INDIAN INSTITUTE OF SPACE SCIENCE AND TECHNOLOGY,

THIRUVANANTHAPURAM

PROCESS INSTRUMENTATION AND CONTROL

INTERNAL PROJECT REPORT

Submitted By

ROHAN DUTTA

VASU DUBEY

IN

AVIONICS

IN

Singrauli Super Thermal Power Station, NTPC Ltd.

August, 2010
ABSTRACT

With increase in demand of power in India, new power projects are being
constructed with higher capacity and advancement technology for the better economy and
reliability of operation. Compared to lower capacity power plant, 500 MW capacity power plants
have incorporated certain special technical features, which are of importance from control point
of view. 500 MW Turbine at Singrauli Super Thermal Power Station (SSTPS) is of Kraftwork
Union, West Germany design and Boiler is supplied by BHEL. This dissertation work is a case
study of various control aspects in thermal power plant. It describes starting from fundamentals
of a thermal power plant up to the latest technology in control called DDCMIS. Implementation
of controllers like P, PI, and PID is also studied in this dissertation.

2
TABLE OF CONTENTS

 CERTIFICATE
 ACKNOWLEDGEMENT
 ABSTRACT
 LIST OF SYMBOLS & ABBREVIATIONS USED

CHAPTER – 1 INTRODUCTION 7
a. INTRODUCTION 7

CHAPTER – 2 OVERVIEW OF THERMAL POWER PLANT 9

a. BOILER 9

b. FUEL & AIR SYSTEM 10

c. TURBINE 10

d. CONDENSATE WATER SYSTEM 11

e. FEEDWATER SYSTEM 11

f. GENERATOR 11

CHAPTER – 3 NEED OF AUTOMATION IN THERMAL POWER PLANT

12

CHAPTER – 4 IMPORTANT PARAMETERS & INSTRUMENTATION

a. PRESSURE MEASUREMENT 14
b. STRAIN MEASUREMENT 16
c. TEMPERATURE MEASUREMENT 17
d. TURBO-SUPERVISORY INSTRUMENTS 18
e. LOCATION OF DETECTORS 22

3
CHAPTER – 5 CONTROL LOOPS IN POWER PLANTS 23

a. FIRING RATE CONTROL 23

i. FUEL FLOW CONTROL 23
ii. AIR FLOW CONTROL 23
b. INLET VANE POSITION CONTROL 24
c. PRIMARY AIR HEADER PRESSURE CONTROL 24
d. MILL AIR FLOW CONTROL AND OUTLET TEMPERATURE
CONTROL 24
e. FEEDWATER CONTROL 25
f. SUPER HEAT STEAM TEMPRATURE CONTROL 25
g. REHEAT TEMPERATURE CONTROL 26
h. DEAERATOR PRESSURE CONTROL 26
i. DEAERATOR LEVEL CONTROL 26
j. HOTWELL LEVEL CONTROL 26

i. HIGH LEVEL CONTROL 27

ii. LOW LEVEL CONTROL 27

k. REHEATER TEMPERATURE CONTROL 28

a. BURNER TILT 28
b. RH SPRAY SYSTEM 28
CHAPTER – 6 ELECTRO HYDRAULIC GOVERNING SYSTEM 29

a. ELECTRO HYDRAULIC CONTROLLER 29

b. SPEED CONTROLLER 29
c. SPEED CONTROL LOOP 30
d. DN/DT MONITORING 31
e. LOAD CONTROLLER 32
f. LOAD CONTROL LOOP 32
g. PRESSURE CONTROLLER 33
h. VALVE POSITION CONTROL 33
CHAPTER – 7 DDCMIS 34

a. COMPARISION 34

4
 b. GEOGRAPHICALLY DISTRIBUTING THE HARDWARE 35
c. FUNCTIONALLY DISTRIBUTING THE HARDWARE 35
d. OPERATOR STATION 36
e. PLANT MONITORING SYSTEM 36
f. ENGINEERING STATION 36

CHAPTER – 8 FURNACE SAFEGUARD SUPERVISORY SYWSTEM (FSSS)

