TRAINING REPORT

SA.SANTHOSH
SUMMER TRAINEE 2011

SRM UNIVERSITY

CONTROL&INSTRUMENTATIONPROJECT ENGINEERINGMANAGEMENTBHEL,NOIDA

ACKNOWLEDGEMENT
I takethisopportunemomenttoexpressmydeepsenseofgratitudeto Mr.KAMALSHARMA(ENGINEERC&I)forhis unstinted support and encouragement to me. I express my heartfelt thanks to the Department Head Mr. K.R. BHARADWAJ (C&I) and Mr. S.BHATNAGAR (Section Head I01, C&I) for being a source of guidanceandinspirationformeduringthisperiod.Theirwonderfulstyle of mentoring has surely made my training period a great learning experience. I would also like to offer my indebtedness to Mr. Kamal Kumar(ENGINEERC&I)forhiseverwillingnesstoextendtechnical supportthroughoutthisperiod.Iexpressmysincerethankstoallthe membersofC&IDept.fortheirfriendlyandhelpfulattitude. 29.06.11

ABSTRACT
Thepurposeofthisreportistogiveabriefideaaboutwhathas been done in the training. This report comprises of various activities/orientation programmes constituting the training. Broadly,thevariousactivitieswhichmadeapartofourtraining were PEM familiarization, familiarization with work particularlyinC&Iandfinallythedaytodaylearningofthe routineworkinthedepartment.

TABLEOFCONTENTS

ACKNOWLEDGEMENT ABSTRACT
1. About the Company 2. About the Department 3. Role of C&I 4. Overview of power plant 5. P&ID-Introduction 6. KKS Identification Scheme 7. Instrument Schedule

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8. Control System 8.1 Binary Control System 8.1.1 Sequence Control Scheme 9. Conclusion

AboutTheCompany
BHEL isthelargestengineeringandmanufacturingenterpriseinIndiainthe energyrelated/infrastructuresector,today. BHELsvisionistobecomeaworldclassengineeringenterprise,commitedto enhance stakeholder value. The company is striving to give shape to its aspirationsandfulfilltheexpectationasaNavratnaCompany. BHEL manufactures over180products under30major productgroups and caters to core sectors of the Indian Economy viz., Power Generation & Transmission, Industry, Transportation, Telecommunication, Renewable Energy,etc. Thewidenetworkof BHEL's15manufacturingdivisions,fourPowerSector regionalcentres,over100projectsites,eightservicecentresand18regional offices,enablestheCompanytopromptlyserveitscustomersandprovidethem withsuitableproducts,systemsandservicesefficientlyandatcompetitive prices. Thehighlevelofquality&reliabilityofitsproductsisduetotheemphasison design,engineeringandmanufacturingtointernationalstandardsbyacquiring and adapting some of the best technologies from leading companies in the world,togetherwithtechnologiesdevelopedinitsownR&Dcentres. BHELhasacquiredcertificationstoQualityManagementSystems(ISO9001), EnvironmentalManagementSystems(ISO14001)andOccupationalHealth& SafetyManagementSystems(OHSAS18001)andisalsowellonitsjourney towardsTotalQualityManagement. BHELhas: Installedequipmentforover100,000MWofpowergenerationforutilities, captiveandindustrialusers.

 Supplied over 2,25,000 MVA transformer capacity and sustained equipmentoperatingintransmission&distributionnetworkupto400KV AC&DC. Suppliedover25,000motorswithDriveControlSystemtoPowerproject, Petrochemicals,Refineries,Steel,Aluminium,Fertilizer,Cementplantetc. SuppliedTractionelectricsandAC/DClossestopowerover12,000Kms Railwaynetwork. SuppliedoveronemillionvaluestoPowerPlantsandotherindustries. BHELsoperationsareorganizedaroundthreebusinesssectors,namely: Power,Industry includingTransmission,Transportation, Telecommunication &RenewableEnergyand OverseasBusiness. ThisenablesBHELtohaveastrongcustomerorientation,tobesensitivetohisneeds &torespondquicklytothechangesinthemarket. ThegreateststrengthofBHELisitshighlyskilledandcommitted46,848employees. Everyemployeeisgivenanequalopportunitytodevelophimselfandgrowinhis career.Continuoustrainingandretraining,careerplanning,apositiveworkculture andparticipativestyleofmanagement.Allthesehaveengendereddevelopmentofa committedandmotivatedworkforcesettingnewbenchmarksintermsofproductivity, qualityandresponsiveness.

