power plant automation
TRANSCRIPT
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Presented By- Pankaj TrivediDIL ,C& I
L
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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
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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
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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
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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
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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
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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
© Invensys 8 October 2012Invensys proprietary & confidential86
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System
Management
© Invensys 8 October 2012Invensys proprietary & confidential87
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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.
06-10-2012 95DIL , C&I
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Anyquestion ?
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