GYAN VIHAR UNIVERSITY, JAIPUR

DEPARTMENT OF ELECTRONICS & COMMUNICATION SUMMER TRAINING REPORT: Study of Power Plant Control&

Instrumentation
TRAINING PLACE: NATIONAL THERMAL POWER

CORPORATION ADDRESS: BARH (BIHAR). WEB SITE: www.ntpc.co.in TRAINING PERIOD: 01/06/2012 TO 30/06/2012

SUBMITTED BY: NAME: SHALINI SINGH BRANCH: ELECTRONICS & COMMUNICATION ENGG. BATCH: 2009 TO 2013

ACKNOWLDGEMENT
I vocational trainee-2012 batch would like to thank the management of NTPC Limited for arranging a well-managed training programmer for the vocational training. I hope it is highly beneficial to the organization and students in course of time. I sincerely acknowledge the cooperation and complete support provided by Sh. Saroj Kumar, DGM(C&I) Sh.Malay Kumar Rai (Sr. Engg. C&I) and all executives of C&I Erection department posted at Barh Super Thermal Power Project. I am deeply indebted to Mr. Anurag Sinha, our Training Coordinator, Sh. N.K Singh, DGM(HR) and all seniors for giving us all valuable support and information which was instrumental in all stages of our training at Barh STPP. I take the opportunity to extend our heart felt thanks to NTPC Ltd.

Name of the trainee (Shalini Singh)

PREFACE
Instrumentation in any industry can be compared to the nervous system of the human body. INSTRUMENTATION & CONTROL controls and operate various pumps, motors, dampers, valves etc. and help us in achieving targets. Modern power plant relies heavily on the instrumentation for automation processes, efficient, reliable and safe operation, and preventive, predictive and breakdown maintenance. Accurate, reliable and fast instrumentation is the backbone of a modern power plant. The term instrumentation means A device or a combination of devices used directly or indirectly to measure and display a variable. In industry and processing plants, instrumentation makes use of various measuring components designed to suit the process and the purposes. As some of the big industries and power plants need to control different process variable from a remote distant control room, the further measuring, transmitting indicating, recording, abnormality alarm system are innovated .The process of innovation is marching ahead in fast rate and in near future we will enter into more sophisticated CONTROL AND INSTRUMENTATION.

INDEX
1. Introduction 2. Working of power plant 3. Measurement required in power plant a) Temperature measurement b) Pressure measurement c) Level measurement d) Flow measurement 4. Distributed control systems 5. Plc & ddcmis 6. Control philosophy of coal plant system

INTRODUCTION
Location
The project site is located about 3 kms east of Barh town in Patna district in the state of Bihar, location being Latitude 25o 28' N & Longitude 85o 45' E. The plant and township are located between NH-31 and railway line. The ash disposal area is located in the south of the railway line.

Land requirement
Approximately 1200 acres of land has been identified between NH-31 and railway lines for the plant area, switchyard, green belt, labor colony, ash based units and township. Approximately 1750 acres of land has been identified for the ash disposal area in the south of railway line.

Coal availability and linkage

Coal requirement for Barh STPP, stage-1 is proposed to be met from Amrapali block of North Karanpura coalfields. Coal requirement for the project in estimated as 10 million tones/annum considering a GCV of 3350 kcal/kg and 80% PLF. Coal from Amrapali block of North Karanpura coalfields is proposed to be transported to the project site through Indian railways system for a distance of approximately 250 kms via shorter route following the route: Hazaribagh-Koderma-Rajgir-Bakhtiyarpur-Barh.

Water requirement
The project site is located near the river Ganges. The makeup water requirement for the project is proposed to be drawn from river Ganges near village Nevada, at a distance of 2kms. The makeup water requirement for the project is estimated at 9200 m3/hr with ash

water recirculation system and 10200 m3/hr once through ash water system respectively. A closed cycle cooling water system using induced draft cooling towers is proposed.

Startup power
The requirements of the construction power supply for the project would be met at 33Kv level from the nearby BSEB substations. Necessary 33kV substation and 11kV ring main /LT substations shall be provided for the power plant area.

Beneficiary state
The states & UTs of Northern & Western regions and state of Bihar.

