GENERATOR

CONTROL
&
INSTRUMENTATION
Gyanendra Sharma
 CAPACITY AND RANGES

• THW GENERATORS 200/210/235 MW

• THRI GENERATORS 210/250 MW
• TARI GENERATORS 80MW TO 150MW ( APPROX)
• THDF GENERATORS 500 / 660MW

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 TECHNICAL DATA

RATED OUTPUT 588 MVA/500 MW

TERMINAL VOLTAGE 21 KV

RATED STATOR CURRENT 16166 AMP.

RATED POWER FACTOR 0.85

RATED HYDROGEN PRESSURE 3.5 BAR(g)

RATED EXCITATION 4040 A / 340 V

SHORT CIRCUIT RATIO 0.48

GENERATOR EFFICIENCY 98.64 %

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 GENERATOR SYSTEMS(500MW M/Cs)

• GENERATOR INSTRUMENTATION
• EXCITER INSTRUMENTATION
• GENERATOR SEAL OIL SYSTEM
• GENERATOR PW COOLING SYSTEM
• GENERATOR GAS SYSTEM
• GENERATOR WASTE GAS SYSTEM
• GENERATOR WASTE FLUID SYSTEM

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 C&I FUNCTIONS

• MEASUREMENT / MONITORING
• CONTROLS
• ALARMING
• PROTECTION
• DIAGNOSTICS

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 MEASUREMENT CIRCUITS

• SEAL OIL PRESSURE

• H2 PRESSURE (CASING / MANIFOLD)
• SEAL OIL / H2 DIFF PR.(TE/EE)
• SEAL OIL INLET TEMP
• H2 PURITY IN AIR ( THERMAL
CONDUCTIVITY BASED)
• H2 PURITY IN CO2 (DURING FILL/PURGE)
• CO2 IN AIR ( DURING FILL/PURGE)

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 MEASURING CIRCUITS - Continued

• PW CONDUCTIVITY AFTER FILTER

• PW CONDUCTIVITY AFT. ION EXCHANGER
• PRIMARY WATER FLOW THRU WDGs.
• PW FLOW THROUGH R,S,T BUSHINGS
• PW TEMP AT INLET TO WDGs
• DP ACROSS STATOR WDGs
• STATOR WDG TEMP
• STATOR CORE TEMP

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 MEASURING CIRCUITS - Continued

• BEARING VIBRATIONS IN X,Y PLANES

• SHAFT VIBRATIONS IN X,Y PLANES
• BEARINGS TEMP
• H2 PURITY ( DENSITY BASED)
• PW TANK LEVEL
• COLD GAS TEMP
• HOT GAS TEMP
• EXCITER HOT AIR TEMP
• DP AMONG PW / COLD GAS TEMP
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 MONITORING CIRCUITS

• GEN TERMINAL BOX LIQUID LEVEL

MONIROTING
• SEAL OIL LEVEL MONITORING IN TANKS
• OIL LEVEL IN PRECHAMBERS
• PW TANK PRESSURE MONITORING
• MCBs MONITORING
• H2 PRESSURE AT MANIFOLD
• ALKALISER DOSING TANK LEVEL
• FLOW THRU BYPASS FOR DOSING

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 CONTROL CIRCUITS

• AC SEAL OIL PUMP-1,2 (AIR SIDE)

• DC SEAL OIL PUMP -3 (AIR SIDE)
• AC SEAL OIL PUMP (H2 SIDE)
• BEARING CHAMBR EX.BLOWER-1,2
• CO2 VAPOURISER
• PRIMARY WATER PUMP-1,2
• GAS DRIER HEATER & BLOWER
• EXCITER ANTICONDENSATION HEATERS &
BLOWER
- Continued
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 CONTROL CIRCUITS - Continued