ProjectEngineeringManagement
ProjectEngineeringManagementDivision(PEM)isadivisionwithin the power group to provide total Systems Engineering for BHEL equipment,aswellasforprocurement,erection&commissioningofnon BHELsystems&equipmentforthermalpowerstations. BHELbusinessisinthefieldofpowergenerationequipment,whichis handledbythePowerGroupandcoversalltheservicesrelatedtopower projectsfromconcepttocommissioninginkeepingwiththecorporate aim of developing BHEL into a worldclass engineering organization. Power Generation Sector comprises thermal, gas, hydro and nuclear powerplantbusiness.Asof31.3.2006,BHELsuppliedsetsaccountfor
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76,741 MW or nearly 65 percent of the total installed capacity of 1,18,561MWinthecountry,asagainstNiltill196970. Inviewofthehighdegreeoftechnicalexcellenceachieved,thereisan everincreasingparticipationinNational&InternationalPowerProjects.

AboutTheDepartment

Name of the department: Control & Instrumentation (C&I)

Instrumentation&controliswidelyusedcollectivetermcoveringtwo distinctaspectsofplantoperation.Instrumentsarethoseitemsattachedto
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aplant,whichgivesanindicationtotheoperatoroftheconditionsthat exists withinthesafetylimits&operationalparameters for whichthe plant was designed. Examples of indicative quantities are operating pressures,temperatures,flows&leveletc.

RoleofControl&Instrumentation(C&I)
INTRODUCTION
ThemainobjectiveofC&Iistoselect&marktheproperinstrumentsonprocess diagrams,preparethelistofinstruments,controllogics(analog&binary), controlroomlayout,cableschedule,cableterminationdetailsetc.InC&I dept. plant schematics are prepared by using AutoCad software for implementation on CRTs for control & monitoring the plant by their electronicsdivisionnamelyBHELEDNBangalore(sisterunit). Allcontrollogicsarealsobeingtranslatedtosoftwarei.e.maxDNAcontrolsystem byBHELEDN. The unit overview scheme shows the various equipments of the plant & Main operatingprocessparameters whicharerealtimeparametersinnature&allthe indications related to temperature, pressure, flow, levels etc. are displayed automaticallyonCRTs,incaseofsomefaultormalfunctioningtheautomaticalarmis blinkedonCRTforoperatorsactioninmaincontrolroom.

C&IENGINEERINGOUTPUTS
1. DesignphilosophyforC&I. 2. DesignphilosophyforHMI. 3. Analog/Binarydrivecontrolphilosophy. 4. Alarm. 5. Powersupplies. 6. Cablingphilosophy. 7. Controlpanelsarrangement/locationsandUCB 8. MarkingofInstrumentsonP&IDs. 9. InstrumentSchedule. 10. RootValveSchedule. 11. DriveList. 12. Binary/SequenceControlLogicDiagramsincludingUnit IntegratedScheme. 13. AnalogControlandMeasuringSchemes. 14. I/OList(AnalogandDigital). 15. ControlValvedatasheet.

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16. Flowelementdatasheet. 17. SWAS(SteamandWaterAnalyserSystem). 18. TechnicalspecificationandBOM. 19. ControlroomandSWASlayout.