Barh STPP Phase - I under construction

SOME KEY DATA

Foundation Stone Laid Plant Capacity Plant Type Gas Turbine Electrical Substations Fuel 1999 3300 MW Coal-fired Three-unit 660*3 MW Barh I, and Two-unit 660*2 MW Barh II Six 400KV substations link Barh to Kahalgaon, Sasaram and Biharsharif Annual coal requirement estimated at Around 10 million tones per year

The three-unit 1,980MW Barh I is being built by Russian Power Machines & TPE Group, and the two-unit 1,320MW Barh II extension by BHEL.

WORKING OF A POWER PLANT

BASIC POWER PLANT CYCLE: The thermal (steam) power plant uses a dual (vapor-a super heated steam, and liquid) phase cycle. This is based on the RANKINE CYCLE. Electricity generation is in three steps *Coal to steam *Steam to mechanical power *Mechanical to electrical and its transmission

COAL TO STEAM:

Coal from coal wagons is provided with bottom discharge hoppers fitted with pneumatically operated automatic door actuating mechanism. For unloading of coal from wagons and under ground track hopper is provided at the power station. Line side equipment is installed by the track hopper for initiating the opening of doors in-group of 10-14 wagons. The unloading operation of 60 tones per load wagon takes about 20/30 seconds. And then coal comes to the coal handling plant (CHP) .by conveyor belt it is transferred to crusher mill and after that a small piece of coal goes to transfer point (TP) by

conveyor belt where it converted into the powder form. This coal powder is goes to boiler in a mixed stage with hot and cold air (with PA fan-simple air, FD fan-hot air). Water from boiler feed pump passes trough economizer and reaches the boiler drum. Water from the drum passes through down comers and goes to the bottom ring header. Water from ring header is divided to all the four sides of the furnace .Due to heat and the density difference the water raises in the water wall tubes. Water is partially converted into the steam as it rises up in the furnace. This steam and water mixture is again taken into the boiler drum, where the steam is separated from water. Water follow the same path while the steam is sent to super heaters for the steam leaving the high pressure cylinder goes back to the boiler for reheating and returns by further pipe to intermediate pressure cylinder. Here it passes through another series of stationary and moving cylinder. Finally the steam is taken to the low-pressure cylinders, each of which it enters at the center flowing outwards in the opposite direction through the rows of turbine blades (known as the DOUBLE FLOW TO EXTRIMITIES). As the steam gives its energy to turbine its temp and pressure falls down and it expands. Because of this expansion blades are much larger and longer towards the low-pressure ends of the turbine. The turbine usually rotes at the speed of the 3000rpm .As for required frequency 50 Hz F= p*n/120 Where f= frequency P=no of poles. Used for the generator machine used. Steam exhausted to condenser containing 2000 tubes of 25mm dia. filled with cooled water coming from cooling tower .as steam passed over it condensed into water. Because water has a much smaller comparative volume than steam, a vacuum is created in the condenser. This allows the steam to reduce down to pressure below that of the normal atm. and more energy can be utilized. From the condenser, the condensate is pumped through low-pressure heaters by the extraction pump, after which its pressure is raised to boiler pressure by the boiler feed pump. It is passed through feed headers to the economizer and the boiler for the reconversion into the steam.

A power station generating 660MW of electricity requires about 70,000 cubic meters of water an hour for cooling purpose.

Diagram of a typical coal-fired thermal power station

STEAM TO MECHANICAL POWER:

From the boiler, a steam pipe conveys steam to the turbine through a stop valve and through control valves that automatically regulate the supply of steam to the turbine. Stop valve and control valves are located in a steam chest and a governor, driven from the main turbine shaft, operates the control valves to regulate the amount of steam used. Steam from

the control valves enters the high-pressure cylinder of the turbine, where it passes through a ring of stationary blades fixed to the cylinder wall. These acts as nozzles and direct the steam onto a second ring of moving blades mounted on a disc secured to the turbine shaft. The steam passes through each stage in turn until it reaches the end of the high-pressure cylinder and in its passage some of its heat energy is changed into mechanical energy. The steam leaving the high-pressure cylinder goes back to the boiler for reheating and returns by a further pipe to the intermediate pressure cylinder. Finally, the steam is taken to the low-pressure cylinder, each of which enters at the center flowing outwards in opposite directions through the rows of turbine blades-an arrangement known as double flow-to the extremities of the cylinder. The turbine shaft usually rotates at 3000 revolutions per minute. When as much energy as possible has been extracted from the steam it is exhausted to the condenser. This runs the length of the low-pressure part of the turbine. The condenser contains 20,000 tubes each about 25mm in diameter. Cold water from the estuary, river, sea or cooling tower is circulated through these tubes and as the steam from the turbine passes round them it is rapidly condensed into water-condensate. From the condenser, the condensate is pumped through low pressure feed heaters by the extraction pump, after which its pressure is raised to boiler pressure by the boiler feed pump. It is passed through further feed heaters to the economizer and the boiler for recon version into steam.