• COLD GAS TEMP CONTROL

• PRIMARY WATER TEMP CONTROL
• ALKALISER DOSING

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 ALARMING

• LOCAL ALARMS
• UCB WINDOW ALARMS
• CRT ALARMS

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 GENERATOR PROTECTIONS

• ELECREICAL PROTECTIONS
• GENERATOR MECHANICAL PROTECTIONS

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 GEN . ELECTRICAL PROTECTIONS

• DIFFERENTIAL ( 0.2-0.4 In, t < 60ms)

• STATOR EARTH FAULT (t< 1s , I <15A)
• ROTOR EARTH FAULT ( 2 STAGE)
• UNDER EXCITATION
• OVER CURRENT ( 1.3 In, 6-8 S max) { additional as
inverse time lag impedance based)
• LOAD IMBALANCE PROTECTION ( 2 STAGE)
• RISE-IN VOLTAGE (Instant trip at 1.45 Un , delayed trip
for low rise till 1.2 Un)
• UNDER FREQUENCY PROTECTION
• REVERSE POWER (50-80% of reverse power, 20-4 s dly)
• OVER VOLATGE (surge arrestors, 1.2-1.4Un, power freq
spark over voltage 2*Un,impulse
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 GEN . MECHANICAL PROTECTIONS

• PW FLOW THRU STATOR WDGs EMERGENCY LOW

• PW FLOW THRU TERMINAL BUSHING “R”
• PW FLOW THRU TERMINAL BUSHING “S”
• PW FLOW THRU TERMINAL BUSHING “T”
• PW TEMP AFTER COOLERS EMERGENCY HIGH
• COLD GAS TEMPERATURE EMEREGENCY HIGH
• LIQUID IN TERMINAL BUSHINGS
• SEAL OIL TEMPERATURE EMERGENCY HIGH
• EXCITER HOT AIR TEMPERATURE EMERGENCY HIGH

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 TYPICAL DOCUMENTS FOR C&I

• LIST OF FEEDER LOADS

• OVERALL GENERAL ARRANGEMENT
• CABLING DIAGRAM
• MEASURING POINTS LIST
• LIST OF JBs / LIST OF ALARMS
• SCHEMATICS
• LOGIC DIAGRAMS
• LIST OF INDICATORS/RECORDERS
• MANFR. DOCU/ O&M MANUALS
• CONSOLE INSERT

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 CONTROL CABINETS ….
 DC SEAL OIL STARTING CABINET
 GENERATOR INSTR. CABINET
 ANNUNCIATION CABINET
 GAS ANALYSER CABINET
(THERMAL/DENSITY PRINCIPLE)
 GAMP (FROM EDN)
 RESISTANNE BOX FOR DC S.OIL
MOTOR
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 NEW PLATEFORM FOR C&I

MAX1000+PLUS
(ALSO CALLED MAXDNA)

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EXCITATION SYSTEM

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 MAIN COMPONENTS OF EX. SYSTEM
• PILOT EXCITER
• BRUSHLESS EXCITER
• ROTATING DIODES AND FUSES
• RC CIRCUITS
• QUADRATURE AXIS COILS
• CJN CABINETS (THYRISIEM 03-4)
• AVR ( 1 AUTO + 1 MANUAL)
• ROTOR TEMP MEAS. THRU INDIRECT
METHOD
• CONSOLE INSERT AT CONTROL DSK
• DIODES/ FUSE MONITORING
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DIAGNOSTIC SLIDE 1/ 05.09.2001
 DIAGNOSTIC FEATURES
• FLOW MONITORING THRU INDIVIDUAL
STATOR BARS
• DEW POINT BEFORE / AFTER GAS DRIER
• ON LINE PARTIAL DISCHARGE
• RF MONITOR
• GEN END WDG VIBRATIONS DETECTION
• GEN CONDITION MONITORING
• TEMP RISE CHECKING WITH TAGGING
COMPUNDS
• GBM
• SHAFT TORSONAL MONITORING
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 HYDROGEN PURITY
MEASURING SYSTEM
* GENERATORS USE H2 FOR COOLING
THEREBY IMPROVES OPERATING EFFICIENCY