37

a. SYSTEM DESCRIPTION 37

CHAPTER – 9 CONCLUSION & FUTURE DIRECTION 38

a. CONCLUSION 38

b. FUTURE DIRECTION 38

i. SLIDING SET POINT OPERATION 38

ii. MAX DNA 38

APPENDIX 39

REFERENCES 45

5
LIST OF SYMBOLS & ABBREVIATIONS USED

: Valve

: Pump

: Gauge

: OR Gate

: Turbine

MW: Mega Watt D/A: De-Aerator

DAS: DATA Acquisition System TSE: Turbine Stress Evaluator

HPT: High Pressure Turbine PI: Proportional Integral

IPT: Intermediate Pressure Turbine PID: Proportional Integral Differential

LPT: Low Pressure Turbine VDU: Visual Display Unit

PA: Primary Air DC: Direct Current

FD: Force Draft RH: Re-Heater

ID: Induced Draft MFT: Master Fuel Trip

SH: Super Heater UCB: Unit Control Board

BFP: Boiler Feed Pump CRH: Cold Re-Heat

CEP: Condensate Extraction Pump HRH: Hot Re-Heat

HEA: Heavy Energy Arc

6
CHAPTER - 1

INTRODUCTION

1.1 INTRODUCTION:
The 500 MW unit of Singrauli Super Thermal Power station is itself an institution where
learning is unlimited. As the power plant has different units like Boiler, Turbine, Generator etc.,
different logics have been used to meet the requirements. A case study is done about the different
control systems in the different areas of a power plant. It is of great importance to know that how
the implemented control system is achieving its target.

The control system being used in Singrauli Super Thermal Power station is centrally located as it
is very tedious to maintain a good environment for electronic hardware locally, because of the
conditions there.

As shown in the fig 1.1 equipment room is the heart of the control system. It receives the
commands from control room panel and also from local/ field. It also receives feedback and the
inputs, from fields. The signals are processed here and send either to control room panel (for
alarm or indication) or field to actuators, or to DATA Acquisition System (DAS) and printers.

A View of

7
 SINGRAUL
I SUPER
THERMAL
PLANT

PANEL

DAS

COMMAND FROM LOCAL

I
EQUIPMENT ROOM N

P
F
E U

E T

B F
TRANSDUCERS
A R
K O

M
I

P MOTOR VALVE

FIELD

Fig . 1.1 CONTROL SYSTEM

8
CHAPTER - 2

OVERVIEW OF A THERMAL POWER PLANT

2.1 INTRODUCTION:
Thermal power plant, used to generate electricity, can be coal based or oil based. This fuel is
burnt in boiler through which steam is generated. This steam is taken to turbine which is coupled
with Generator. When turbine rotates, Electricity is produced through generator.

Here is discussed a brief case study of 500 MW unit of Singrauli Super Thermal Power Station.

The three essential units of any Thermal Power plant as shown in the figure 2.1 are:

 Boiler
 Turbine
 Generator

2.2 BOILER:

The boiler is Radiant, Reheat, Controlled circulation, Single drum, and Dry bottom type unit.
Each boiler corner is fitted with tilting tangential burner boxes comprising of 4 high Energy Arc
Igniters, 4 light–up heavy oil fired burners & eight pulverized coal burners.(Refer to Appendix)

9
2.3 FUEL & AIR SYSTEM:

The system for firing pulverized coal utilizes bowl mills to pulverize the coal and a tilting
tangential firing system to admit the pulverized coal, together with the air required for
combustion to the furnace. As crushed coal is fed to each pulverizer by its feeder, Primary Air
supplied from Primary Air (PA) Fan, which dries the coal as it is being pulverized and transports
the coal through coal piping system to the coal nozzles in wind box assembly of furnace. Fully
Preheated Secondary Air for combustion enters the furnace around the pulverized coal nozzles.
Combustion is completed as the gases spiral up in the furnace.

2.4 TURBINE:

The turbine is a reaction, condensing type, tandom compound with throttle governing and
regenerative system of feed water heating. It is coupled directly to the generator. Te turbine is
single shaft machine with separate HP, IP & LP turbines. The HP turbine is single flow cylinder
where as IP & LP is a double flow cylinder as shown in fig. 2.4.

10
2.5 CONDENSATE WATER SYSTEM:

The condensate extraction pumps deliver the condensate through the three low pressure
feedwater heaters, the Deaerator to the Feed storage tank Storage Tank., which is start point to
Feedwater System. Low pressures Feedwater Heaters receive extraction steam from the turbine.
Condensate absorbs heat from the extraction steam as it passes through the heaters.(Refer to
Appendix)

2.6 FEEDWATER SYSTEM:

The purpose of feedwater system is to provide adequate flow of properly heated & conditioned
water to the boiler and maintain boiler drum level compatible with boiler load. Feedwater flows
from Deaerator storage tank to Boiler Feed Pumps. The flow continues through High Pressure
Feedwater Heaters string to the boiler Economizer inlets. Finally feedwater enters the boiler
drum.

2.7 GENERATOR:

Turbo Generator for 500 MW units is two pole water and Hydrogen gas cooled generators. The
primary water flows through the stator winding and picks up heat losses arising in generator
directly, which are transferred to the Secondary cooling water. Core losses, windage losses and
rotor winding losses are picked up by circulating Hydrogen and transferred to Hydrogen cooling
water in the gas coolers. A brushless exciting system with rotating diodes is provided to excite
the machine. It consists of pilot exciter which is a 3 phase permanent magnet, 16 pole revolving
field, the output of which is rectified and controlled by thyristor voltage regulator to provide a
variable dc current for main exciter. The main exciter is 6 pole, revolving armature unit. The
three phases are induced in the rotor of the main exciter and is rectified by the rotating diodes
and to the field winding of generator rotor through DC leads fed in the rotor shaft. Since the
rotating Rectifier Bridge is mounted in the rotor, the slip rings are not required and the output of
rectifier is connected directly to the field winding through the generator rotor shaft.

11
CHAPTER - 3

NEED OF AUTOMATION IN THERMAL POWER PLANT

The word ‘Automation’ is widely used today in relation to various applications such as office
automation, plant or process automation etc. This dissertation presents the application of a
control system for the Automation of a process/plant, such as a power station. Complete plant
automation provides the operating personnel with the necessary tool to increase plant availability
& efficiency.

Automation actively controls the plant during the three phases of operation.

 Plant start up,

 Power generation in stable or transient conditions

 Plant shut down.

1) The automation system is of a particular importance when the plant behaves in an

unpredictable way. The automation will then automatically and immediately respond
without time delay to bring plant into a safe operating state with respect to environment
process components and human beings.
2) During stable generation of power, the analog portion of the automation system keeps the
actual generated power value within the limits of the desired load demand.
3) During major load changes the automation system automatically redefines new set points
and switches ON or OFF process pieces to automatically bring the individual processes in
an optimally coordinated way to the new desired load demand. This load transfer is
executed according to preprogrammed adaptively controlled load gradient and in safe
way.
4) In thermal power plant it has become necessary to pay special attention to the additional
thermal stresses which results from thermal changes. These stresses damage heavy
masses of turbine and rotor. Turbine Stress Evaluator (TSE) takes care of this in an
automated plant. It stops further increasing of load or lowers main steam temperature or
flow if excessive stress in the metal temperature are indicated

12
5) For start up, acquisition and analysis of a wide variety of information pertaining to
various parameters of steam turbine, demand quick decisions and numerous operations
from the operating personnel. In order to reduce the tedious task of monitoring various
parameters and effect sequential start up, we have to minimize the possible human errors.
And to achieve start up in minimum time in optimum way Automatic Run Up System
(ATRS) is introduced.
6) Furnace Safeguard &Supervisory System (FSSS), is the system, which has been designed
to protect Boiler and its auxiliaries. It offers maximum protection, minimum nuisance
trips, minimum power consumption and max life of the components used. It includes oil
guns, HEA Igniter, Flame scanner, Heavy oil trip valve, Heavy oil recirculation valve etc.
7) Availability, reliability and efficiency of a boiler, turbine unit hinge around the close
control of the chemical regimes of the working fluids, i.e. water / steam in the circuits as
well as the combustion in the boiler. To monitor this Analytical Instruments and their
control system has been incorporated. Which continuously monitors O 2, CO2 and CO
formation in boiler, and conductivity, cation conductivity, pH, sodium, silica, Hydrogen
in water/steam circuit.

13
 CHAPTER – 4

IMPORTANT PARAMETERS AND INSTRUMENTATION

This chapter is about the various parameters that are to be measured in a thermal power plant and
the respective instrumentation that is required for the same.

1. PRESSURE:

Pressure measurement not only is critical to the safe and optimum operation of such industrial
process as steam generation, hydraulic equipment operation, air and gas compression, vacuum
processing (measurement), hydrostatic pressure, differential pressure etc.

Pressure measuring devices:

• Manometers using water ,mercury and other liquids of known density for low pressure
measurement.

• Diaphragm, capsule bellows for measuring medium pressures.

• Bourdon tube gauges for measuring medium and high pressures.

• Transducers of different types for measuring pressure of all ranges for telemetering
purposes.

14
 p2 p1

Well Manometer

Absolute – pressure Manometer

Bellows : This is thin wall metal tubes with deeply convoluted side walls which permits axial

expansions and contraction.

Common form of bellows used in pressure gauge

15
 The Pigtail is used on horizontal
pipelines where there is sufficient space
above the pipe.

'U' type is used when mounting the gauge

on a vertical pipeline, or on horizontal
pipelines where there is not sufficient
space for a ring type siphon.

2. STRAIN:

• If a wire is held under tension, it gets slightly longer and its cross-sectional area is
reduced.

• This changes its resistance (R) in proportion to the strain sensitivity (S) of the wire's
resistance.

• The strain sensitivity is also called the Gauge factor (GF).

Typical metal-foil strain gages

3. TEMPERATURE :

• Assess the material fatigue, heat balance, heat transfer etc.

• Assessing the process condition

16
 • Efficient and economic operation at determined load.

• Vital information display for safe operation of the plant.

