GSRC On-Site Training - APS

AUTOMATIC PLANT START-UP
& SHUTDOWN SYSTEM (APS)

GULF SRC COMPANY LIMITED
SRIRACHA POWER PLANT PROJECT
Contents
1. BASIC CONCEPT OF APS
2. BASIC BLOCKS OF APS
3. EXTENT OF AUTOMATION PERFORMED BY THE APS
4. OPERATION OF APS
© 2020 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved. 2
1. BASIC CONCEPT OF APS
3
Basic Concept of APS
 The Automatic Plant Startup & Shutdown(APS) function has been designed to perform the
plant startup and shutdown for the Gas Turbine (GT), Steam Turbine (ST) and Heat Recovery
Steam Generator (HRSG) within suitable plant conditions.
 The APS controls plant start‐up and shut‐down within a narrow error margin.
 Startup : GT / ST / HRSG start‐up according to ST initial conditions (cold/warm/hot) to APS min load setting.
 Shutdown : Load down from full load combined cycle operation to safe shut down condition.
The APS reduces operator work load, during these busy periods of operating cycle. It closely controls the
plant operation reducing the chances of deviating from design conditions.
The APS provides normal, economical plant start‐up and shut‐down on demand by controlling the plant
as close as possible to design parameters.
Safe operation of the plant is provided by during the most stressful part of the plant operating cycle by
monitoring all plant conditions, without delay, avoiding potential trip conditions.
Main plant & equipment is controlled automatically by APS so operator is free to monitor plant
operating conditions.
Plant Control Hierarchical Structure
 Power plant automation is implemented with the below control hierarchical structure
Top Level
APS
GROUP /
SEQ LOGIC
Middle Level
SUB GROUP
LOGIC
DRIVE LEVEL LOGIC 1st Level
Interlock protection system is provided independent of above control hierarchy in order to safely
shutdown the plant in case of any Emergency.
Plant Control Group Structure
DRIVE LEVEL
SUB GROUP
GROUP APS
SELECTION
APS Basic Configuration
Plant BOP/HRSG Control System (PCS)
Drive Level Logic APS APR

(Start‐up/Shut‐down Control
Group Break Point Program)
Level Logic
FIELD CONTROL STATION
OPC
Communication Vnet/IP
Turbine Control Plant Common
System (TCS) Control System (PCCS)
DATA WAY CONTROLLER FIELD CONTROL STATION
TURBINE Group
Start/Stop Level Logic
Sequence
Drive Level Logic Drive Level Logic
ACTUATOR
2. BASIC BLOCKS OF APS
8
Basic Block of APS
 Basic building Blocks of GSRC Power Plant Automatic Plant Sequence are as below :
 Mode Selection Logic :
 Operator has to press the set of Push Buttons as per the required plant
operation to enable the automatic plant start-up or shutdown sequence.
 APS Start-up operation:
 APS Shutdown operation:
Basic Block of APS
 Break Point
 APS Start‐up is divided into several Break Points (BP) which represents the main
milestones in the sequence.
 APS program will monitor the Permissive Conditions for each break point and output
the necessary command to PCCS, PCS & TCS. It also monitors the progress of each
break point until completion.
 The break point sequence will progress according to the selected pattern based upon
the required plant operation after the APS sequence completion.
 After the completion of each BP, the next BP starts automatically in case of Full Auto
Mode (or) after the operator intervention in case of Semi Auto Mode.
APS Control Mode
 Based on the Plant Operating Condition, the operator has to select the APS Control Mode as
below :
 Full Auto mode:
If Full Auto Mode is selected, the start‐up or shut‐down sequence proceeds from the
first Breakpoint to the final Breakpoint without operator’s intervention
 Semi Auto mode:
If Semi Auto Mode is selected, the start‐up or shut‐down sequence proceeds from one
Breakpoint to the next Breakpoint after confirmation by the operator.
Plant Startup: Fuel selection
 Operator has to select Operating Fuel as below before Plant Start‐up :
 Gas Mode :
If Gas Mode is selected, the APS ensures the readiness of the Fuel Gas System before
starting the Unit Preparation Break point.
 Oil Mode :
If Oil Mode is selected, the APS ensures the readiness of the Fuel Oil System before
starting the Unit Preparation Break point.
Break Point Activation
 Activated by automatic signal from APS.