* CONTAMINATION OF H2 BY OIL VAPOUR ,

WATER OR AIR INCREASE THE WINDAGE
LOSSES

* 1% REDUCTION IN H2 PURITY CREATES A 12

% INCREASE IN WINDAGE LOSSES

* H2 MAKES AN EXPLOSIVE MIXTURE WITH

AIR BETWEEN 4 TO 74 % BY VOLUME
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 HYDROGEN PURITY
MEASURING SYSTEM
MEASURING PRINCIPLE :

Difference in thermal conductivity of various

gases used as the parameter to measure
purity. Instrument is microprocessor based .

MEASURING RANGES :

1. 0-100 VOL % CO2 IN AIR

2. 100-0 VOL% H2 IN CO2
3. 100-80 / 90 VOL% H2 IN AIR

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 H2 PURITY MEASURING SYSTEM
TECHNICAL DATA :

A. ANALYSER :
MICROPROCESSOR BASED
MEASURING RANGES :
1. 0-100 VOL % CO2 IN AIR
2. 100-0 VOL% H2 IN CO2
3. 100-90 VOL% H2 IN AIR
POWER SUPPLY : 220 V AC , + 15%,-20%, 50 HZ
PROTECTION : FLAME PROOF
REPEATABILITY : < 1% OF SPAN
LINEAR DEVIATION < 2% OF SPAN
AMBIENT : +5C TO 50C
ZERO DRIFT < 2% PER WEEK
TEMP EFFECT < 0.5% OF SPAN / 10C
OUTPUT 4 TO 20 MILI AMP

B. ANALYSIS PANEL :
1200 MM(W) X 800 M(D) X 2100MM(H)

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 H2 PURITY MEASURING SYSTEM
LEGENDS :

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 H2 PURITY MEASURING SYSTEM
INTERCONNECTIONS WITH OTHER SYSTEMS :

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 H2 PURITY MEASURING SYSTEM
GENERAL ARRANGEMENT DRAWING :

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 H2 PURITY MEASURING SYSTEM
GA DRAWING INTERNAL DETAILS :

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 SCHEMATIC DIAGRAM
( DENSITY BASED H2 ANALYSER)

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 DIFERENT LOGIC DIAGRAMS
FOR GEN

• PW COOLING
• SEAL OIL SYSTEM
• GAS DRYING
• BEARING EXHAUST BLOWERS
• EXCITER ANTICONDENSATION HEATERS
• GENERATOR MECHANICAL PROTECTIONS
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 Plant information network
ENGINEER’S
STATION

MAXSTATIONS

Redundant 100 Mbps MAXNET

MAXLINK

FIBRE OPTIC
LINK
REMOTE PROESSING UNITS
PLANT SUB-SYSTEMS

REMOTE I/O

TYPICAL CONFIGURATION DIAGRAM

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 BRIEF BACKGROUND
•OFFSHOOT OF L&N
•5 BILLION EURO COMPANY
•BASE LANDALE,PENNISLYANIA
•70% AUOTAMTION BUSINESS IN CHINA
•STARTED WITH TOKEN PASSING- MAX1 SYSTEM
•NEXT VERSION 585 OP. STN STILL SUPPORTED
• EVOLUTION OF MAX100,MAX1000 % NOW ...
•RELEASE E CHANGED TOKEN PASSING TO
ETHERNET
 - CONTINUED
•IN ETHERNET PROTOCOL,PACKETS ARE
BROADCASTED WITHOUT NEEDING
PERMISSIONS.
•IN EVENT OF COLLISIONS,PACKETS ARE
RETRANSMITTED
•MAX1000++ (ALSO CALLED CHICAGO
RELEASE) HAS BEEN SUPPLIED IN BASIN
BRIDGE PROJECT IN T.N.
•TEL AVIV RELEASE BASED ON WINDOW
NT PLATEFORM WAS NAMED
MAX1000+PLUS.
 -CONTINUED
•32 BIT CONTROLLER
•100 MBPS SPEED DATA HIGHWAY
•COMMON ENGINEERING STATION FOR CONTROLS
AND HMI
•AS BUILT DOCUMENTATION DIRECTLY FROM
PROCESS
•CENTRALISED DOWN LOADING CAPABILITY
•HIGHER LEVEL DIAGONSTICS
•REDUNDANT “I/O” CONFIGURATIONS
•BUILT-IN 1 MILLI SECOND SOE FOR ALL DIGITAL
INPUTS. HENCE,NO EXTERNAL SOE NEEDED
 MAXSTATION
• True open system architecture
• Seamless communications with
plant and business networks
• Scaleable from small process
applications to complete plant
control
• On-line graphic monitoring
• On-line Self-documenting
configuration
• Ultra high speed graphic
building and display updates
• Centralised Engineering
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capability
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 Windows NT