• Analysis

Instruments

• PRIMARY INSTRUMENTS

Thermocouple

Resistance thermometer (Pt100,Cu53)

• SECONDARY INSTRUMENTS

Instruments that use electronic bridges. (For alarm, protection)

Selection of instruments at a particular place in a power plant is done on the following

basis :

• The accuracy required

• The range of temperature

• Process media on sensing element

• The layout conditions and restrictions

• Facilities available for calibration of the instrument

THERMOMETER ASSEMBLY

4. TURBOSUPERVISORY INSTRUMENTS (TSI)

Hallprobes:

PROXIMITY SENSOR :

17
Principle of a proximity sensor:

The oscillator in the matching unit supplies (RF signal) the coil in the sensor with a load
Independent, high frequency alternating current. If the sensor is brought near to a metal object,
the eddy currents are induced in surface of the object and the power is absorbed thus alternating
the voltage across the coil. The alternating voltage is proportional to the distance between the
measured Object and the sensor. The output amplifier forms a load independent D.C. Voltage
signal.

SIESMIC SENSOR:

18
Measuring relative expansion :

19
 DISK

CHAPTER - 5

CONTROL LOOPS IN POWER PLANT

In this chapter various control loops in a Thermal Power Plant have been discussed with
reference to 500MW unit of Singrauli Super Thermal Power Plant, NTPC.

5.1 FIRING RATE CONTROL:

 Firing rate control is achieved by controlling the flow of fuel as well as air going in the
furnace.

 Fuel flow to the boiler is controlled by varying the speed of coal feeders or by variation
of the fuel oil flow.

 Airflow has to be controlled in proportion to the fuel flow to maintain a good

combustion at all load conditions.

5.1.1 FUEL FLOW CONTROL:

The boiler demand signal, produced in the boiler demand control is fed through a minimum
selector and compared with a signal, representing the total fuel flow and the control deviation is
fed to a PI controller The output signal of on be controller is the set point signal for the eight coal
feeders. To speed up mill response a derivative signal of boiler demand is added to the controller
output, via an analog memory which is tracking the feeder setpoint, when on auto. A bias setter
in the setpoint signal to each feeder allows different loads of the mills on auto.

The calibration of feeder speed signal representing coal flow, can be achieved by manually via
an analog memory, when the calorific value of coal varies.

5.1.2 AIR FLOW CONTROL:

The boiler demand signal and the fuel flow signal (delayed according to mill response time) are
fed to a maximum selector and the higher of this signal is compared with the calibrated air flow
signal. The control deviation is fed to two controllers which position the two electric actuators
for control of the Force Draft (FD) Fan blade pitch.

20
5.2 INLET VANE POSITION CONTROL:

To save energy and to keep the FD fan inlet vanes always in a good control position, the fan
speed is controlled. The average inlet van position of the fans on auto is compared with the
desired set point, for instance 80%, and the control deviation fed to the three individual
controllers. These controllers supply more or less pulses and position the scoop tubes of the
hydraulic couplings between motors and fans.

5.3 PRIMARY AIR (PA) HEADER PRESSURE CONTROL:

Primary air supply to all pulverizes is maintained by controlling the primary header pressure at
the common discharge duct of two PA Fans. PA header pressure is controlled by regulating the
blade pitch of constant speed, axial reaction type PA Fans.

5.4 MILL AIRFLOW CONTROL & OUTLET TEMPRATURE CONTROL:

Coal air temperature at the mill outlet and PA flow to each mill is controlled by modulating hot
air and cold air dampers in PA line to mill as shown in Fig 5.2. Measured value signal is
compared with a desired value signal generated by characterization of feeder speed signal. The
output of proportional plus reset action PA flow controller acts on the hot air damper to regulate
the primary air flow. Provision is given to ensure a preset minimum flow through the mill at all
times. Coal air temperature at the mill output is compared with the manually selected desired
value signals in a proportional, reset and rate action controller. The output of this controller shall
act on the cold air damper for regulating coal air temperature. Interlocks are provided for
automatically opening the cold air damper and closing the hot air damper on a pulverizer trip,
based on the signals from, FSSS (discussed later).

21
 COAL FROM
FEEDER
AIR & COAL AIR & COAL
MIXTURE MIXTURE
TO TO
FURNACE FURNACE

BOWL MILL

ROLLERS

HOT
PA AIR

Fig. 5.2 BOWL MILL

DAMPERS

COLD AIR

5.5 FEED WATER CONTROL:

The boiler drum level has to be kept constant under all load condition. Under normal load
conditions ( above 20% load) the controller system acts as three element control utilizing steam
flow as feed forward signal, feedwater flow as feedback signal and the drum level control
deviation as main control signal. This control varies the speed of the two Turbine Driven feed
pumps or through a hydraulic coupling of one electric motor driven feed pumps. On low load
control is achieved by positioning a low load control valve with drum level as the only influence.

5.6 SUPER HEAT (SH) STEAM TEMPERATURE CONROL:

This control loop has a task to maintain the SH temperature at a constant value. The boiler has
two SH lines; each line has two injection coolers for temperature control. The final super heaters
are placed after injection coolers. Temperature is adjusted by two circuit controllers. The dual

22
loop controllers are composed of a PI controller, which actuates the injection valve in
dependence of the control deviation of the boiler outlet temperature and in dependence of the
rate of change the temperature behind the injection cooler. The rate of change is raised by an
integrator. The input signal of the integrator is consisting of the difference between its output
signal and the actual value of the temperature.

5.7 REHEAT TEMPERATURE CONTROL:

The reheat steam temperature is controlled on the one hand by changing the burner tilt position
on the other hand by means of injection coolers. The burner tilt position is precontrolled
according to the load. This signal is corrected by the output of the PID temperature controller. In
case of fast load changes an additional D-part of the boiler load index is superimposed. Required
set point is set through a setter. There are two injection control valves available for one cooler;
one valve is in operation; and other is standby.

5.8 DEAERATOR PRESSURE CONTROL:

The pressure in deaerator is normally controlled from the cross over pipes between IP and LP
turbines. During low load and turbine bypass operation, cold reheat steam is used for deaerator
heating as shown in Fig. 5.3. Auxiliary steam is used to maintain the pegging steam pressure at
3.5 atm during bypass operation, hot start up and warm start up and a minimum pressure of 1.5
atm during a cold start up.

5.9 DEAERATOR LEVEL CONTROL:

The D/A control loop maintains the water level in the D/A by regulating the condensate flow to
D/A with help of two 100% capacity flow control valves C and D located in condensate line.
Transmitters are provided to measure:

 Deaerator level
 Condensate flow
 HP heater 5A drain flow
 HP Heater 5B drain flow

23
5.10 HOTWELL LEVEL CONTROL:

Steam after LP Turbine gets condensed and gets collected in Hotwell, from where Condensate
Extraction Pumps (CEP) take suction as shown in Fig.5.5. For healthy operation of CEP and
condenser adequate level has to be maintained in Hotwell. For this two different control loops
regulate the flow of water.

5.10.1 HIGH LEVEL CONTROL:

The condenser hotwell high level is controlled by regulating the flow of excess condensate fro
CEP discharge to condensate storage tank.

5.10.2 LOW LEVEL CONTROL:

Condenser hot well low level is controlled by regulating the make flow to condenser. The make
up can be provided from Deminaralised water plant. The additional make up is given from
condensate storage tank.

24
5.11 REHEATER TEMPERATURE CONTROL

Reheater are the tubes in boiler near Goose Neck area in which CRH from HP Turbine exhaust
enters At 350oC and again gets reheated to 535oC and goes to IP Turbine inlet via HRH lines.

For controlling the temperature of outlet there are two arrangements provided:

1) Burner tilt
2) RH spray system

5.11.1 BURNER TILT:

In the tangential firing system the furnace itself constitutes the burner. Fuel and air are
introduced to the furnace through four wind box assemblies located in the furnace corners, which
can be vertically adjusted by means of movable air deflectors and nozzle tips. These can be tilted
upward or downward through a total of approx 60 o. This movement is effected through
connecting rods and tilting mechanism in each wind box compartment, all of which are
connected to a drive unit each corner operated by open loop control. By tilting arrangement the
flame gets shifted hence temp can be varied.

5.11.2 RH SPRAY SYSTEM:

A direct cooling method is achieved by spraying water to steam in CRH line (RH inlet) by two
injection coolers, one in each CRH line. The water is taken from BFP. Control valves are
provided to control the amount of spray required.

Actual temperature of RH outlet (HRH lines) is sensed by four thermocouples two in LHS and
two in RHS. Thermocouples convert temperature into current.

25
CHAPTER - 6

ELECTRO HYDRAULIC GOVERNING SYSTEM

The turbine is equipped with electro hydraulic governing system to facilitate the operation of the
Turbo-set in an inter connected grid system measuring and processing of signal after the
advantages such as, dynamic stability and simple representation of complicated functional
relationship. The processed electrical system is introduced at a suitable point in the hydraulic
circuit through electro hydraulic converter. The hydraulic control provides the advantage of
continuous control of large positioning forces for control valves. The integration of electrical and
hydraulic system offers the following advantages:

 Exact load frequency drop with high sensitivity.

 Reliable operation in case of isolated power grids.
 Dependable control during load rejection.
 Low transient and low steady state speed deviations under all operational conditions.
 Excellent operational reliability and dependability.
 Safe operation of the Turbo-set in conjunction with the TSE.

6.1 ELECTRO- HYDRAULIC CONTROLLER:

The parameters to be controlled i.e. speed, load and turbine throttle pressure are measured and
converted into electrical signals by means of suitable transducers.

6.2 SPEED CONTROLLER:

The speed controller is used for starting the turbine up to synchronization and block loading. It
can also operate over the full range during emergency such as generator tripping from full load to
house load operation or during rapid load throw-offs or severe frequency fluctuation. The speed
controller is always kept in the readiness for operation even when it is not directly controlling the
turbine by tracking the signal by the other controller in service.

26
6.3 SPEED CONTROL LOOP:

Speed reference value is set by means of potentiometer operated from remote UCB control
Panel) or manually (control cabinet) normally in the range of 0-3000 rpm (0-9V).above a speed
of 47Hz (2830 rpm) a reducing gear box lowers the speed of potentiometer to 1/4 th, to facilitate
exact adjustments, of speed.

SPEED SELECTION CIRCUIT

CONTROLLER
NR NRTD

Fig. 6.1 SPEED CONTROL LOOP

ACTUAL SPEED

The control device for the speed reference value generates the time dependent
speed reference value NRTD which influences the speed controller as shown in Fig. 6.2.. N R is fed
to a high gain DC amplifier. The subsequent integrator responds to a very small imbalance of
the inputs of DC amplifier. Output of the integrator is NRTD which changes like a ramp.

27
 NR NRTD
SPEED SET POINT CONTROL SPEED CONTROLLER
SET PT.
MANUAL dn/dt
n Xd SELECTION
AUTO
SYN CKT.
t
t
NO LOAD
CORRECTION
TSE INFLUENCE
TRIP

M
U
TRACKING DEVICE f
V
3

ACTUAL SPEED
SPEED GRADIENT MONITORING HOUSE LOAD

n Dn/dt
min

Fig. 6.2 TURBINE SPEED CONTROLLER

6.4 DN/DT MONITORING:

During rolling of turbine, if between the speed 600 rpm to 2829 rpm the rate of speed rise is very
slow i.e. less than 108 rpm/min, then DN/DT monitoring operates giving appropriate alarms in
UCB. It blocks further rise in speed and brings back the speed reference to 600 rpm, this is
incorporated to avoid low acceleration rates when the turbine speed lies in the critical speed
range 2850 rpm.

28
6.5 LOAD CONTROLLER:

The load controller used for controlling turbine output during load operation. The loading and
unloading gradients are influenced by TSE and Rate of change of reference.

This controller is designed for two modes of operation:

a) Power operation in conjunction with power system with PI control characteristics.

b) Isolated grid operation with P control characteristics.

6.6 LOAD CONTROL LOOP:

Load reference value is set from reference value setter module on the turbine panel (PR).

The device for the load reference value contains P channel parallel to I channel. On account of
this the response of the device is Proportional to small change and PI for large changes of load
reference value. Control device for load reference value generates PRTD/PLIM which influences the
load controller. This signal rises during start-up at a rate (MW/Min) selected through load
gradient setter until the final load reference value P R has been reached. PLIM is also subjected to
the additional limits because of TSE margins (if the same is in switched on). If the rate of P RTD is
limited by load gradient setter the proportional channel is automatically switched off and the
response of PRTD is purely integral.

FREQUENCY
INFLUENCE

SEL
LOAD
PR PRTD MIN.. CONTRO CKT
LLER

TSE LOAD GRADIENT LOAD LIMITER ACTUAL LOAD

Fig. 6.3 LOAD CONTROL LOOP

29
6.7 PRESSURE CONTROLLER:

Pressure controls the turbine load with respect to the main steam pressure deviation, and prevents
(during quick load increase) large pressure drops. There are two modes of operation of pressure
controller:

In initial pressure mode, pressure controller tries to maintain initial pressure (turbine inlet
throttle pressure). It reduces the difference between reference pressure and the actual pressure to
zero by sacrificing load.

In limit pressure mode the boiler storage capacity is utilized. The pressure controller influences
the turbine CV’s to support boiler pressure control only if a preset main steam pressure deviation
is exceeded. This provision allows the load controller to handle small, quick load variation until
pick up limit pressure control is reached. This pick up limit is seldom reached in the usual
frequency supported load control mode since boiler pressure control holds pressure deviation
within narrow limits.

THROTTLE PRESSURE SEL

PR. CONTROLLER CKT

ACTUAL PR.

Fig 6.5 PRESSURE CONTROL LOOP

6.7 VALVE POSITION CONTROL:

The output from the speed controller and the load controller are compared in a MAX –
MIN selector, and the output from this is again compared with the pressure controller
output in a minimum selector. The output from this is fed to the valve position controller.
Therefore the signals from the speed, load and pressure control are superimposed and
selected to give an output to the valve position control.

30
CHAPTER - 7

DDCMIS

DDCMIS stands for Distributed Digital Control and Monitoring and Information System.
Distributed control implies that the actual control and management functions are in fact
distributed throughout the entire plant in several processing units. In such configuration plant is
divided in many small groups and each group is controlled by a dedicated set of processors and
other hardware. The tasks of measurement, control, operation, communication, sequence control
etc. are distributed amongst a number of processing units, each incorporating a microcomputer.
These microcomputers are linked via a common hiearchy and are configured in a hierarchical
common structure.