OverviewofPowerPlant
THERMALPOWERPLANT

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A thermal power station near Sofia, Bulgaria A thermalpowerstation comprisesalloftheequipmentandsystems requiredtoproduceelectricitybyusingasteamgeneratingboilerfired withfossilfuelsorbiofuelstodriveanelectricalgenerator.Someprefer tousetheterm energycenter becausesuchfacilitiesconvertformsof energy,likenuclearenergy,gravitationalpotentialenergyorheatenergy (derivedfromthe combustion of fuels)intoelectricalenergy.However, powerplantisthemostcommontermintheUnitedStates,whilepower station prevailsinmany Commonwealthcountries andespeciallyinthe UnitedKingdom. Suchpowerstationsaremostusuallyconstructedonaverylargescale anddesignedforcontinuousoperation.

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Diagramofatypicalcoalfiredthermalpowerstation

Typical diagram of a coal-fired thermal power station

1.Coolingtower 2.Coolingwaterpump 3.Threephase transmissionline 4.Stepuptransformer 5.Electricalgenerator 6.Lowpressuresteam turbine 7.Boilerfeedwaterpump 8.Surfacecondenser

10.Steamcontrol valve 11.Highpressure steamturbine 12.Deaerator 13.Feedwaterheater 14.Coalconveyor 15.Coalhopper 16.Coalpulverizer

19.Superheater 20.Forceddraught (draft)fan 21.Reheater 22.Combustionair intake 23.Economiser 24.Airpreheater

25.Precipitator 26.Induceddraught 17.Boilersteamdrum (draft)fan

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9.Intermediatepressure steamturbine Steamgenerator

18.Bottomashhopper 27.Flue gas stack

Schematic diagram of typical coalfired power plant steam generator highlightingtheairpreheater(APH)location.(Forsimplicity,anyradiant sectiontubingisnotshown.) The steam generating boiler has to produce steam at the high purity, pressureandtemperaturerequiredforthesteamturbinethatdrivesthe elecrical generator. The generator includes the economizer, the steam drum, the chemical dosing equipment, and the furnace with its steam generatingtubesandthesuperheatercoils.Necessarysafetyvalvesare locatedatsuitablepointstoavoidexcessiveboilerpressure.Theairand flue gas path equipment include: forced draft (FD) fan, air preheater (APH),boilerfurnace,induceddraft(ID)fan,flyashcollectors(electric precipitatororbaghouse)andthefluegasstack. Forunitsoverabout200MWcapacity,redundancyofkeycomponentsis providedbyinstallingduplicatesoftheFDfan,APH,flyashcollectors andIDfanwithisolatingdampers.Onsomeunitsofabout60MW,two boilersperunitmayinsteadbeprovided.

Boilerfurnaceandsteamdrum
Theboilerfurnaceauxiliaryequipmentincludes coal feednozzlesand igniterguns,sootblowers,waterlancingand observationports(inthe

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furnacewalls)forobservationofthefurnaceinterior.Furnaceexplosions duetoanyaccumulationofcombustiblegasesafteratripoutareavoided byflushingoutsuchgasesfromthecombustionzonebeforeignitingthe coal. Thesteamdrum(aswellasthesuperheatercoilsandheaders)haveair ventsanddrainsneededforinitialstartup.Thesteamdrumhasinternal devicesthatremovesmoisturefromthewetsteamenteringthedrumfrom thesteamgeneratingtubes.Thedrysteamthenflowsintothesuperheater coils.

Fuelpreparationsystem
Incoalfiredpowerstations,therawfeedcoalfromthecoalstoragearea is first crushed into small pieces and then conveyed to the coal feed hoppers at the boilers. The coal is next pulverized into a very fine powder.Thepulverizers maybe ballmills,rotatingdrum grinders,or othertypesofgrinders. Somepowerstationsburn fueloil ratherthancoal.Theoilmustkept warm(aboveitspourpoint)inthefueloilstoragetankstopreventtheoil fromcongealingandbecomingunpumpable.Theoilisusuallyheatedto about 100C before being pumped through the furnace fuel oil spray nozzles. Boilersinsomepowerstationsuse processednaturalgas astheirmain fuel.Otherpowerstationsmayuseprocessednaturalgasasauxiliaryfuel intheeventthattheirmainfuelsupply(coaloroil)isinterrupted.Insuch cases,separategasburnersareprovidedontheboilerfurnaces.

Fuelfiringsystemandignitersystem
Fromthepulverizedcoalbin,coalisblownbyhotairthroughthefurnace coalburnersatananglewhichimpartsaswirlingmotiontothepowdered coaltoenhancemixingofthecoalpowderwiththeincomingpreheated combustionairandthustoenhancethecombustion. To provide sufficient combustion temperature in the furnace before igniting the powdered coal, the furnace temperature is raised by first

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burningsomelightfueloilorprocessednaturalgas(byusingauxiliary burnersandignitersprovideforthatpurpose).

Airpath
External fans are provided to give sufficient air for combustion. The forceddraftfantakesairfromtheatmosphereand,firstwarmingitinthe airpreheaterforbettercombustion,injectsitviatheairnozzlesonthe furnacewall. The induced draft fan assists the FD fan by drawing out combustible gasesfromthefurnace,maintainingaslightlynegativepressureinthe furnacetoavoidbackfiringthroughanyopening.Atthefurnaceoutlet, andbeforethefurnacegasesarehandledbytheIDfan,finedustcarried bytheoutletgasesisremovedtoavoidatmosphericpollution.Thisisan environmentallimitationprescribedbylaw,andadditionallyminimizes erosionoftheIDfan.

AuxiliarysystemsFlyashcollection
Fly ash is captured and removed from the flue gas by electrostatic precipitatorsorfabricbagfilters(orsometimesboth)locatedattheoutlet ofthefurnaceandbeforetheinduceddraftfan.Theflyashisperiodically removed from the collection hoppers below the precipitators or bag filters.Generally,theflyashispneumaticallytransportedtostoragesilos forsubsequenttransportbytrucksorrailroadcars.

Steamturbinedrivenelectricgenerator
The steam turbinedriven generators have auxiliary systems enabling themtoworksatisfactorilyandsafely.Thesteamturbinegeneratorbeing rotatingequipmentgenerallyhasaheavy,largediametershaft.Theshaft thereforerequiresnotonlysupportsbutalsohastobekeptinposition whilerunning.Tominimisethefrictionalresistancetotherotation,the shaft has a number of bearings. Oil lubrication is provided to further

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reducethefrictionbetweenshaftandbearingsurfaceandtolimittheheat generated.

Condenser

Diagram of a typical water-cooled surface condenser Thesurfacecondenserisashellandtubeheatexchangerinwhichcooling wateriscirculatedthroughthetubes.Theexhauststeamfromthelow pressure turbine enters the shell where it is cooled and converted to condensate (water) by flowing over the tubes as shown in the adjacent diagram. Such condensers use steam ejectors or rotary motor-driven exhausters for continuous removal of air and gases from the steam side to maintain vacuum. The condenser generally uses either circulating cooling water from a cooling tower or once-through water from a river, lake or ocean.

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DEARATOR

Diagram of boilerfeedwaterdeaerator(withvertical,domedaeration sectionandhorizontalwaterstoragesection Asteamgeneratingboilerrequiresthattheboilerfeedwatershouldbe devoidofairandotherdissolvedgases,particularlycorrosiveones,in ordertoavoidcorrosionofthemetal. Generally,powerstationsusea deaerator toprovidefortheremovalof air and other dissoved gases from the boiler feedwater. A deaerator typicallyincludesavertical,domeddeaerationsectionmountedontopof a horizontal cylindrical vessel which serves as the deaerated boiler feedwaterstoragetank. Therearemanydifferentdesignsforadeaeratorandthedesignswillvary fromonemanufacturertoanother.Theadjacentdiagramdepictsatypical conventional trayed deaerator. If operated properly, most deaerator manufacturerswillguaranteethatoxygeninthedeaeratedwaterwillnot exceed7ppbbyweight(0.005cm/L).