• Standard Operating System for all

MAXSTATIONS
• Largest base of software applications
• Strongest standards for compatibility
• High reliability and security
• Easily upgraded
• Latest intuitive windows interface for easy
operator training and use
• Currently Microsoft Windows NT 4.0
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ELEMENTS OF CONTROL SYSTEM

• I/O MODULES
•DATA PROCESS. UNIT ( DPU4E)
•NETWORK SWITCHES
•FIBRE OPTIC 100MBPS CABLES
•10MBPS COAXIAL CABLES
•POWER SUPPLIES
•MAXSTATIONS
 I/O MODULES (MAXPAC SERIES)
• 16 DISCRETE INPUTS FOR BIN. SIGNALS ( COMMON/ISOLATED)
• 16 DISCRETE ANALOG INPUTS (4-20MA,0-2.5VDC)
(ISOLATED/COMMON)
• 16 THERMOCOUPLE/MV ANALOG INPUTS
• 8 RTD INPUTS ( 3 WIRE TYPES ONLY)
• 4 CHANNEL POSITION OUTPUT TYPE (QPAT)
• 16 DISCRETE BINARY OUTPUTS
• 8 CHANNEL ANALOG OUTPUTS ( 4-20MA)
• 16 CHANNEL FORM-A (NO) RELAY OUTPUTS
• 10 CHANNEL FORM-C (COC) RELAY OUTPUTS
• HEAVY DUTY RELAY OUTPUT 10A INDUCTIVE LOAD RATING
• OPTICAL BUS EXTN. MODULES (SUPPORTS 60 I/OS UPTO 100M)
•KIT WITH 16 100 OHMS RESISTORS
 REDUNDANCIES
•DPUs MAY BE MADE REDUNDANT
•I/O MODULES -REDUNDANT,SHARED OR
COMBINATION OF THE TWO
•REMOTE PSUs ARE USUALLY MADE REDUNDANT
•MAXNET (NTWORK A/B) IS ALWAYS REDUNDANT
•MAXLINKS MAY BE MADE REDUNDANT
MAXSTATION SOFTWARES
•MAXTOOLS4E CONFIGURATOR
•MAXVUE EDITOR
•MAXVUE RUNTIME
•SOFTWARE BACKPLANE
•WINDOW NT
•WONDOW CE
•DONGLE HARDWARE SWITCH
 MAXSTORIAN
• Historical Data Collection and
Archiving Software for
MAXSTATION
• “Delta-Save” data storage
maximizes system data capacity
• Relational database to simplify
reports and queries for data analysis
• Archival storage to CD-ROM
• Supports interface to plant-
management networks
• Windows-NT based

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 MAXLINK
• Interface to external
MAXNet
systems:PLC networks (Coal
Handling Plant, Ash Handling
Plant etc.)
• Supports multiple simultaneous
communication protocols
• Supports data transfer from
other systems and networks
Plant Sub-Systems • All data available to
MAXSTATIONS
• Windows-NT based
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• Software
500 MW TurbogeneratorBackplane
C&I
®
compatible
59
MAXNET Communications Network