SWITCHING AND TRANSMISION:

Electricity is usually produced in the stator windings of large generators at about 25kv and is fed through terminal connections to one side of a generator transformer that steps up the voltage to 132kv, 22kv, or 40kv with the help of switches: (1) Isolator (2) Circuit- breaker (3) Another isolator. The circuit breaker, which is a heavy-duty switch capable of operating in a fraction of second, is used to switch off the current flowing to the transmission lines. Once the current has been interrupted the isolators can be opened. These isolate the circuit breaker from all

outside electrical sources, so that there is no chance of any high voltages being applied to its terminals. From the circuit breaker the current is taken to the bus bars-conductors, which run the length of the switching compound-, and then to another circuit breaker with its associated isolators, before being fed to the grid. Circuit breakers work like combined switches and fuses but they have certain special features and are very different from the domestic switch and fuse. When electrical current is switched off by separating contacts, an arc is created between them. One type of circuit breaker has its contacts immersed in insulating oil so that when the switch is opened, either by powerful electrical coils or mechanically by springs the oil quickly extinguishes the arc. Three wires are used in a three-phase system for large power transmission as it is cheaper then the two wire single-phase system that supplies the home. The center of the power station is the control room. Here engineer monitor the output of electricity, supervising and controlling the operation of generating plant and high voltage switchgear and directing power to the grid system required.

MEASUREMENT REQUIRED IN POWER PLANT

In any process the philosophy of instrumentation should provide a comprehensive intelligence feedback on the important parameters viz. temperature, pressure, level and flow.

TEMPERATURE MEASUREMENT:
It is based on the fact that {rise in molecular activity of substance on application of heat; which increases the internal energy of the body. This property of some specific material body is used to measure the temp. of different substances. The following methods are: 1. RTD (RESISTANCE TEMPERATURE DETECTOR): It consists of some pure metal or alloy (nickel, platinum, copper and its alloy) whose resistance increases with temp. And decreases with decrease in temp. (Nearly 0.3%per degree centigrade). It senses to electrical voltage signal of temp changes like transducer.

2.) PRINCIPLE OF THERMOELECTRIC EFFECT SEEBECK discovered in 1821 that when junction of Bismuth and Copper was heated an e.m.f. Was produced. The direction of the current was from the Bismuth to the Copper. This discovery led to the later development of the thermocouple, a suitable combination of two materials capable of producing an e.m.f. The magnitude of which is related to temperature. The ranges covered are from a few degrees absolute to 3000o C. Seebeck produced a list of materials the order of which is important. An extract from the list is given below. BISMUTH PLATINUM COPPER LEAD TIN SILVER ZINC IRON --------------- LOW THERMOCOUPLE: ------------- Current is flowed from high to low i.e. Copper to Iron -------------- HIGH

-It is a two different metal wire made construction whose two end junction kept at two

different points (reference and measuring) in which temp. Difference creates potential difference b/w junction. Limitation it senses error only more than 1degree centigrade. Some example-molybdenum and Tungsten, chromel and alumel.

3) THERMISTOR: Thermistors are temperature sensitive resistors. All resistors vary with temperature, but Thermistors are constructed of semiconductor material with a resistivity that is especially sensitive to temperature. However, unlike most other resistive devices, the resistance of Thermistors decreases with increasing temperature. That's due to the properties of the semiconductor material that the Thermistors are made from.

PRESSURE MEASUREMENT:
SINGLE TUBE MANOMETER: This is used for measuring low pressure and for testing and recalibration low-pressure instruments of all types. If the ratio of the area of one tube is considerably greater than other, then practically all the movement takes place in the small manometer tube and for all practical purposes only the one limb need to be read. KENTOMETER: The low pressure produced in the steam condensers are usually measured in inches of mercury marking downwards from atmospheric pressure. A high working vacuum of29.5inches of mercury is the same as an absolute pressure of 0.5 inch of

mercury, or approximately 0.25 p.s.i (absolute). One device for measuring the absolute pressure in a condenser is the Kentometer.