 Used with the Step Sequence Macro Function Logic. When BP is activated,
associated Step Logic starts to progress according to the startup or shutdown
program.
BREAKPOINT SERVICE NAME/TAG.NO
START‐UP ABN LAMP INDICATION
START PB / LAMP INDICATION (ABN OCCURED : ORANGE)
(IN PROGRESS : RED FLICKER) ABN RESET PB / LAMP INDICATION
BREAKPOINT TARGET LAMP INDICATION (RESET AVAILABLE : CYAN)
(ESTABLISHED : BLUE) AUTO CONDITION LAMP INDICATION
(ESTABLISHED : CYAN)
AUTO CONDITION BYPASS PB / LAMP INDICATION
(BYPASS MODE : WHITE)
GO PB / LAMP INDICATION
(ESTABLISHED : RED)
HOLD PB / LAMP INDICATION PRE OPERATION CONDITION LAMP INDICATION
(ESTABLISHED : GREEN) (ESTABLISHED : CYAN)
PRE OPERATION CONDITION BYPASS PB / LAMP INDICATION
(BYPASS MODE : WHITE)
PERMISSIVE CONDITION LAMP INDICATION
(ESTABLISHED : CYAN)
READY LAMP INDICATION
(READY : CYAN)
COMPLETED LAMP INDICATION
(COMPLETED : RED)
Plant Shut-down
 Operator has to select the shutdown modes as below before plant shut down.
 Normal Shutdown mode :
Normal Shutdown mode is used to load down & shutdown the plant from running
condition to GT shut down to HRSG & Feedwater System Stop. Maintaining the
Condenser Vacuum or breaking based on operator selection.
 Maintenance Shutdown Mode :
Maintenance Shutdown mode is used to load down the plant to a minimum load &
shutdown the plant after ST cooling. The ST rotor is forcibly cooled with the lower steam
temperature.
This mode includes shutting down of Condenser Vacuum, Condensate Water, Circulating
water Systems & finally starting ACW System.
3. EXTENT OF AUTOMATION
PERFORMED BY THE APS
15
Conditions to be established before APS start
 Following condition shall be established before APS put in service
 GT/ST related equipment :
 Turning Gear Motor Running & Gear Engaged (or) L4‐Turbine Master Signal ON
 Emergency Lube Oil Pump in Auto
 Main Lube Oil Pump A (or) B Run & Oil Pressure Established
 Jacking Oil Pump Running & Oil Pressure is Established (or) ST Speed >1500 rpm
 Control Oil Pump A (or) B Run & Oil Pressure Established
 Generator Seal Oil Pump A (or) B Run & Oil Pressure Established
 GT Package Ventilation Fan (2/3) running
 Main Lube Oil Vapor Extractor Fan A (or) B in operation & Tank Pressure Normal
 Lube Oil Purifier Unit in Operation
 Generator related equipment :
 AVR “Auto”
 ASS “Auto”
 Lockout relay “Reset”
Conditions to be established before APS start
 BOP related equipment :
 Circulating Water Pump Pit Level is Normal
 CW Condenser A & B Inlet Isolation Valves are Opened
 Closed Cooling Water Pump in Operation
 Fuel Oil / Fuel Gas System is Ready for Operation
 Instrument Air System in Operation & Air Pressure is Normal
 Fire Protection & Gas Detection System in Operation
 Condenser Hot Well Level is Normal
 Aux Steam Header Temperature & Pressure are Normal
 Cooling Tower Fan Start Command is Issued
 HRSG related equipment
 All HRSG drives & valves in Auto Mode
 Feed Water Group Equipment in Auto Mode
Items out of scope of APS
 Start‐up Preparation & Operation related to periodic inspection will be excluded from scope
of APS
 Start‐up Preparation
 Confirmation of instrument isolation valve and manual valve, etc.
 Turbine Lubrication Oil & Turning Gear operation in service
 Control System Power in service
 Confirmation of water quality
 Initial filling up operation of oil, water and chemical. e.g. Condenser, Drum, Turbine oil,
Chemical filling to chemical injection system
 Operation related to periodic inspection
 Valve operation for maintenance and storage.
 N2 seal operation.
 Acid cleaning operation.
Out Service of APS mode
 When any of the following conditions is established, the APS automation is out of service.
Then, each DCS controller will separate from APS
 GT Trip (or) ST Trip
 Runback Occurred
 APS “OUT” mode is selected
 APS start‐up and/or shut‐down completed
4.OPERATION OF APS
Start‐up operations: Shutdown operations:
 4.1 APS Start‐up operational panel  4.2 APS Shutdown Operational Panel
 4.1.1 APS Start‐up Mode (Cold start)  4.2.1 Normal Stop Mode
 4.1.2 APS Start‐up Mode (Warm/Hot start)  4.2.2 Maintenance Stop Mode
 4.1.3 APS Start‐up Mode (Cold start)  4.2.3 Individual Shutdown Mode
20
APS START UP OPERATION SCREEN
Information to Operator
 Following information is available to operators through APS operation panel on VDU
graphics
 APS progress monitoring of each break points
 Target Break Point in the APS sequence
 Completed conditions of each break points and related sub‐group
 Time over alarm for each Breakpoint
 Permissive conditions for each break point
APS START-UP FLOW (1/2)
APS MODE START UP COMPLETED
(APS MODE OUT)
UNIT PREPARATION BREAK POINT
UNIT PREPARATION BREAK POINT
OUT
AUTO
HOLD HOLD HOLD HOLD HOLD
HRSG/GT PREPARATION BREAK POINT
HRSG/GT PREPARATION BREAK POINT
OUT
AUTO
GT START BREAK POINT
GT START BREAK POINT
OUT
AUTO
GT SYNCHRO BREAK POINT
GT SYNCHRO BREAK POINT
OUT
AUTO
ST START BREAK POINT
ST START BREAK POINT
OUT
AUTO
APS SHUT DOWN FLOW
APS SHUT-DOWN OPERATION SCREEN
TURBINE STOP BREAK POINT
TURBINE STOP BREAK POINT
OUT
HOLD HOLD HOLD
HRSG STOP BREAK POINT
HRSG STOP BREAK POINT
OUT
HOLD HOLD HOLD
UNIT SHUTDOWN BREAK POINT
UNIT SHUTDOWN BREAK POINT
OUT
HOLD HOLD HOLD

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AUTOMATIC PLANT START-UP

& SHUTDOWN SYSTEM (APS)

1. BASIC CONCEPT OF APS

2. BASIC BLOCKS OF APS

3. EXTENT OF AUTOMATION PERFORMED BY THE APS

DRIVE LEVEL LOGIC 1st Level

Drive Level Logic APS APR

 APS Shutdown operation:

 Operator has to select Operating Fuel as below before Plant Start‐up :

 Activated by automatic signal from APS.

 Following condition shall be established before APS put in service

HOLD HOLD HOLD HOLD HOLD

HOLD HOLD HOLD HOLD HOLD

HOLD HOLD HOLD HOLD HOLD

HOLD HOLD HOLD HOLD HOLD

HOLD HOLD HOLD HOLD HOLD

HOLD HOLD HOLD

HOLD HOLD HOLD

HOLD HOLD HOLD

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