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OTHERSYSTEMS: Monitoringandalarmsystem
Allofthemajorplantcomponentsandsystemsrequireprecheckingfor startup during the first start or after a shutdown for any reason whatsoever. The safety aspects and the normal procedures haveto be looked into at all stages of operation. Manual intervention is also unavoidable;however,muchthesystemismadeautomatic.Inviewof this necessary protection, monitoring with alarms for out of limit parameters,andautoandmanualcontrolequipmentareprovidedonthe operatorconsoles,bothonthemechanicalandelectricalequipment.

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P&ID-INTRODUCTION (PROCESS & INSTRUMENTATION DIAGRAM)

A piping and instrumentation diagram/drawing (P&ID) is defined by as follows: A diagram which shows the interconnection of process equipment and the instrumentation used to control the process. In the process industry, a standard set of symbols is used to prepare drawings of processes. P&IDs play a significant role in the maintenance and modification of the process that it describes. It is critical to demonstrate the physical sequence of equipment and systems, as well as how these systems connect. During the design stage, the diagram also provides the basis for the development of system control schemes. For processing facilities, it is a pictorial representation of

Key piping and instrument details Control and shutdown schemes Basic start up and operational information

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KKS KraftwerkKennzeichensystem) ( POWERPLANTIDENTIFICATIONSYSTEM

The KKSPowerPlantClassificationSystemisastandardisedsystem for the classification of power stations. It serves during engineering, construction, operation and maintenance of power stations for identificationandclassificationoftheequipment.Thesystemisknownin shortasKKSwhichistheabbreviationoftheGermanterm.KKSwillbe replacedinfutureby ReferenceDesignationSystemforPowerPlants, RDSPP.RDSPPhasalmostsamestructureasKKS90%ofthecode lettersinthefunctionkey,otherkeysmuchless.

Contents
1StructureandFormat 2Examplesofcodes 3FunctionKey(MainGroups) 4FunctionKey(MainGroupsandSubgroups) 5EquipmentUnitKey(MainGroups) 6EquipmentUnitKey(MainGroupsandSubgroups) 7ComponentKey(MainGroups) 8Standardsandfurtherdevelopment 9Externallinks

StructureandFormat
TheKKShasthreedifferenttypesofcodes: Processrelated code, for identification of systems and equipment accordingtotheirfunctionsinthepowerstationprocess. Pointofinstallationcode,foridentificationofpointsofinstallationof electrical,controlandinstrumentationdevices

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Location code, for identification of locations of equipment and structures.

INSTRUMENTSCHEDULE
An instrument schedule is a list of instruments in a P&ID This list describes all parameters of the instrument and contains following informationofeachinstrument. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. SerialNumber TagNo(KKSNumber) Status TypeofFieldinstrument(level,Pressure,Flowetc) Medium Range Setpoint Operatingparameters DDCMIScontrol ReferenceP&IDnumber SrviceDescription

1.

KKSNumber:
This column contains the unique KKS number assigned to the instrument.

2.

FieldInstrument:
Thiscolumnisfurtherdividedintotwocolumns:onedescribingthe typeoftheinstrument(Eg.LT:LevelTx,CrAl:BimetallicStrip etc.)andtheothergivesthenameofthedivisionofBHELunder whosescopethisinstrumentiscovered(Eg.EDN:BHELEDN)

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3.

Medium:
This describes the medium that the instrument is designed to measurethepropertyof.Eg.Water,steam,DMwater,airetc.

4.

Range:
Thisstatestherangeofvaluesthattheinstrumentisdesignedto measure.

5.

OperationalParameters:
This shows the temperature and pressure of the medium that is flowingthroughtheinstrumentandisdesignedtomeasure.

6.

DDCMIS:
Thiscolumnshowswhattheoutputofthedifferentinstrumentsis goingtobeatdifferentpointsoftimeinthecontrolsystem.Italso controlstheworkingofthealarmdependingupontheoutputofthe differentinstruments.

7.

ReferenceP&IDNo.:
This column shows the P&ID no. of the drawing on which the particularinstrumentisused.

8.

Description:
Itgivesabriefdescriptionwheretheparticularinstrumentispresent andwhatitisgoingtomeasureorcontrol.

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CONTROL SYSTEM
NEED FOR AUTOMATIC CONTROL
The Power Generating Plant's behavior can be seen by observing certain physical parameters, which are the characteristics of the plant processes. The important process parameters are temperature, pressure, flow; fluid levels, rotating speeds etc. The measured values of the most significant of these parameters are transmitted from the plant to a Central Control Room (CCR) where these are indicated to an operator. If the plant is to be operated at designed optimum conditions, the measured values of each of the characteristic parameters has to be maintained as close as possible to desired value. These requirements are met by regulating the plant processes using process equipments like Valves, Dampers, servo motors etc. so that the deviations of the measured values of characteristic parameters from their desired values may be corrected. This is done with the help of push buttons, CRT station, controllers etc. Due to fast varying load demands and also the inter-relationship of behavior of various components, operator is unable to take decisions correctly in the short time available to him. Auto control systems provide
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solutions for such situations. Further, many subsystems have complexity in Start/Stop/Running e.g. BFP, CEP etc in terms of safe conditions to start, conditions for tripping the machine for process/equipment protection. High capital cost of modern day power plant necessitates its having extended life cycle. To obtain this, flexibility, efficient and safe operation, substantial degree of Automatic Control is required to be built in. There are two types of Control systems: Closed loop control System (Analog control Schemes) Open Loop Control System (Binary control Schemes)

CLOSED LOOP CONTROL :

System utilizes feedback to measure the actual system operating parameter being controlled such as press, temp, flow etc. The feedback signal is sent back to the controller where it is compared with the desired system set point. The controller develops an demand signal that initiates corrective action and drives the final output device to obtain desired process value.

OPEN LOOP CONTROL:

No feedback loop is employed and system output is given to the field devices (motors, pumps etc) The interlocks and protections are built-in the control systems.

Closed Loop systems have the following features:

Controller compares the system reference with the system feedback & generates the error signal. Set point establishes the desired operating point around which the system should operate.

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 Feedback signal informs the controller of the operating point of system (process measurement). Final Control Element responds to the system demand to bring the desired process value. Tuning elements provide system stabilization & adjust system response time. These are Proportional, Integral, Derivative functions.

PROPORTIONAL CONTROL
This is primary alternative to ON/OFF control. The output is proportional to the difference between the Desired value and the measured value. P* (Desired Current) P is a constant proportional gain set by the designer. This shall determine the time taken by the plant to reach new SP (Overshoot or Undershoot is minimized). The biggest problem with Proportional Control alone is that you want to reach desired output quickly & avoid overshoot and minimize ripple. We can derive the information of the rate of change of plant O/P. If the output is changing rapidly, overshoot or undershoot may lie ahead. In such cases we can reduce the size of change suggested by Proportional Controller.

PROPORTIONAL-DERIVATIVE CONTROL
The rate of change of a signal is known as its Derivative. The Derivative at the current time is change in value from the previous sample to the current one. D* (Current - Previous)

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D is a constant Derivative gain. PD controllers work well in practice. The net effect is slower response time with far less overshoot & ripple than P controller alone.

INTEGRATION CONTROL
PD alone may not be enough if individual error remains below the threshold for action by the proportional term. I* E(Desired Current) An integral is a sum of all past errors in the plant output. Even though integral gain factor is small, persistent error will cause the integral term to force a change in the drive signal. To sum it all ON-OFF and PROPORTIONAL control are two basic techniques of CLCS. However, DERIVATIVE and/or INTEGRAL terms are added to Proportional controls to improve the qualitative property of plant response.

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BINARY CONTROL SCHEMES

1FDFANACONTROLSYSTEM
1. The steam generators supplied today are larger in size and sophisticated in nature. Failure of any equipment calls for expensive replacement and results in costlier down time. This emphasises careful planning on the correct procedure for; 1. Safe sequence of start-up of equipments in the power plant. 2. Continuous trouble free & efficient operation. 3. Safe sequence of shutdown of the equipment when needed. This also leads to provision of adequate & reliable protection to safeguard the various plant equipments under abnormal and dangerous conditions. The operation of the protections shall be accompanied by visual and audible annunciation, which provide definite indication of the primary cause or causes of operation of the protection. Restarting of the equipment, which has once been tripped by protection either by remote, automatic or manual control shall be possible only after the elimination of the cause of tripping.

