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Plant Control, Operation & Monitoring
Plant Control, Operation & Monitoring
INDEX
In this part we shall explain the PART E i.e. Instrument air system.
Operation & Control of equipment related to silo unloading system have been dealt
here sequentially. Following are the equipments associated with the instrument air
system.
1. Instrument Air Compressors
2. Air Drying Plants
D) Associated documents:
The System
1.1.0 The Instrument Air System comprises Instrument Air Compressors (IAC), air drying
plants (ADP) and Air receiver along with all necessary instruments and accessories to
cater to the instrument air requirement for operation of various pneumatic equipment
under the ash handling system including bag filter pulse jetting & silo system.
1.2.0 Three nos instrument air compressors (two nos working and one no stand by) and
Three sets (two nos working and one no stand by) of Air drying plants are provided for
Units # 4 & 5. Besides instrument air requirement for unit wise devices/equipment,
instrument air requirement for common water & slurry system as well as silo area
devices/equipment are also provided by these I.A compressors. These three nos
instrument air compressor and three sets of Air drying plant are located in the
equipment building. Three nos. Air receivers are placed adjacent to this building.
2.0.0 CONTROL DEVICES & LOCATION
Please clarify the parameter to be A PRESET TIME FROMOPENING OF COOLING WATER VALVE
used as the interlock to signify AIR TEMP NORMAL AT INTER COOLER
that the compressor is in
unloaded condition.
COMPRESSOR IS IN UNLOAD CONDITION
COOLING WATER PRESSURE AT INLET OF CYLINDER JACKET IS NORMAL
* RUNNING INSTRUMENT AIR COMPRESSOR IS TRIPPED
(FOR IA COMPRESSOR IN AUTO WAITING MODE)
DIFFERENTIAL PRESSURE ACROSS SUCTION FILTER IS NORMAL
TRIP CONDITIONS
3.2.3 Operation:
3.2.3.1 Out of three (03) Instrument air compressors provided for two units, two nos. would be
normally working and one will be as standby in Auto mode. However in manual mode,
all the compressors can be operated simultaneously in parallel. In auto mode of
operation, the standby compressor will take start in the event of tripping of the running
compressor subject to availability of all starting permissives non-availability of trip
conditions.
3.2.3.2 At first operator will start the selected compressor in manual mode, then keep the
selector in auto standby mode for the compressor to be brought in auto standby mode.
3.2.3.3 With actuation of start command, at first solenoid-operated valve on cooling water
supply line will automatically open and subsequently cooling water supply line pressure
will be established. The cooling water source is provided from purchaser’s cooling water
header.
3.2.3.4 After starting, the compressor will continue to run if the lubricating oil pressure becomes
normal within a preset time.
3.2.3.5 The compressor will always remain unloaded during starting. It will start getting loaded
after a preset time (adjustable) form the starting of the motor. Under “Load-unload”
regulation, the drive motor will run continuously.
3.2.3.6 When the air-receiver pressure goes below the lower set value sensed by the pressure
transmitter, a solenoid valve on the pulse air line (from air-receiver) gets energised and
the pulse air supply to the compressor cylinder suction valves is cut-off. The
compressor thereby runs at loaded condition.
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3.2.3.7 Similarly when the air-receiver pressure reaches the higher set value sensed by the
same pressure transmitter, the solenoid valve gets de-energised and the pulse air
supply (from air receiver) keeps the compressor cylinder suction valves open. The
compressor thereby runs at unloaded condition.
3.2.3.9 In auto mode operation, if any one compressor trips, then compressor kept in stand by
mode will start automatically subject to availability of all starting permissives. Under this
condition, manual intervention is required for rectification of tripped compressor. Once
tripped compressor is ready for operation, one should change a Auto Standby-selection
is put on that compressor and this compressor shall become Auto stand by compressor.
[ The auto start command will be withdrawn after a short time of it’s initiation or it will be
withdrawn with the run feed back of the respective drive, whichever happens earlier ]
Keeping selection in manual position, any or all the four compressors can be
started through their respective START push button on HMI.
3.2.3.10 Solenoid operated auto drain trap with in built cyclic timer will be provided with inter
cooler and after cooler for periodic draining of accumulated water.
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3.3.2 There are three (03) nos. Regenerative heated type blower reactivated air drying plant
(ADP) for all the units, out of which three nos. ADP are in operation during running of
three nos. instrument air compressors. One ADP is dedicated to one IA compressor.