BELLOWS-TYPE DETECTORS
The need for a pressure-sensing element that was extremely sensitive to low pressures and provided power for activating recording and indicating mechanisms resulted in the development of the metallic bellows pressure-sensing element. The metallic bellows is most accurate when measuring pressures from 0.5 to 75 psig. However, when used in conjunction with a heavy range spring, some bellows can be used to measure pressures of over 1000 psig. Figure 1 shows basic metallic bellows pressure sensing element. The bellows is a one-piece, collapsible, seamless metallic unit that has deep folds formed from very thin-walled tubing. The diameter of the bellows ranges from 0.5 to 12 in. and may have as many as 24 folds. System pressure is applied to the internal volume of the bellows. As the inlet pressure to the instrument varies, the bellows will expand or contract. The moving end of the bellows is connected to a mechanical linkage assembly. As the bellows and linkage assembly moves, either an electrical signal is generated or a direct pressure indication is provided. The flexibility of a metallic bellows is similar in character to that of a helical coiled compression spring. Up to the elastic limit of the bellows, the relation between increments of load and deflection is linear. However, this relationship exists only when the bellows is under compression. It is necessary to construct the bellows such that all of the travel occurs on the compression side of the point of equilibrium. Therefore, in practice, the bellows must always be opposed by a spring, and the deflection characteristics will be the resulting force of the spring

RESISTANCE TYPE TRANSDUCER: The pressure can affect the resistance of the wire by creating distortion in the wire internally. This property used in this type of transducer .It generally consists of the fine wires grid like construction. R= kl/a, where R= resistance As the wire grid is distorted by elastic deformation, its length is increased, and its crosssectional area decreases. These changes cause an increase in the resistance of the wire of the strain gauge. This change in resistance is used as the variable resistance in a bridge

circuit that provides an electrical signal for indication of pressure.

INDUCTANCE-TYPE TRANSDUCERS
The inductance-type transducer consists of three parts: a coil, a movable magnetic core,

And a pressure sensing element. The element the core, and, as pressure varies,

is attached to

figure. The element causes the core to move inside

the coil. An AC voltage is applied to the coil, and, as the core moves, the inductance of the coil changes. The current through the coil will increase as the inductance decreases. For Increased sensitivity, the coil can be separated into two coils by utilizing a centre tap, as Shown in Figure As the core moves within the coils, the inductance of one coil will in.

CAPACITIVE-TYPE TRANSDUCERS
Capacitive-type transducers, illustrated in Figure, consist of two flexible conductive plates and a dielectric. In this case, the dielectric is the fluid. Increase, while the other will decrease. As pressure increases, the flexible conductive plates will move farther apart, changing the Capacitance of the transducer. This change in capacitance is measurable and is proportional to the change in pressure.

BOURDON PRESSURE GAUGE:

The Bourdon pressure gauge uses the principle that a flattened tube tends to change to be straightened or larger circular cross-section when pressurized. Although this change in cross-section may be hardly noticeable, and thus involving moderate stresses within the elastic range of easily workable materials, the strain of the material of the tube is magnified by forming the tube into a C shape or even a helix, such that the entire tube tends to straighten out or uncoil, elastically, as it is pressurized. a flattened thin-wall, closed-end tube is connected at the hollow end to a fixed pipe containing the fluid pressure to be measured. As the pressure increases, the closed end moves in an arc, and this motion is converted into the rotation of a (segment of a) gear by a connecting link that is usually adjustable. A small-diameter pinion gear is on the pointer shaft, so the motion is magnified further by the gear ratio. The positioning of the indicator card behind the pointer, the initial pointer shaft position, the linkage length and initial position, all provide means to calibrate the pointer to indicate the desired range of pressure for variations in the behaviour of the

Bourdon tube itself. Differential pressure can be measured by gauges containing two different Bourdon tubes, with connecting linkages.

SPECIAL TYPE OF PRESSURE GAUGES SPIRAL TUBE: This type is used for low-pressure indication and recording when a C shaped Bourdon tube is not suitable and where power is required. By making the oval tube in the form of a spiral an enlarged movement of the free end is achieved and thus the tube becomes more sensitive over pressure ranges below 10p.s.i. HELICAL TUBE: For higher pressures the tube is wound in the form of a helix and is often used in pressure recorders. Range: 0-80,000 p.s.i. CRITICAL TYPE: This is used in boiler houses to enable distant reading of the steam pressure to be made to the nearest 1 p.s.i. over a range of say +/- 15 p.s.i. The movement of a pressure sensitive element is transmitted to a pointer and scale via linkages, which only allow the pointer to operate over a selected range of pressure to either side of the normal steam pressure.

