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Submitted by:
GAURAV RAI
IET, BUNDELKHAND UNIVERSITY
JHANSI (UP)
Power plant C&I (IPC) systems
&
Tending to Zero Forced Outage
by
Internalization of Best Practices
1.Some definitions & basics of Pressure, Flow & Temp. measurement
Pitot tubes are used to measure air flow in pipes, ducts, stacks, and
liquid flow in pipes, open channels.
While accuracy and rangeability are relatively low, pitot tubes are simple,
reliable, inexpensive, and suited for a variety of environmental
conditions, including extremely high temperatures and a wide range of
pressures.
Pitot Tubes
A single-port pitot tube can measure the flow velocity at only a single point in the
cross-section of a flowing stream.
The probe must be inserted to a point in the flowing stream where the flow
velocity is the average of the velocities across the cross-section, and its impact
port must face directly into the fluid flow.
Pitot Tubes
The point velocity of approach (VP) can be calculated by taking the square root
of the difference between the total impact pressure (PT) and the static pressure
(P) and multiplying that by the C/D ratio, where C is a dimensional constant and
D is density:
The pitot tube measures the static and dynamic (or impact) pressures of the fluid
at one point in the pipe.
The flow rate can be determined from the difference between the static and
dynamic pressures which is the velocity head of the fluid flow.
Vortex Flow-meters
This measuring principle is based on the fact that vortices are
formed downstream of an obstacle in a fluid flow, e.g. behind a
bridge pillar.
This phenomenon is commonly known as the Kármán vortex street.
Vortex Flow-meters
This is detected by a sensor, such as capacitive sensor and fed to
the electronic processor as a primary, digitized, linear signal.
Capacitive sensors with integrated temperature measurement can
directly register the mass flow of saturated steam as well.
Two sensors mounted on the pipe simultaneously send and receive ultrasonic
pulses.
At zero flow, both sensors receive the transmitted ultrasonic wave at the same
time, i.e. without transit time delay.
When the fluid is in motion, the waves of ultrasonic sound do not reach the two
sensors at the same time.
Ultrasonic flow-meters
This measured "transit time difference" is directly proportional to the flow
velocity and therefore to flow volume.
By using the absolute transit times both the averaged fluid velocity and the
speed of sound can be calculated.
Ultrasonic flow meters measure the difference of the propagation time (transit
time) of ultrasonic pulses propagating in (normally an inclination angle around
30 to 45° is used) flow direction and against the flow direction.
This time difference is a measure for the averaged velocity of the fluid along
the path of the ultrasonic beam
Ultrasonic flow-meters
Advantages:
With homogeneous fluids, the principle is independent of pressure,
temperature, conductivity and viscosity
Usable for a wide range of nominal diameters Direct meter
installation on existing pipes
Non-invasive measurement
No pipe constrictions, no pressure losses
No moving parts. Minimum outlay for maintenance and upkeep
Coriolis Mass Flow-meters
If a moving mass is subjected to an oscillation perpendicular to its
direction of movement, Coriolis forces occur depending on the
mass flow.
A Coriolis mass flow meter has oscillation measuring tubes to
precisely achieve this effect.
Advantage
This principle is used in a huge range of industry sectors,
including pharmaceuticals, chemicals and petrochemicals, oil and
gas, food etc.
Major issues for selecting flow-meters
Accuracy
Repeatability
Linearity
Reliability
Range/Span
Dynamics(Response time)
Safety
Maintenance
Cost
Measurement Devices
Thermocouples
Resistance Thermometers
Thermistors
Bimetallic Thermometers
Acoustic Pyrometers
Local Instruments
Thermocouple
IT IS BASED ON ‘SEEBECK’ EFFECT WHICH SAYS THAT
WHEN HEAT IS APPLIED TO A JUNCTION OF TWO
DISSIMILAR METALS AN ‘EMF’ IS GENERATED WHICH CAN
BE MEASURED AT THE OTHER JUNCTION
T/C Connection
COMPENSATING CABLE
HOT JUNCTION
TO DDC CARDS
Advantages: - Disadvantages: -
- Low Cost - Sensitivity low & low voltage output
- No moving parts, less likely to be broken. susceptible to noise
-Wide temperature range. - Accuracy not better than 0.5 °C
-Reasonably short response time. - Requires a known temperature
- Reasonable repeatability and accuracy. reference
RESISTANCE THERMOMETER (RTD)
THE RESISTANCE OF A CONDUCTOR CHANGES WHEN ITS
TEMPERATURE IS CHANGED .THIS PROPERTY IS UTILISED TO
MEASURE THE TEMPERATURE.