FD FAN INTERLOCKS 1.1 Conditions prior to starting FD fans: a) FD Fan A and FD Fan B off b) Fan blade pitch control tilted to maximum opening c) Outlet dampers are fully open d) Fan blade pitch control regulator disconnected e) Lube oil pumps of FD fans off 1.2 Starting FD fan A (FD fan B is off): a) FD Fan A shall be prohibited from starting until the following conditions are satisfied: i. ID Fan A or ID Fan B is on

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ii. Fan A blade pitch in the minimum position iii. Outlet damper of fan A in closed position iv. Fan/motor bearing temperature not very high v. Motor winding temperature not very high vi. Lube oil system permissives satisfied (Ref. Clause 6.0) b) When FD fan A is started (FD Fan B is off) impulses shall be given for: i. Outlet gate of fan A to open after the motor reaches rated speed ii. The outlet damper of FD fan B to close & blade pitch control of fan B to be driven to minimum position iii. Connecting the blade pitch control of Fan A control drive to auto control 1.3 Starting of FD fan B (FD fan A is off): Interlocks similar to those at clause 2.2 shall hold good for this condition. 1.4 Tripping of FD fan A (FD fan B is off) a) FD fan A shall trip automatically under the following conditions: i. FD fan A bearing temperature too high (prior to this, FD fan A bearing temperature high will be annunciated in DDCMIS) ii. FD fan A motor bearing/winding temperature too high (prior to this, FD fan A motor bearing/ winding temperature high will be annunciated in DDCMIS) iii. Both ID fans trip iv. Post purge fan trip v. Vibration level of fan or motor very high (high to be alarmed). For fan, trip shall be initiated with a delay of 10 minutes during starting and running of fan. b) When FD Fan A trips (FD fan B is off) impulses shall be given for: i. Disconnecting the blade pitch control drive from auto control system (output signal from A/M station) ii. Bringing the blade pitch of Fan A to the maximum position iii. Bringing the blade pitch of FD fan B to the maximum position iv. Opening the outlet damper of FD fan B v. To open the emergency scanner air damper vi. Boiler tripping vii. The outlet damper of FD fan A shall remain open. 1.5 Tripping FD fan B (FD fan A is off): Interlocks similar to those of clause 2.4 shall hold good for this condition 1.6 Starting FD fan B (FD fan A is on): a) FD fan B (FD fan A is on) shall be prohibited from starting until the following conditions are satisfied: i. Two ID fans are on ii. Fan B blade pitch control in the minimum position iii. Outlet damper of Fan B in closed position iv. Fan and fan motor bearing temperature not very high v. Motor winding temperature not very high. vi. Lube oil system permissive satisfied (Ref. Clause 6.0) b) When FD fan B is started (FD fan A is on) impulses shall be given for: i. Opening the outlet damper of FD fan B after the motor reaches rated speed ii. Connecting the blade pitch control drive of FD fan B to auto control 1.7 Starting FD fan A (FD fan B is on): Interlocks similar to those at clause 2.6 shall hold good for this condition. 1.8 Tripping of FD fan B (FD fan A is on):