• Proven Industry Standard, Switched Fast Eathernet

• Ultra high speed (100 Mbps) redundant network
• Multiple simultaneous communication
• Utilises intelligent switching
• No collisions occur. Traffic is never stopped
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 Inter-Hub Communications
Full Duplex Switched Hub Full Duplex Switched Hub

100 Megabits per Second

Full Duplex

• All standard communication media supported -

Fiber optic and Others
• Future Gigabit and high communications rates

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 Switched Ethernet
• Multiple simultaneous conversations
• Full-Duplex communications between switched hubs
• Similar to telephone system

Switch 1 Switch 2

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 Network Domains
MAXSTATIONS MAXSTATION

Switched
Hub

RPUs RPU
MAXSERVER
• Global access of data for data acquisition and control
• Separates discrete sections of DCS - e.g. plant units
• Provides security and assures performance
• Simplifies maintenance
• Allows integration of other systems
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 Distributed Processing Unit
• 32 Bit Intel Processor
• Windows CE Operating System.
Supports off-line simulation and testing
• Open architecture
• Uses MAXNET Ethernet Data Highway
• Object-Oriented Configuration
• Rack Mounted
• 8 MB flash RAM, 32 MB SDRAM
• Modulating Control, Logic, Data
Acquisition
• Event Reporting to 1 msec Resolution

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 DPU 4E Redundancy

• Primary and secondary are selected through

configuration
• Fatal diagnostic error causes transfer in <3 msec
• Secondary DPU configuration can be modified
and transfer initiated for testing purposes
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 I/O Redundancy
I/O Can be Redundant ...

I/O I/O

I/O I/O

I/O I/O ... And Shared

Redundant
DPU Bus
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 Software Backplane
Software Backplane

• Connects applications clients with providers

of data
• Very high performance
• Simple - READ / Write / Register /
Subscribe
• Network Independent
• Operating System Independent
• Revision Independent
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 Full Duplex Communications

MAXSTATIONS • Effectively doubles

the communications
Switched Hub bandwidth
Switched Hub • One DPU can send
alarm information
while another is
DPUs
receiving operator
commands
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 REMOTE PROCESSING UNIT
•EACH DPU SUPPORTS 60 MODULES WITH MAX 32
DIGITAL INPUTS/OUTPUTS
•254 ADDRESSES PER DPU
•0-31 ADDRESSES FOR DIGITAL MODULES
•32-254 ADDRESSES FOR ANALOG MODULES
•EACH ANALOG MODULE CONSUMES 2 ADDRS
•DPU IS PLACED IN TOP OF RACK (BELOW PSUs)
•DPU TAKES 2 SLOTS OUT OF 8 AVAILABLE IN RACK
•6 RACKS FOR MODULES CAN COME IN ONE PANEL
•IN DOUBLE WIDTH PANELS,MARSHALLING IS DONE
FROM REAR SIDE.
•THE PLUG-IN CONNECTIONS DIRECTLY COME ON
MODULES
 OLE OBJECTS
•BUTTON CONTROL
•BAR CHART CONTROL
•SINGLE POINT VALUE CONTROL
•LIST CONTROL
•TIME/STATE CONTROL
•TREND (CORE/WRAPPER TREND)
CONTROL
•ALARM/LIST CONTROL
•TEXT/STATE CONTROL
•MAXSCRIPT CONTROL
•SBP WRAPPER CALCULATIONS
 FUNCTION BLOCKS
•AIB / DIB
•AOB/DOB
•RTD / TC
•PLSIO / QPAT
•ATAG / DTAG
•QUALFRCE /FLIPFLOPS / TRIGGER
•AND /OR / EQ / XOR / NOT /CMPARE
•PACK / UNPACK
•FSTOUT/ TON / TOFF /TPUSLE
•DEVLOG /SEQMSTR /STEPSEQ/SIGSEL
/FUNGEN / LEADLAG
 ALARM ANNUNCIATOR
•MAX. 2 STATIONS TO BE CONFIGURED
•SOUND FROM WAVE FILES
•SOUND MAY ALSO BE FROM EXT.HOOTER
•SILENCE FROM ANY MAXSTATION
•SYSTEM DIAGNOSTICS ALARM
•PROCESS ALARMS
•ALARM SUMMARY,ALARM LIST
•ALL ISA SEQ NOT SUPPORTED INCL. RING BACK
•AUTO RESET OF ALARMS
 STEPS FOR SYSTEM BUILDUP