LEVEL MEASUREMENT
It is done for the safety of the personal and the power plant and is measure in terms of the height of a liquid and solid above the reference line . The vessels content can be displayed in units of the level (meters), volume (litres), or mass (kg) because vessels all datas which are related and calculated before. There are following methods are employed:

1. MAGNETIC BOND METHOD: -

The magnetic bond mechanism consists of magnetic float, which rises and falls with level.

Nonmagnetic

tube, which houses an inner

magnet, connected to a level indicator. When the float rises and falls, the outer magnet will attract the Inner magnet, causing the inner magnet to follow in the vessels tubes. 2. ELECTRICAL METHODS: It used where is the minimum limitation on the transmission distance b/w the transducer and display or control devise. These are basically of two types: a) Conductivity method-in this system a no. Of different length of conductor connected together by a series of resistors which can shorted on increasing the level and resistance got shorted and overall resistance decreased, this imply that the current increases if there were applied potential be constant. CURRENT is directly proportional to the LEVEL. b) Capacitance method:-It consist of an electrodes which extend the full length of the tank and the earth where earth may be a vessels, the contents or a concentric cylinder around the electrodes depending upon the types of electrodes used .A variation of capacitance will occur when the depth of the medium in the vessels alters therefore the capacitance change will proportional to the level, hence level of the liquids, powders, or granular solids may be measured.

3. CONDUCTIVITY PROBE METHOD

Conductivity probes level Detection system. It consists of one or more level Detectors, an operating relay, and a controller. When the liquid makes contact with any of the electrodes,

an electric current will flow between the electrode and ground. The current energizes relay, which causes the relay contacts to open or close depending on the state of the process involved. The relay in turn will actuate an alarm, a pump, a control valve, or all three. A typical system has three probes: a low level probe, a high level probe, and a high level

alarm

4. ULTRASONIC METHOD:
Ultrasonic beams are the form of energy transmitting by means of the mechanical vibration and carried through the transmitting converting one type of the energy into the mechanical vibrations in are received by the device which convert it into usable form of energy after receiving it. Its freq-above 20 kHz PRICIPLE OF OPERATION: When certain material (nickel, iron cobalt) are placed within the magnetic field, there lengths will vary by an amount dependent on the strength of the magnetic field. It is a nickel tube, which carries the coil and bias magnet; coil either weakens or strengthens the magnetic field depending upon the current direction. Application of the alternating current cause the length of the tube to increase or decrease at the supply frequency it will tend to oscillate longitudinally as the half wave resonator. Similarly the receiving end in reverse serial way (as the first sound wave on the diaphragm

then nickel tube movement and magnetic field strength change& thus e.m.f. In the coil hence current).

DIAPHRAGM TYPEIt is used for remote level indication in open tanks or docks etc. Pressure changed created by the movement of a diaphragm is proportional to a change in liquid level above the diaphragm. This consists of a cylindrical box with a rubber or plastic diaphragm across its open end as the level increases the liquid pressure on the diaphragm increases and the air inside is compressed. . FLOW MEASUREMENT Flow in the industrial undertakings occur in two general form-either flow in the tube (channel) or flow in the open channel (main is rate of flow) Both the liquid and gas flow in the litres / sec or kg/sec. but when they are transferred for their energy content, such as the sale of natural gas, the flow rate may be expressed in the Gj/hour or btu/day. Most flow meter is used to calculate the volume or mass flow rate, which is then adjusted to the energy flow rate, by the use of the computer. RATE FLOW MEASURING INSTRUMENT: 1Differential pressure flow meters a) Orifice plate b) Venturimeter c) Pitot tube 2. Variable area flow meter 3. Electromagnetic flow meter 4. Ultrasonic meter 1. DIFFERENTIAL PRESSURE FLOW METER: a) Orifice plateAn orifice plate is a plate with a hole through it placed in the flow it constricts the flow and measuring the pressure differential across the constriction gives the flow rate .it is basically

a crude form of venture meter, but with higher energy loss. Types-concentric eccentric and

segmental. b) Venturi meter: A venturimeter constricts the flow in some fashion, and pressure sensors measure the differential pressure before and within the constriction. Use-to measure the flow rate is n the transmission of the gas through pipelines and having coefficient of discharge is (0.93,