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(a) FD fan B shall trip (when FD fan A is on) under the following conditions: i. ID fan B trips ii. FD fan B motor bearing/winding temperature too high (prior to this, FD fan B motor bearing/winding temperature high shall be annunciated in DDCMIS) iii. FD fan B bearing temperature too high (prior to this, FD fan B bearing temperature high shall be an annunciated in DDCMIS) iv. Vibration level of fan or motor very high (high to be alarmed). For fan, trip shall be initiated with a delay of 10 minutes during starting and running of fan. b) When FD fan B trips (FD fan A is on), impulses shall be given for: i. Disconnecting regulating impulse from acting on blade pitch control drive of fan B ii. Bringing blade pitch control of fan B to the minimum position iii. Closing the outlet damper of fan B iv. Reducing boiler load to 50% MCR. v. Tripping coal elevation in service more than four through FSSS 2 INTERLOCKS FOR FD FAN LUBRICATING OIL SYSTEM: 2.1 FD fan A lube oil system: a) Pump A will start automatically if pump B trips provided A/M switch is in auto position b) Pump A will start automatically with a time delay of 30 seconds if lube oil pressure falls below a set value and the pump B is working provided A/M switch is in auto position. c) Pump B will start automatically if pump A trips/has not started provided A/M switch is in auto position. d) Pump B will start automatically with a time delay of 30 seconds if lube oil pressure falls below a set value and the pump A is working provided A/M switch is in auto position. e) Pump A or pump B can be started/tripped by pressing the respective push button provided on local pushbutton box when A/M switch is in manual position. f) FD fan A shall be prohibited from starting until the lube oil pressure is adequate. g) Both lube oil pumps shall be switched OFF automatically after a delay of 30 min. after the FD fan A is OFF. 2.2 FD fan B lubricating oil system: Interlocks similar to those at 6.1 (a) to (g) above shall hold good for FD fan B lubricating oil system. Note: An alarm shall be initiated for the following conditions: after a time delay of 2 min. when both Lube oil pumps of a FD fan are running. when the lube oil tank level is low. DP across lube oil filter is high. Lube oil pressure is less than set value. 2.3 Tripping of FD fan A (FD fan B is on): Interlocks similar to those at clause 1.8 shall hold good for this condition. Note: When the control oil pressure is less than the set value, the corresponding FD fan regulating device shall remain in stayput position. This is to be taken care in auto-control system.

8.1.1

SequenceControlSchemeFDFanA

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P&IDAir&Fluegaspath

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CONCLUSION Powerplantcontrolsystemisthenucleusofapowerplantoperation.
Thereductionofoperatingtimethroughthemanagementofdailyand periodicoperation,improvementandeaseofmaintenance,andimproved efficiencywhilereassuringreliabilityandsafetyareallmeritsofpower plantcontrolsystems. ProjectEngineeringManagement,beingthecoreengineeringdivisionfor designofpowerplantisagreatplatformtostarttheprocessoflearning aboutthepowerindustryandthetechnicalaspectofpowerplants.This division is a hub of learning and engineering activity which enables overallunderstandingandprovidesasummateviewofapowerplant. BeingpartofControl&Instrumentationhasenabledmetogetanoverall pictureofthepowerplantfunctioningandmanagement.C&Iengineering touchesalmostallpartsofapowerplantandthismakestheareaofwork very vast and interesting. Power plant automation has become a very challenginganddynamicfield. Advanced communication networks have helped the growth of power plantautomationinaphenomenalmanner.Thespeedwithwhichsignals flowbetweenprocessorsincontrolroomandvariousdistributedcontrol locations in power plant has made it possible to automate almost the entirepowerplant.Theadvancementinthetechnologyoftransmitterand valveactuatorshassimplifiedtheoverallpowerplantcontrolsystem. Stateoftheartautomationandcontrolsystemsguaranteethesimpleand thesafeoperationofsteampowerplant.Theoverallcontroloftheplant takescareofoperationalregulationsaswellastheprimarysystems.This requiresanintegratedcontroloftheseparts.Allprocesssignalsshouldbe managedwithoutmultipleengineering.Inordertoallowaneasyfuture expansion,thelocalandremotecommunicationofthesystemhastobe basedonmodulartechnology.

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Inthechangingsocialscenario,continuousdemandofpowerhasmade longerdowntimeofpowerplantimpossible.Thisinturnhasmadethe job of power plant automation very demanding. The failures of equipmentshavetobeeitherpreventedorbereportedimmediately.This allisleadingtoariseinthechallengesofpowerplantautomation. Thechallengeisnotonlytowardstheautomationofnewplantsbutthere isanadditionalchallengetomodernizethecontrolsystemoftheexisting plants.

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