• SELECT HARDWARE CONFIGURATION LIKE NO. OF DPUs,

I/Os,SWITCHES, LINKS, MAXSTATIONS FOR EACH DOMAIN
•PREPARE FUNCTIONAL DIAGRAMS THRU FBs, CUSTOM BLOCKS
BASED ON LOGIC DIAGRAMS
•DOWNLOAD THE CONFIGURATION IN VITUAL DPU
•OBSERVE SIMULATED PERFORMANCE
•MAKE CORRECTIONS
•UPLOAD THE FINAL CONFIGURATION
•EXPORT TO AUTOCAD FOR USER FRIENDLY PRINTS
•CREATE HMI THRU MAXVUE EDITOR USING VECTOR / RASTOR
TOOLS & OLE OBJECTS.
•TEST MIMICS OFFLINE THROUGH TEST BUTTON
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 MEASURING POINTS LIST
CONTENTS
 TAG NUMBERS
 SERVICE
 PID REFERENCE
 RANGE / UNIT
 INSTRUMENT TYPE
 OPERATING VALUE
 MOUNTING LOCATN.
 JUNCTION BOX NO.
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 SIGNAL / TYPE
 CABINET CODE
 IND./RECORDER
 ANNUN LOCATION
 DDCMIS REQ.
 SET POINT/CODE
 BINARY CONTROL
 VALUE/CODE
75
Types of Excitation Systems
• High Frequency Excitation system
•Static Excitation System
•Hybrid AVR type Excitation system
•Brushless Excitation System
•SEE with Digital AVR
Design Features of Excitation
System
• Fast response for better stability
•Inertia free control of power electronics
•Facility for manual operation
•Bumpless transfer from auto to manual
•Minimum power drainage
•High MTBF
Objectives of Excitation System
•Good response in voltage and reactive
power control
•Satisfactory steady state and dynamic
stability
•Transient stability for all stated conditions
•Quick voltage recovery after fault clearance
 Technical Particulars for
Excitation System
•Range of voltage control in Auto 90-110% Un
•Frequency range of operation Fn +-5%
•Transformer drop /droop compensation: upto
15%
•Maximum change in Gen Voltage during
changeover from auto to manual : 1%
•Range of exciation control in manual: 0-110% I fn
•Accuracy of voltage control : +/- 0.5% Un
 Main subassemblies of SEE
•Rectifier transformer
•Thyristor bridges
•Control electronics
•Field flashing
•Field Suppression
•Over voltage protection
•Digital AVR
•Digital Limiters
 Main subassemblies of B’less
Ex. system
•Rectifier transformer
•Thyristor bridges
•Control electronics
•Field Suppression
•Digital AVR
•Digital Limiters
 Limiter Functions
•Field current limitation
•Stator current limitation ( for both leading and
lagging stator current)
•Load angle limitation
•Power system stabiliser
 Main subassemblies of B’less
Ex. system
•Rectifier transformer
•Thyristor bridges
•Control electronics
•Field Suppression
•Digital AVR
•Digital Limiters
Excitation System Monitoring

•Actual values signals for Gen voltage

& current
•Voltage reference for excitation
build-up circuit
•V/f monitoring
•Pulses monitoring
 Protection & Monitoring in
Excitation System
•Excitation transformer over current protection
•Rectifier transformer temp monitoring
•Thy. Bridges over current protection
•Thyristors Hole storage protection ( dv/dt)
•Protection against high inrush current to
Thyristors
•Air flow monitoring
•Field over voltage protection
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