0.97).

c. Pitot tube: A pitot tube is a pressure-measuring instrument used to measure fluid flow velocity by determining the stagnation pressure and specification (dynamic pressure, fluid velocity) with the help of BERNOULLIS equation

2. VARIABLE AREA FLOW METER: The variable area (VA) meter, also commonly called rotameter, consist of a tapered tube, typically made of the glass, with afloat inside that is pushed up by fluid flow and pulled down by gravity .As the flow rate increases, greater viscous and pressure forces on the float cause it rise until it becomes stationary at the location in the tube that is wide enough for the forces to balance. Floats are made of different size (sphere, spherical ellipse) and are available with air or water. They can be made to reliably measure flow down to 1%

accuracy.

3.ELECTROMAGNETIC FLOW METER: The electromagnetic flow meter is similar in principle to the generator. A pipe placed between the poles of a magnet so that the flow of the fluid in the Pipe is normal to the magnetic field replaces the rotor of the generator. As the fluid flows through this magnetic field, an Electromotive force is induced in it that will be mutually normal (perpendicular) to both the Magnetic field and the motion of the fluid. This electromotive force may be

measured with the Aid of electrodes attached to the pipe and connected to a galvanometer or an equivalent. For given magnetic field, the induced voltage will be proportional to the average velocity of the fluid.

4.ULTRASONIC FLOW METER: Devices such as ultrasonic flow equipment use the Doppler frequency shift of ultrasonic signals Reflected from discontinuities in the fluid stream to obtain flow measurements. These Discontinuities can be suspended solids, bubbles, or interfaces generated by turbulent eddies in the flow stream. The sensor is mounted on the outside of the pipe, and an ultrasonic beam from piezoelectric crystal is transmitted through the pipe wall into the fluid at an angle to the flow Stream. A second piezoelectric crystal detects signals reflected off flow disturbances Located in the same sensor. Transmitted and reflected signals are compared in an electrical circuit, and the corresponding frequency shift is proportional to the flow velocity.

DCS
A distributed control system (DCS) refers to a control system usually of a manufacturing system process or any kind of dynamic system, in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each component sub-system controlled by one or more controllers. The entire system of controllers is connected by networks for communication and monitoring. DCS is a very broad term used in a variety of industries, to monitor and control distributed equipment.

Electrical power grids and electrical generation plants Environmental control systems

Traffic signals Radio signals Water management systems Oil refining plants Metallurgical process plants Chemical plants Pharmaceutical manufacturing Sensor networks Dry cargo and bulk oil carrier ships

OBJECTIVES: 1. Safe operation of power plant 2. Longest equipment life 3. Maximum efficiency hence energy conservation also there. 4. Lowest cost of generation

BENEFITS: 1. High reliability 2. Improved response time 3. Improved operator interface to plant 4. Improved accessibility of the plant data to engineering and management personals

PLC & DDCMIS

PLC:
A programmable logic controller (PLC) or programmable controller is a digital computer used for automation of electromechanical processes, such as control of

machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed-up or non-volatile memory.

PLC Hardware
The hardware components of a PLC system are CPU, Memory, Input/Output, Power supply unit, and programming device. Below is a diagram of the system overview of PLC.

CPU Keeps checking the PLC controller to avoid errors. They perform functions including logic operations, arithmetic operations, computer interface and many more.

Memory Fixed data is used by the CPU. System (ROM) stores the data permanently for the operating system. RAM stores the information of the status of input and output devices, and the values of timers, counters and other internal devices.

I/O section Input keeps a track on field devices which includes sensors, switches.

O/P Section - Output has a control over the other devices which includes motors, pumps, lights and solenoids. The I/O ports are based on Reduced Instruction Set Computer (RISC).

Power supply Certain PLCs have an isolated power supply. But, most of the PLCs work at 220VAC or 24VDC. Programming device This device is used to feed the program into the memory of the processor. The program is first fed to the programming device and later it is transmitted to the PLCs memory.

System Buses Buses are the paths through which the digital signal flows internally of the PLC. The four system buses are: Data bus is used by the CPU to transfer data among different elements. Control bus transfers signals related to the action that are controlled internally. Address bus sends the locations addresses to access the data. System bus helps the I/O port and I/O unit to communicate with each other.

Working
The Programmable logic controller functions in four steps.

Input scan: The state of the input is scanned which is connected externally. The inputs include switches, pushbuttons, and proximity sensors, limit switches, pressure switches. Ideally, they are transformers and not relays.

Program scan: The loaded program is executed to carry out the function appropriately.

Output scan: The input sources have a control over the output ports to energize or de-energize them. The outputs include solenoids, valves, motors, actuator, and pumps. Depending on the model of PLC, these relays can be transistors, triacs or relays.

Applications The simple suitable application is a conveyor system. The requirements of the conveyor systems are as follows:

A programmable logic controller is used to start and stop the motors of the conveyor belt. The conveyor system has three segmented conveyor belts. Each segment is run by a motor. To detect the position of a plate, a proximity switch is positioned at the segments end.

The first conveyor segment is turned ON always. The proximity switch in the first segment detects the plate to turn ON the second conveyor segment. The third conveyor segment is turned ON when the proximity switch detects the plate at the second conveyor. As the plate comes out of the detection range, the second conveyor is stopped after 20 secs. When the proximity switch fails to detect the plate, the third conveyor is stopped after 20 secs.

Advantages

PLCs can be programmed easily which can be understood clearly well. They are fabricated to survive vibrations, noise, humidity, and temperature. The controller has the input and output for interfacing.

Disadvantages

It is a tedious job when replacing or bringing any changes to it. Skilful work force is required to find its errors. Lot of effort is put to connect the wires. The hold up time is usually indefinite when any problem arises.

DDCMIS

(DISTRIBUTED

DIGITAL

CONTROL,

MONITORING

&

INFORMATION SYSTEM) : INTRODUCTION

The DDCMIS utilizes point out - regarding fine art microprocessors it is influenced by most recent proven technology. It does that features of pattern as well as modulating controls, seed start up / shut down, to all regimes regarding grow performing including catastrophe conditions.

The DDCMIS involves Close Loop Control System (CLCS), Open Loop Control System (OLCS), Man Machine Interface System and also Plant Information (MMIPIS), Measurement system, Sequence involving Events Recording System (SERS) plus Slave Clock System useful blocks.

BASIC FEATURES OF DDCMIS

Seven (7) figures of coloration CRTs usually are linked to MMIPIS sensible stop, for Control system operation, plant checking plus facts features & security alarm checking functions. Each on the coloration CRTs is definitely 100% interchangeable (any control / checking / escalating functions for almost any element from the place is usually performed every coloration CRT) in addition to provides finish control, monitoring, supervisory and also present options with regard to manage method issues in addition to manage procedure status. The units consist of most manipulate associated displays, bar graph displays, number displays, system sensors and authentic time frame trend display. These platforms are generally available about manage CRTs to the rating impulses since well. The method is configured in order to help permit efficient grow plants surgery to all modes connected with function viz. start up, normal operation, turn down, etc. through control CRTs and Keyboards. The monitoring / supervision options are created while on-line program which process, showcase as well as store information to supply the actual operator, also automatically or even about d demand, specific information with finish plant. The monitoring / watch functions include operation calculations, displays, logs, security alarm keeping track of & Retrieval. Two shade graphic printers, one collection and also three us dot matrix

printing companies are usually furnished pertaining to logs, accounts along with alarms. In inclusion to be able to this, one permanent magnet cartridges tape product pertaining to traditional storage and collection program along with a pair of figures with 6 pin microprocessor dependent craze recorders to get trending connected with items are generally provided. One console each one will be furthermore offered together with respective dot matrix equipment with regard to Gen. Manager, Dy. Gen. Manager plus Shift supervisor. 100% hot well not required controllers are used equally to get CLCS along with OLCS. Hardware for CLCS and also OLCS tend to be individual along with independent of each one other. In CLCS, that inputs connected with a number of measurements are generally wired to part ways enter adventures for you to stay away from sole place failure. All modulating drives are generally offered directly through standard hardwired backup A/M stations mounted on UCB and are unbiased in the accessibility with unnecessary controllers. In OLCS, redundant feedback modules are usually provided. All the OLCS drives are interfaced through unnecessary drive adventures to OLCS controllers. Maximum amount connected with motoring and these can be clubbed mutually of hospitality attire set of like redundant push manipulate modules are restricted to your utmost regarding 4. If commute deal with quests will not be in any way out there when using the supplier, and then repetitive O/P modules tend to be give en max. no. Connected with drives each group of like O/P modules restrained to four only. Wherever push control keys are usually supplied for OLCS hard disks youre functioning by means of most of these thrust switches is unbiased connected with the actual availableness of well not required controllers. The OLCS, with the major gear like boiler, turbine, power generator auxiliaries, strength operated valves and also dampers, etc. was created to allow optimum degree of rights although sustaining sufficient simple ness that will ensure reliability, maintainability along with minimum of annoying turn down. In case associated with disappointment involving system bus or even CRT / KBD, the particular guide book operation with regards to 10% regarding

complete drives, i.e., drives by means of back press buttons. The device is usually furnished by way of back force buttons. The basic necessary rights of the motoring can be found continually perhaps to the disappointment of OLCS controllers. The strategy is according to the design point that will it'd always operate without the decrease of function or perhaps protection feature in case associated with disappointment involving single apparatus / component. The modifications around method configuration, rotating constants and also same engineering and servicing characteristics will not be made possible involving view, these kinds of features are usually allowed merely from Engineers / Programmers gaming console in CER under locking mechanism along with Key operation. Separate consoles usually are supplied with regard to encoding / modification around MMIPIS as well as Control System in conjunction with particular peripherals. A separate have alone microprocessor centered strategy is provided for routine with activities monitoring capabilities for you to enable study involving tripping. The system monitors these SOE inputs, which includes a resolution regarding one millisecond. The SERS have, specific to it dedicated dot matrix printer manufacturers for stamping reports. The method is furthermore provided with its committed beautiful storeroom in addition to retrieval system to be able to store each of the SER logs & reports. One PC AT can be supplied with erasable optical disk and also hard disks interfaced together with process bus regarding on range storage of seed data. Necessary electronics as well as software package is usually given to attain data transfer in essential format. One master as well as slave clock method is in addition provided to make sure standard timing through the entire unit & plant. The grasp call is definitely time period synchronized along with DDCMIS as well as SERS.

CONTROL PHILOSPHY OF COAL HANDLING PLANT SYSTEM . i) 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 acontrol desk and suitable control panel will be provided at the Main CHP Control Room . The main Control Room of CHP shall have control desk in which the operating station along with CRT and keyboard will be mounted and control panel shall have

the CHP mimic, indicating lamps, push buttons meters, totalizer etc. and the alarm fascia windows at the top. CHP main Control Room will house system cabinets in addition to control desk. The main switchgear will be housed in the main control room building for CHP and located near the crusher house, the I/O cards and the relays for drives and the equipments which are around the crusher house shall be mounted in the system cabinets which are located in the main control room building. ii) The traveling Trippler and its associated drives shall be controlled from local panel located near the bunker floor MCC room .The system cabinet for remote I/O cards relays and interfacing equipment etc. for the Traveling Trippler drives and equipment shall be located in its MCC room to provide status indication /alarms for traveling Tripler operation in the main CHP control room. The system cabinets shall be suitable for protection class IP-65 . iii) 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. The ON/OFF operation of paddle feeders shall be controlled from this panel apart from its local Control Panels. The control room in this building shall be provided with glass panel to have full view of rakes unloading operation The integrated weigh bridges shall be provided for the measurements of weight for each wagon at wagon trippler complex. Each weighing bridge shall have built in diagnostic and weight measurements software .The weigh bridges shall be controlled from the panel located in control room at Tripler complex.. The remote I/Os relays, interfacing equipment etc. will be located in system cabinets in building at Tripler complex to provide status indication/alarm of the unloading operation in the main control room.

iv)

Stacker Reclaimer shall be provided with PLC system. The remote I/O and relays will be provided on operators cabin of stacker re-claimer to indicate Stacker reclaimer operation in the main control room. Following Equipment will come under sequential interlock scheme and can be started / stopped from control desk in the main CHP control room with indication on CRT and mimic panel with fault annunciation facility: i. ii. iii. iv. v. All belt conveyors. Vibrating feeders. Screens Crushers Flap Gates.

The sequential control system shall provide stream selection from under ground conveyor of track hopper, from crusher conveyor to stacking yard conveyor, from stacker re claimer to staking yard conveyor during reclaim mode etc. However, all the above mentioned equipment will have its local control panels/ station for start / stop and /or any other function required with suitable lockable type local / remote selector switch shall be housed in local panel and placed near drives