Rt = Ro (1+βdT)
β = TEMP CO- EFFICIENT OF RESISTANCE ; dT = TEMPERATURE DIFFERENCE
WHERE
REPAIR
TESTING:
1. ELECTRONIC MODULES
2. RELAYS
Group Control
Sub-Group Control
Sub-Loop Control
Drive Level Control
Programmable Logic Control(PLC)
Drive Level Control : Start and Stop or Opening and Closure of a Drive is
carried out by Drive Control. The Drive logic shall have Protection, release
,auto and manual commands and these are executed as per pre-determined
logic.
AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP
CLCS TERMINOLOGY:
Desired Value or Set Point : The value of the variable/parameter which needs
to be controlled at the required condition.
Process Variable(PV) : The present value of the Parameter of Process at that
particular instant. This is sometimes referred as Measured Value.
Error/Deviation : It is the Difference between Set Point and Process Variable,
and can be +ve or –ve. It has three components: a) Magnitude b) Duration and
c) Rate of change.
Controller : A Controller is a device that receives data from a Measurement
Instrument, compares the data with the Set Point and if necessary, signals a
Control element to take Corrective action. This Corrective action ensures that
the PV shall always be maintained at the Set Value.
The Controller can be a) Electronic, b) Pneumatic and c) Hydraulic type.
AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP
Controller types: Functionally, Controllers can be
a) Continuous and b) Step Controllers.
Depending on the control loop; controller action can be adjusted as (i)
Direct acting:-Increase of process value increases controller output
(ii) Reverse acting:- Increase of process value decreases controller
output
Usually, both P and I Controls are combined and the Controllers are tuned to
minimize Error(e) and controller is termed as PI controller.
Analog inputs:
1. Thermocouple Input ( mV )
K-Type T/C ( Cr-Al ) : For temp < 600 Deg C& used in Flue Gas path
after FSH outlet.
R-Type T/C ( Pt-Pt-Rh ) : For temp > 600 Deg C used in PSH & FSH
region of FG path.
FUNCTIONS OF DAS:
Alarm Management.
Production of hardcopy print outs in different printers.
Operator Guidance Messages.
Graphic Displays of plant sub-systems.
Trending of analog variables on recorders.
Sequence Of Events ( SOE ) recording following unit /
equipment trip conditions.
Efficiency calculations
DATA ACQUISITION SYSYTEM
DATA PROCESSING: It has the following parts
COMPUTER PROCESSING UNIT ( CPU )
BULK ( SOLID STATE ) MEMORY WITH BATTERY BACKUP
MAGTAPE UNIT
COMMUNICATION CABINET & MODEM
MOVING HEAD DISC DRIVE
VIDEO HARD COPIER
TREND RECORDER
UNIT CONTROL DESK & PROG. ROOM CRT
PRINTERS
DATA ACQUISITION SYSYTEM
Features:
REAL TIME VARIABLE CALCULATION
Summing, Subtraction, Maximum , Minimum, Averaging,
Hourly & Daily integration, rate of changes & comparison
of limits etc.
ON-LINE DATABASE EDITION
1. Assign points to any process parameter
2. Scan, Off-scan , Delete , Activate , inactivate a
process parameters , calculated points when reqd.
3. Change the Engg. Unit
4. Change the range , alarm limits & dead bands
5. Change the scan frequency
6. Review total analog and digital points depending on its
quality flag like alarm , channel failure , off-scan etc.
DATA ACQUISITION SYSYTEM
ALARM MANAGEMENT:
All the analog points which cross their normal limits or all the digital points
which go into their alarm state come on the alarm CRT with associated time
& blink as long as the alarms remain unacknowledged.
Alarm will come in RED colour
If all the pages are full (normally no. of alarm pages & alarm per page is
predefined) and any new alarm comes , then oldest alarm will disappear
from the alarm page as FIFO basis
CRT Displays
1. Alarm CRT display
2. Utility CRT display
DATA ACQUISITION SYSYTEM
DATA REPRESENTATION:
TYPES OF TREND LOG PRINOUTS
TIME ACTIVATED
EVENT ACTIVATED
DEMAND LOGS
SOE PRINTOUT
TIME ACTIVATED LOG:
Automatic Triggered Logs
Sample frequency is 1 Hour.(Normally)
Time of trigger can be specified
DATA ACQUISITION SYSYTEM
TIME ACTIVATED LOG:
Max. 15 nos. of points can be assigned
Normally printed in the logging printer in UCB
Examples :
1. Shift Log
2. Efficiency Log
3. Boiler Drum / Tube Metal Temp. Log
4. FSH / RH Metal temp. excursion Log
EVENT ACTIVATED LOG:
Automatic Triggered Logs
Used for Unit or Equipment Outage Analysis
Minimum Sample frequency is 10 seconds.
