besides, one of the most
important FSSS task is to implement process protections with provision for a first up
annunciation facility on operating console with respect to the first actuated protections.
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AFS 1000 Burner management system employs plug in printed circuit board
assemblies.This permits maintenance by replacing board without causing the total
shutdown. The Burner Managent System logic comprises of ten nos. of subsystems
(Excluding Maintenance subsystem II) per each unit each responsible for predefined
portion of the overall system. There are two CRT master subsystem ,one purge and fuelsafety subsystem, one oil burner subsystem & six mill subsystems. Each subsystem is
responsible for a portion of overall control.
A subsystem consist of a single - board control card (80186 up based ) , solid state
input / output printed circuit board assemblies, starburst keyboard with
intercommunication through fiber optic Assembly and a shared operation interface
through fiber of the cable assembly and having touch screen facility. There are also
some logic derived inputs that got transmitted from one subsystem from another and all
subsystem operate independently of other subsystem.
1. CRT master subsystem:
The primary function of each CRT master subsystem is to act as controller ofthe intercommunication bus (ICB) used to pass data back and forth between the
master and the other subsystem. It also decodes commands that it receives from
CRT screen. In the CRT screen the last acknowledged alarm, Printer ON/OFF
status and Command elements appear of which print out can be taken if
required. For depicting valves ,dampers and drives different symbols were used
and when status changes the colour changes.
2. Purge and fuel safety subsystem :
The purge and fuel safety subsystem comprises of the following logic.
Purge logic has the major responsibility for insuring that the furnace is purged
thoroughly with air to remove any combustible before the fuel is released into
the headers & into the furnace. For starting the purge the following conditions
should be met.
a). All burner oil valves closed.
b). Oil trip valve closed.
c). Oil re-circulation valve closed
d). No flame detected
e). Scanner Air fan on.
f). Any Induced Draught & Furnace Draught running,
g). All primary fans , pulverizers & Raw coal feeders off.
h). All hot air damper closed.
i). Igniter trip valve closed.j). No trip (Boiler) present
k). Air flow >30%
After all these conditions are satisfied PURGING takes place for 10Minutes.
03. Pre light Logic: When furnace purging is completed pre light logic is responsible
for the safe release of fuel into the headers. Pre light logic is also responsible for
communicating to the banners subsystem that furnace conditions are satisfactory for
banner operation.
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04. Fuel Safety logic Fuel safety logic is responsible for overall boiler safety. It
monitors the potential danger points throughout the boiler. If the predetermined limits
are crossed, the fuel safety logic shuts off some or all fuel to the furnace depending
upon the conditions. The cause of first out alarm function indicators the cause of the
tripping. The MFT 1 and MFT 2 relays get trip command when any of the following
conditions is / are initiated.
1. Both the ID fans off.
2. Both the FD fans off.
3. Operator trip
4. Drum level high / low
5. Loss of all fuel
6. Loss of all flame
7. Unit trip from BPS
8. Furnace pressure high/ low
9. Delayed light off (10 min after purging)
10. Air flow (< 30%) low.
05. Burner control sub system It is responsible for following a predetermined
programme in safety placing burners in service, removal from service, purging of
burners that have been removed from service and for monitoring burner operations.
1. Mill control subsystem- Milling subsystem is responsible for controlling the
coal burners and associated pulverizer, primary Air fans, feeders and
associated program in safety taking burners in service, removal from service
and monitoring burner operation.
2. Maintenance subsystem-II.
The MS-II is an equipment helping for fault finding or trouble shooting of the
systems input as well as to change the program logic. It comprises of on operation
console, a control unit, interfacing cable assembly, graphic CRT / KBD and menu
driver software.
7. DATA ACQUISITION SYSTEM
The Data Acquisition System of 4x210 Mw KhSTPP was supplied by M/S
ESPL ,Chandigarh. This is a WDPF family of system manufactured by Westinghouse
with software level version 6.4. This system is a microprocessor based distributed
modular type with independent system, drops connected to each other through high
speed standard Westnet data highway having 100% redundancy. The drops talk to eachother directly over the data highway, which eliminate the need of host computer. The
system caters 900 analog points and 1400 digital points in each unit Each system
supports two units. The standard WDPF drops and products perform specific functions,
which allows a custom system to be configured by determining required functions and
selecting the appropriate standard equipment.
8. UPS PACKAGE
UPS system of capacity 75 KVA has been supplied by M/S KELTRON
,Trivendrum for each of the four units which caters the power supply for all C&I
system including Data Acquisition system. FSSS, Instrument supply, ACS etc. The
system consists of 2 nos. chargers, 2 nos. inverters, and one paralleling unit, one servo
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controlled voltage stabiliser (SVCS) and one set of Battery (550AH) for one-hour
backup at 75KVA load. The two inverters, each of which is rated at 75KVA, are
connected together to the O/P busbar to share 50% of the load. In case of failure of one
inverter the other one takes up the full load automatically. The two chargers, which are
meant for feeding the inverters and changing the battery, also work in parallel and each
one can take the load if needed. The set of battery is connected at the output of thechargers and input of the inverters. In case of failure of both the chargers the battery
automatically takes up the load and starts feeding to the inverters without any
interruption. The SCVS is also connected to the output busbar. In case of failure of both
the inverters the SCVS gets connected to the output busbar through the static switch
with a maximum time delay of 20millisec.
9. ANALYSER AND MISC. C&I EQUIPMENT PACKAGE:
The package was awarded to M/S Keltron, Aroor. The package contents of supply
of the below mentioned instruments.
(1) Analyser for steam and water. Analyse system and Flue gas oxygen analyser.
(2) Miscellaneous C&I equipment such as switch drivers etc. and maintenance and
Calibration equipment for plant.
(i) The supply and erection and commissioning were in the scope of M/S Keltron.
(i) Only the supply was in the scope of M/S Keltron.
Part (1) is consisting of the following major equipment.
(a) Flue gas oxygen Analyser.
(b) Secondary coolers.
(c) Silica Analyser.
(d) Hydrogen Analyser.
(e) PH analyser.
(f) Conductivity.
(g) Phosphate Analysers.
(h) Dissolved oxygen.
Part (2) consists of the following major. Equipment's.
(a) Temperature gauges.
(b) Temperature switch.
(c) D.P switch.
(d) Level switch.
(e) Flow switch.
(f) Thermocouples
(g) Flow elements.
Maintenance and calibration equipment.
(a) Pneumatic test bunch.
(b) Vacuum tester.
c. Thermocouple test furnace.
d. Flowmeter calibrator.
e. Coil winding machine.
f. Soldering iron
g. Radial drilling machine.
h. Solder sucker.
i. Variac.
j. Rheostat/Potentiometer.
k. RCL Bridge.
l. Logic Probs.
m. Portable pneumatic calibrator.
n. Portable vibration meter.