7.1 COMPARISION:

A basic difference between hardwired and distributed system is given below:

HARDWIRED DISTRIBUTED

A) Control system not flexible Control system programmable

B) Signal transmission via numerous Signal transmissions via coaxial cable

cable

C) Component drift introduces error Drift doesn’t effect in performance

in performance

D) Distribution of control not Geographical & functional

possible distribution of control

E) System tuning/optimization System tuning/optimization

not easy easy with friendly man machine interface

F) Limited diagnostic feature Extensive self diagnostic features

G) Many varieties of modules Fewer varieties of modules

31
H) Data acquisition is a separate Combined data acquisition &

system control system can be offered

i) All sub systems are not available Single source of supply

from single source

The above mentioned function can be achieved in two ways:

 Geographically distributing the hardware

 Functionally distributing the hardware
7.2 GEOGRAPHICALLY DISTRIBUTING THE HARDWARE:
In this concept the hardware is distributed geographically in the plant, i.e. the electronics module
are not placed in a central; location but segregated in small groups and kept near the respective
systems being controlled. These systems have the advantage of saving a lot of cabling costs, as
the signals need not be routed all the way to the central equipment room. However this system is
not used in NTPC because of environment condition present in power plants, due to which it is
difficult to maintain required environment for microprocessor base hardware at many places in
plant.

7.3 FUNCTIONALLY DISTRIBUTING THE HARDWARE:

In this concept the hardware is kept in a centralized control equipment room but the electronic
hardware is functionally divided to perform the function independently, i.e. failure of group/sub
group does not affect or jeopardize another group/sub group. This concept is adopted by NTPC,
as this needs only one centrally air conditioned room for the electronic module.

7.4 OPERATOR STATION:

The operator station can consist of two different techniques: Conventional stations with push
buttons, lamps and indicators or VDU stations. The VDU station provide the possibility to tune
individual control loops and perform interface monitoring functions, such as simple indication
function, tabulations, bar charts, trends, mimic displays or simple protocols.

32
7.5 PLANT MONITORING SYSTEM:

The plant monitoring system informs the plant personnel on overall plant behavior and historical
data. This data allows the plant management, operator and maintenance personnel to take
decision in regard to:

 Scheduling of further plant output

 Operation of the plant
 Recording of plant operational data
 Scheduling of plant maintenance outage
The plant monitoring system provides via VDU printer, hard copy unit or plotter, plant real or
non real time data or calculated data such as:

 Plant efficiency
 Life time calculation and monitoring
 Early detection of deterioration of process components

7.6 ENGINEERING STATION:

The engineering station allows diagnosing and recording control system internal disturbances.
This station also allows developing programs, control schemes directly via VDU keyboard.

Fig. 7.3 A typical DDCMIS screen depicting parameters in the IPT & LPT

33
 CHAPTER - 8

FURNACE SAFEGUARD SUPERVISORY SYSTEM (FSSS)

8.1 SYSTEM DESCRIPTION:

The Furnace Safeguard Supervisory System (FSSS) is designed to ensure the execution of a safe,
orderly operating sequence in the start up and shut down of firing equipment and to prevent
errors of omission or commission in the following such as safe operating procedure.

To maintain the decentralized and hierarchical structure of FSSS the design envisages 3 local
buses each for control of each mill elevation. Separate local bus provided for each oil elevations.

Further three local buses are assigned for boiler trip functions (MFT), mill protection & oil
protection each in 2 out of 3 mode. Another local bus controls the unit functions like Boiler
Purge, etc. Master fuel trip initiation is shown in fig. 8.1. It trips the boiler, if any of the
conditions are met.

LOSS OF UNIT 220 V DC

ALL FD FAN OFF

ALL ID FAN OFF

DRUM LEVEL VERY HIGH

MASTER
OR
DRUM LEVEL VERY LOW FUEL
TRIP
FURNACE PRESSURE VERY HIGH

FURNACE PRESSURE VERY LOW

REHEAT PROTECTION TRIP

FLAME FAILURE

Fig 8.1 MASTER FUEL TRIP

CHAPTER – 9

34
CONCLUSION & FUTURE DIRECTION

9.1 CONCLUSION:

The described Distributed Digital Control & Monitoring System uses high speed microprocessor
to perform all tasks in a power plant using one type of hardware. The special features of this
system are its extended partitioning and Intra plant Bus. The control and automation function can
be partitioned in various levels and island with each level to comply with particular process
requirements. The Intra Plant Bus replaces signal cabling by distributing the control system
hardware through the plant and making marshaling racks superfluous.

9.2 FUTURE DIRECTION:

The new technologies in the field of power plant are Sliding Set point operation & MAX DNA.

9.2.1 SLIDING SET POINT OPERATION:

In this concept the electric power is controlled using the close loop control equipment of the
turbine and the steam pressure using the close loop control equipment of the steam generator
(boiler). The basic set point for the unit power is set according to the schedule transmitted via a
subsequent set point control circuit. This concept is applicable to run the plant in Availability
Based Tariff regime, in which the power demand frequently increases or decreases. In the
original concept fuel is fixed to raise the load, which takes a significant time. But in sliding set
point concept the turbine valves are throttled in such a manner that the capacity of the boiler is
utilized. But to restore the capability of boiler, fuel is fired in such a way that it gives least
stresses to boiler.

9.2.2 MAX DNA:

MAX DNA is Distributed control system for new generation. The system allows user flexibility
to operate a small stand alone control system to a mega control system with plant automation. Its
open architecture permits the integrity of process control, management information system, local
& wide area network. It provides for high resolution graphics utilizing 32 bit graphical user
interface. Customer has flexibility when it comes to expanding the system or linking to third
party system. It also has on-line simulation and testing facility.

APPENDIX

35
Coal to Electricity:

Why Coal?

RES Nuclear
5% 3%

Hydel
26%
Advantages of Coal Fuel
Coal
Abundantly available in India 55%

Low cost Diesel

1%
Technology for Power Generation
Gas well
10%
developed
Easy to handle, transport, store and use

36
Boiler:

Water System:

37
Steam System:

Air System:

CONDENSER

Parameters Measured:
Parameter Instrument Used Control Circuit Display Units Equipment Example
Contains Used
Temperatur Thermometer Direct Contact Instrument Itself Room Temp

38
e

Temperature Direct Contact Instrument Itself Bearing, Casing,

Gauge Mounted on Fluid. Gas, Air, Steam
equipment Temp

Thermo couple Direct Contact Indicator

Mounted on Recorder CRT Bearing, Casing,
equipment Fluid. Gas, Air, Steam
Temp
RTD Direct Contact Indicator
Mounted on Recorder CRT
equipment Bearing, Casing,
Fluid. Gas, Air, Steam
Optical Direct Non Instrument Temp
Pyrometer Contact Screen

Direct Non Furnace, Hot Pipe

Infrared Contact Type Computer CRT Temp
Thermometer

High Tension Lines &

Transformers
Pressure Manometer / Directly Instrument Itself Condenser Vacuum
Kenetometer Connected to
System
Pressure Gauge Directly Instrument Itself Fluid. Gas, Air, Steam
Mounted
Pressure Directly Indicator Fluid. Gas, Air, Steam
Transmitter Mounted Recorder CRT
Flow Orifice Installed inside Indicator, Fluid. Gas, Air, Steam
Venturi Pipe or duct & Recorder, CRT
pr drop across
measured &
converted into
flow
Axial Shift Indicator, Turbine Shaft
Recorder, CRT
Thermal Indicator, Turbine casing &
Expansion Recorder, CRT Rotor
Speed Taco meter Instrument Itself Turbine, Pumps Fans
Stroboscobe Instrument rotor speed in rpm
Hallprobe Screen
Indicator,
Recorder, CRT
Vibration Vibration Pickup Directly Indicator, Turbine, Pumps, Fans,
Mounted on Recorder, CRT Generators

39
 equipments
Bearings

Flame Flame Scanners

Intensity Discremenating Directly Intensity Meter Oil Gun Flame
Type Mounted
Cooled by air

Fire Ball Directly Intensity Meter Coal Flame

Scanners Mounted
Cooled by air
Level Float Float mounted Scale Gauge Fuel oil, DM water,
inside Tank Mounted at tank Condensate storage
tanks
Level Indicator Connected Seen physically All Tanks
across Impulse (Glass Tube)
lines

Dial Gauge Mounted at top Instrument Itself Main & Control

tank, works on (FRF) oil tank
the principle of
float
displacement

Sonarprobe Mounted at Indicator, Lube & Governing oil

opposite sides Recorder, CRT tanks
of tank
Hydrastep Connected Indicator, Boiler Drum & High
across Impulse Recorder, CRT Pressure Heaters
lines. Works
on the
principle of
density
difference

REFERENCES

40
 “Fuel Firing System”, NTPC Singrauli, 500MW Unit, Stage II, Instruction Manual, BHEL

 “Automatic Turbine Run UP System”, Operation And Maintenance Manual vol.1, KWU

 “Control & Instrument Package”, NTPC Singrauli 2*500 MW Stage II, Operation and
Maintenance Manual, vol. XIV

 “Boiler 500 MW”, Operation and Maintenance Manual, vol.1

 “Turbine 500 MW”, Operation and Maintenance Manual, vol.1

 “Generator 500 MW”, Operation and Maintenance Manual, vol.1

 “Turbine & Generator Set”, Singrauli Power Station, Instrumentation & Control Manual,
vol. 1, KWU

 “Electro hydraulic Turbine Control”, Singrauli Power Station, Control & Instrument
Package manual, vol. 3

 “Advances in Power Station construction”, Pergamon Press, 1988

 “Large Power Steam Turbines Operation” vol. 1&2, Pennwell Publishing Company
Tulsa, Oklahoma

 “Modern Power plant Engineering”, Prentice Hall of India, 1997

41