DATA ACQUISITION SYSYTEM
EVENT ACTIVATED LOG:
Max. 36 points can be assigned in a log
Logs are triggered by a Trip flag
Normally printed on Logging Printer in UCB
Pre & Post triggered points can be specified
Examples :
1. Post Trip Analysis Log ( PTL )
2. TG. Shutdown Analysis Log
3. Boiler Startup Log.
4. Turbine / Generator Diagnostic Logs
DATA ACQUISITION SYSYTEM
DEMAND LOG:
Not Automatic Triggered Logs
WHAT IS DDCMIS ?
DISTRIBUTED DIGITAL CONTROL MONITORING & INFORMATION
SYSTEM
Distributed means there is no centralized control and control is spread
across multiple units
Digital means processing of process information is done in digital form using
micro-processor based hardware
MIS interfaces the human with process using computers
DDCMIS
TECHNOLOGICAL BACKGROUND
PROGRESS OF INSTRUMENTATION USED TO IMPLEMENT AUTOMATIC
PROCESS CONTROL
LOCAL PNEUMATIC CONTROLLERS
MINIATURIZED AND CENTRALIZED PNEUMATIC CONTROLLERS AT
CONTROL PANELS AND CONSOLES
SOLID-STATE CONTROLLERS
COMPUTERISED CONTROLS
DISTRIBUTED MICROPROCESSOR BASED CONTROL
DDCMIS
Components
CONTROL SYSTEM
DDCMIS
MAN-MACHINE INTERFACE AND PLANT INFORMATION SYSTEM (MMIPS)
LATEST STATE-OF-THE-ART WORKSTATIONS AND SERVERS BASED ON OPEN-
ARCHITECTURE AND INDUSTRY STANDARD HARDWARE AND SOFTWARE TO
ENSURE BETTER CONNECTIVITY.
e.g. HARDWARE FROM COMPAQ/DIGITAL, HP, SUN MICRO-SYSTEM OR OTHER
MAJOR SUPPLIERS (LESS DEPENDENCE ON THE C&I SYSTEM SUPPLIER IN
THE LONG RUN)
FUNCTIONAL DIVISION
SG-C&I SYSTEM
TG-C&I SYSTEM
BOP-C&I SYSTEM
HARDWARE COMPONENTS
POWER SUPPLY
CONTROL PANEL
ELECTRONIC MODULES
DDCMIS
CONTROL SYSTEM
PROGRAMMING & MMIPIS M&S
CONFIGURATION SYSTEM CLOCK
DCS
TG-C&I SYSTEM
ELECTRONIC TURBINE PROTECTION (ETP)
AUTOMATIC TURBINE RUN-UP SYSTEM (ATRS)
AUTOMATIC TURBINE TESTING SYSTEM (ATT)
ELECTRO- HYDRAULIC TURBINE CONTROL SYSTEM (EHTC)
TURBINE STRESS CONTROL SYSTEM (TSC)
LP BYPASS SYSTEM (LPBP)
HP BYPASS SYSTEM(HPBP)
GLAND STEAM PRESSURE CONTROL
GENERATOR AUXILIARY MONITORING PANEL (GAMP)
DDCMIS
BOP-C&I SYSTEM
CONSISTS OF OPEN LOOP CONTROL SYSTEM (OLCS) AND CLOSED LOOP
CONTROL SYSTEM (CLCS)
OLCS - THE SEQUENCE CONTROL, INTERLOCK OF ALL THE PLANT SYSTEMS WHICH
ARE NOT COVERED IN THE SG-C&I AND TG-C&I. THIS INCLUDES MAJOR AUXILIARIES
LIKE FD/ID/PA FANS, AIR-PREHEATER, BFP/CEP/CWP/ BCWP , DMCWP/CLCWP AND
ELECTRICAL BREAKERS.
Global:
Tx / Sw /Fld Dev
7% 2% 4%
Control System
9%
22% EHC / ATRS
17%
Power Supply /
28% Cable
Software / Card
failure
Human Error
9%
2%
UPS
RTD / Tc
Major factors contributing to C&I outage in 2009-10:
5. Human error
All ‘unit protections’ are provided with 2/3 logic and audio visual
alarm is provided on 1/3 to operator on actuation of any one sensor
wherever possible with proper approval.
Single source responsibility for software backup of DCS and storage in fire
proof cabinets in two different locations.
Detailed work instruction are prepared and followed for working on all trip
related devices.
A single source responsibility is fixed for the generation and maintenance
of system passwords so as to maintain system security
Near miss situations are monitored and analyzed. The learning from this
area used to formulate strategies to avoid spurious outages.
All power supply voltages are monitored with a fixed periodicity and
maintained within /- 10% of the rated value.
Other important actions taken for forced outage
reduction
Rerouting of control & power cables in hot zones