The advantage of this dryer is no purge loss and air is available for use continuously.
Please refer the P&I diagram along with this write-up for better understanding. The
Principle of Operation is as Follows:-
3.3.3.1 (A) Tower 1 Drying & Tower 2 regenerating :- (0 – 8 Hrs.)
0- 8 hours - The saturated air flows through the pre-filter (3), the solid particles are
removed, enters into the drying tower 1 through the main three way valve (13) and
leaves through the top left check valve (36) and through the after filter (4) to utility.
0 – 10 min – The right side de-pressurization valve (38), opens and gradually vents out
the pressurized air from tower 2 to atmosphere through the silencer. This operation
avoids sudden exhaust of the tower and safe guard the desiccant from attrition losses.
10 min – 7 hr 20 min - The blower (07) starts and the air from the blower enters into the
heating chamber (05), gets heated to 180 Deg.C leaves the heater, enters through the
bottom right side (36) check valve into the tower 2 from top to bottom, regenerates the
saturated desiccant and leaves through the right side regeneration valve (15). The
regeneration valve is in open condition from 10 min to 7 hr 40 min. The heater is in
operation from 12 min to 5 hr 12 min. During this period the temperature controller
controls the heating temperature from 175 to 180 Deg.C.
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7 hr 20 min – 8 hr – The re-pressurization valve (17) opens and feeds dry air from tower
1 to tower 2. The first 20 minutes of 40 minutes, the dry air purges out the tower 2 and
leaves through right side regeneration valve (15). During the second 20 minutes, the
regeneration valve (15) closes and the dry air re-pressurizes the tower 2 to full operating
pressure.
Summary of valves & other critical components Conditions:-
8 hr 10 min – 15 hr 20 min - The blower (07) starts and the air from the blower enters
into the heating chamber (05), gets heated to 180 Deg.C leaves the heater, enters
through the bottom left side (36) check valve into the tower 1 from top to bottom,
regenerates the saturated desiccant and leaves through the left side regeneration valve
(15). The regeneration valve is in open condition from 8 hr10 min to 15 hr 40 min. The
heater is in operation from 8 hr12 min to 13 hr 12 min. During this period the
temperature controller controls the heating temperature from 175 to 180 Deg.C.
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15 hr 20 min – 16 hr – The re-pressurization valve (17) opens and feeds dry air from
tower 2 to tower 1. The first 20 minutes of 40 minutes, the dry air purges out the tower 1
and leaves through right side regeneration valve (15). During the second 20 minutes,
the regeneration valve (15) closes and the dry air re-pressurizes the tower 1 to full
operating pressure.
Summary of valves & other critical components Conditions:-
- 3 way main valve - 8 – 16 hrs.in ‘energized’
- Regeneration Valve (left side) - 8 hr10 min – 15hr40min ‘energized’
- Regeneration Valve (right side) - 8hr – 16 hr ‘De-energized’.
- Heater - 8hr12 min – 13 hr 12 min ‘energized’
- Blower - 8hr10 min – 15 hr 20 min ‘energized’
- De-pressurization Valve (left side) - 8hr – 8hr10min ‘energized’
- De-pressurization Valve (rt side) - 8hr – 16hr ‘De-energized’
- Re-pressurization Valve - 15 hr 20 min – 16 hr ‘energized’
3.2.4 Associated Control Item Nomenclature
SL. NO. ITEM TAG
1 3-Way automatic inlet changeover valve ADP*ICVSO
2 2-Way automatic exhaust changeover valve ADP*ECV*SO
3 2-Way depressurization valve ADP*DPV*SO
4 2-Way re-pressurization valve ADP*RPVSO
5 Pre-filter auto drain trap ADP*ADT*SO
6 Regeneration line flow switch ADP*FS
7 Temperature controller ADP*TIC
8 Discharge pressure Transmitter ADP*PTL
Read 1st * for ADP A / B / C and 2nd * for valve 1 / 2
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DIFFERENTIAL DIFFERENTIAL
PRESSURE ACROSS PRESSURE
SUCTION FILTER ACROSS SUCTION
FILTER HIGH
BLOWER-1 / TRIP
BLOWER-2
SELECTION FACILITY
ADP
REGENERATION
AIR FLOW LOW
ADP CHANGEOVER
FAILURE
NOTE: