CONTROL & INSTRUMENT INDEX SYSTEMS UNDER C&I DEPARTMENT DISTRIBUTED CONTROL SYSTEM (DCS) SYMPHONY HARMONY INFI 90 SYSTEM COMPOSER™ SYSTEM EMERGENCY TRIP SYSTEM (ETS) FURNACE SAFEGUARD SUPERVISORY SYSTEM (FSSS) LOCAL IGNITION CONTROL SYSTEM UPS GENERAL DESCRIPTION MULTI FLAME DETECTOR CONTROL UNIT & FLAME

SCANNER DEH SYSTEM HART SYSTEM MACHINE MONITORING SYSTEM (MMS) TURBINE SUPERVISORY INSTRUMENTATION (TSI) HPLP BYPASS CCTV SYSTEM RUNBACK MIS SYSTEM (PGIM)

ENTERPRISE ASSET MAINTENANCE (MAXIMO)

GPS SYSTEM

CMS

BOILER TUBE LEAKAGE DETECTION SYSTEM

Systems Under C&I department, SgTPP

IPH SYSTEMS

C&I department is entrusted for maintaining System Automation at all areas of

Power Plant except CHP. The areas under their scope is as following:

1. Distributed Control System (Symphony Harmony 50 System, Make-ABB) with

its panels, Controllers, Modules, power supply, network & HMI

2. Operating Interface Software (Power Generation Portal, Make-ABB)

maintenance, Sequence of Events generation.

3. Operating Interface station (OIS), Engineering Work Station (EWS) & DCS

communication with computer management.

4. Logic & Interlock protection software (Composer 4.3 software, Make-ABB)

maintenance and development if required.

5. Digital Electro Hydraulic System (DEH, Make-ABB) for turbine governing system

6. Furnace Safeguard Supervisory System PLC (FSSS, Make-ABB) with

Master Fuel Trip System (MFT)

7. 90~70 Series Genius PLC for Emergency Turbine Trip System (ETS, Make-

GEIP)

8. 3500 Turbine Supervisory Instrumentation (TSI, Make- Bentley Nevada)

9. 90~30 Series Genius PLC for Turning Gear Automatic Control System (Make-

GEIP)

10. Different kind of field transmitters for measuring Pressure, temperature, flow,

level, vibration, displacement & gauges like Pressure, temperature, level and

different switches for alarm generation and enabling interlocks.

11. Different kind of analytical instruments like Oxygen, CO, dust analyzers, SOX,

NOX, Na, Si, and Conductivity etc. for hydrogen purity, humidity.

12. Boiler tube leakage detection System (Make-Eastern Boiler Co.) & acoustic tube

leakage detector sensors

13. SMART Secondary air Damper Control (SADC) system, Make- CCI KK

consisting 60Nos SAD with local control box

14. SMART Burner Tilting System consisting 8Nos Tilt with local control box

15. Different pneumatic final control elements used in Mill, pyrite system, single &

double acting control valves for different areas.

16. Different electrical actuators for PA fan, FD fan, ID fans.

17. Steam Water Analytical System (SWAS) with Verasamax PLC, Make-GEIP

18. Condensate Polishing System (CPU) Contrologix PLC, Make-Rockwell

Automation

19. Air Pre-heater gap detection system with SLC500 PLC, Make-Rockwell

Automation

20. Air Pre-heater Hot spot detection system with SLC500 PLC, Make-Rockwell

Automation

21. AROS Make 80KVA Dual Uninterruptible Power Supply (UPS) and Ni-Cd

Battery Bank

22. Boiler Oil Burner System consisting LFO & HFO Burner System

23. UVISOR 600 IR Multi-flame detector Flame scanner system with Flame explorer

software

24. TZIDC ABB Make SMART positioner for SADC, Burner Tilt

25. DVC 2000 & 6010 SMART Positioners for Control Valves

26. Auxiliary Boiler instrumentation and control system.

27. Flame TV for boiler flame monitoring

28. Closed Circuit TV (CCTV) server and cameras for 55 locations distributed all

over the plant.

29. Online Condenser tube cleaning system (OLTC).

30. Condenser tube leakage system.

31. HPLP Bypass system (Make-CCI) control system and hydraulic controllers.

32. Highway Addressable Remote Transducer (HART) panel with Cornerstone

diagnostic software to enable transmitter calibration from control room.

33. Machine Monitoring System(MMS) for monitoring vibration of different fans and

pumps.

34. Large Video Screen(LVS) in Control room to display plant important data and

soft annunciation.

OPH SYSTEMS

35. All Ash Slurry sump level switch, Pressure switch and gauges in Ash Handling

Plant. SILO#1, 2, 3 level transmitters and NUVA feeder(dry ash system)

solenoid valves and cylinders.

36. All pressure, flow, level and temperature gauges, switches and transmitters in

Intake pump house, DMP, PTP and Regeneration Building and N-pit.

37. All Conductivity, pH, Si and Na Analyser in DMP and Regeneration Building for

water, acid and caustic quality measurement.

38. All pneumatic solenoid valve operated on-off valves for different ion exchange

vessels (ACF, SAC, WBA, SBA, MB).

39. All pneumatic control valves for degasser water tank recirculation line.

40. All pressure, temperature & level transmitters, level switches, pressure and

temperature gauges for FOPH.

41. All vibration monitoring systems in intake and raw water pump house.

42. Chlorine gas leakage detection systems in RW Chlorination and CW

Chlorination plants.

43. All pressure transmitters, switches and gauges in CW Chlorination plant.

44. All pressure switches and gauges in Fire fighting pump house.

45. All H2 gas leakage detection systems in H2 gas cylinder room.

46. All level switches and indicators, pressure gauges in waste water treatment

plant.

DISTRIBUTED CONTROL SYSTEM(DCS)

Adopting the computer, communications and screen display techniques, carry

out the data acquisition, control and protection functions etc. for production process.

It is a multi-computer monitoring system based on communication and data share

techniques, which possesses the following features, distributed functions,

concentrated display, data, share, high reliability. It can be distributed by the

hardware arrangement according to the concrete circumstances.

DCS comprises of following functional segments :

1. Distributed Control System (Symphony Harmony INFI 90 System, Make-ABB) with

its panels, Controllers, Modules, power supply, network & HMI

2. Operating Interface station (OIS), Engineering Work Station (EWS) & DCS

communication by CNET with computer management.

3. Operating Interface Software (Power Generation Portal, Make-ABB) maintenance,

Sequence of Events generation.

4. Logic & Interlock protection software (Composer 4.3 software, Make-ABB)

maintenance and development if required.

SOME DEFINITION AND ABBREVIATION

Distributed control System, namely DCS

Date Acquisition System, namely DAS

Modulation Control System, namely MCS

Coordinated Control System, namely CCS

Automatic Generation Control, namely AGC

Sequence Control System, namely SCS

Furnace Safeguard Supervisory System, namely FSSS

Master Fuel Trip, namely MFT

Digital Electro- Hydraulic Control, namely DEH

Automatic turbine startup or shutdown control system, namely ATC

Over- speed Protection Control, namely OPC

Uninterrupted Power Supply namely UPS.

Supervisory information system of the plant 1evel, namely SIS

Turbine supervisory instruments, namely TSI

The field bus control system, namely FCS

Following technical terms, definition and abbreviation is applicable to this standard

1 Distributed control System, namely DCS

Adopting the computer, communications and screen display techniques, carry out the

data acquisition, control and protection functions etc. for production process. It is a

multi-computer monitoring system based on communication and data share

techniques, which possesses the following features, distributed functions,

concentrated display, data, share, high reliability. It can be distributed by the

hardware arrangement according to the concrete circumstances.

2 Date Acquisition System, namely DAS

DAS is a supervision system, which is adopted digital computer system to detect the

operating parameters, states for technique system and process, record, display and

alarm to detecting results, calculate and analyze the operating conditions, provide

operating instruction.

3 Modulation Control System, namely MCS

MCS is a system that carries out the boiler, the turbine and the auxiliary system

parameter automatic control. In this system, it includes the parameters automatic

control and deviations alarming. For the former the, its outputs is a continuous

function of inputs. It can be called the closed loop control system CCS in outward

document.

4 Coordinated Control System, namely CCS

UCC is a control system, which controls the boiler and the turbine as a whole,

corresponds boiler and turbine to work through control loop under the automatic

mode, sends the demand to boiler and turbine automatic control system in order to

adapt the variation of load.

5 Automatic Generation Control, namely AGC

AGC is an automatic control system that controls the power according to the power

grid load demand.

6 Sequence Control System, namely SCS

SCS is an automatic control system that controls a certain techniques system or

main auxiliary equipment according to a certain disciplinarian (input signal condition

sequence, action sequence or time sequence).

7 Furnace Safeguard Supervisory System, namely FSSS

FSSS is an automatic control system for boiler ignition and oil gun action program to

prevent the furnace explosion (outside explosion or inside explosion) caused by

boiler extinguishing, overpressure etc. The FSSS includes the Burner Control System

(BCS) and the Furnace Safety System, (FSS)

8 Master Fuel Trip, namely MFT

MFT is a control measures that operates by operator or operates by the automatic

protection signal to cut off all fuels for boiler.

9 Digital Electro- Hydraulic Control, namely DEH

DEH is a turbine control system that consists of sensor designed by electric principle,

computer, amplifier designed by hydraulic pressure principle and hydraulic pressure

servo mechanism.

10 Automatic turbine startup or shutdown control system, namely ATC

ATC is an automatic control system that controls the turbine to complete the startup,

synchronization procedure according to the thermal stress or other parameters of

turbine.

11 Over- speed Protection Control, namely OPC

OPC is a control function that can prevent overspeed. There are two ways to realize

this function, acceleration limit or double positions control. The former can generates

an override instruction to close down the high-pressure, mid-pressure regulating

valve if turbine in overspeed operation. If the acceleration equals zero, the OPC

maintain the normal speed for turbine. The later can close the high-pressure, mid-

pressure regulating valve if the speed equals 103% of rated speed.

12 Uninterrupted Power Supply namely UPS.

13 Supervisory information system of the plant 1evel, namely SIS

SIS provides the real time information and processed information, real time

monitoring and management service for plant level personnel, failure judgements for

dispatch center. It also supports the power unit level information process.

14 Turbine supervisory instruments, namely TSI

TSI represents the instruments used for supervising state (speed, vibration,

expansion, displacement etc.)

15 The field bus control system, namely FCS

FCS is a distributed control system that based on field bus techniques. It connects

the field measurement, control devices, into a network system according to public

and normative protocols to realize the data transmission.

Symphony Harmony INFI 90 System

Harmony Rack Controllers

The Harmony Rack Controllers are high-performance, high capacity process

controllers. They are designed to interface with Harmony block I/O in the Symphony

Enterprise Management and Control System. The Harmony rack controllers are fully

compatible in functionality, communications, and packaging. The Harmony rack

controllers collect process I/O, perform control algorithms and output control signals

to process level devices. They also import and export process data from and to other

controllers or other system nodes, and accept control commands from operators and

computers connected to the network. The controllers communicate on the Control

way with other rack controllers. They communicate with other system nodes on the

control network (C net) via Harmony rack communication modules.

Description

The Harmony rack controllers refer to a series of three controllers differentiated by

their configuration memory capacity, execution speed and I/O support. The Harmony

Bridge Controller (BRC-300) can support block and rack I/O simultaneously. The

Harmony Multifunction Processors (IMMFP11 and IMMFP12) support only rack I/O.

Each controller occupies a single slot in the module mounting unit. It consists of a

single-board module that plugs into the module mounting unit. In the case of the

Harmony Bridge Controller, a Process Bus Adapter card is connected at the rear of

the module to provide cable connections to the Harmony I/O subsystem and

termination unit. As is standard, the module mounting unit provides built-in

connections for rack modules. The Harmony rack controllers use a powerful 32-bit

processor. On-board nonvolatile storage is provided for the control algorithms and

user configurations. LEDs on the module front-plate display

error messages and diagnostic data. One red/green LED displays module operating

status.

Harmony Rack Input / Output

The Harmony Rack Input / Output (I/O) system utilizes a wide variety of input, output,

and signal conditioning modules to interface process signals to the Symphony

Enterprise Management and Control System. Module types, ranging

from standard analog and digital I/O to specialty I/O such as turbine control, field bus,

and sequence of events, can be combined to provide a comprehensive set of

functionality to meet all market and industrial requirements.

The main components of Harmony rack I/O are I/O modules, termination units, and

the I/O expander bus. The Harmony controllers and rack I/O modules communicate

over I/O expander bus. Together a controller and its I/O modules form a subsystem

within the Symphony system. The controller performs the actual control functions; the

I/O modules process any inputs from and outputs to field devices for the controller.

The termination units provide field wiring termination for I/O modules. The controller

can communicate with up to 64 I/O modules connected to the I/O expander bus.

The rack I/O module types include:

Analog input (ASI, FEC).

Analog output (ASO).

Digital input (DSI, DSM).

Digital output (DSO).

Specialized input/output (FCS, HSS, SED).

IMHSS03 Hydraulic Servo

The IMHSS03 Hydraulic Servo module is a valve position control module. It provides

an interface through which a Harmony controller can drive a servo valve or I/H

converter to provide manual or automatic control of a hydraulic actuator. The

controller utilizes function code 55 or 150 (hydraulic servo) to configure and access

the module input/output channels. Typical uses for the module are positioning of

steam turbine throttle and control valves, gas turbine fuel valves, inlet guide vanes,

and nozzle angle. By regulating the current to the servo valve, the IMHSS03 module

can initiate a change in actuator position. The hydraulic actuator can then position,

for example, a gas turbine fuel valve or a steam governor valve. As the valve opens

or closes, it regulates fuel or steam flow to the turbine, thus controlling the turbine

speed. A linear variable differential transformer (LVDT) provides actuator position

feedback to the hydraulic servo module.

The IMHSS03 module is an intelligent I/O module with an onboard microprocessor,

memory, and communication circuitry. In most applications, the IMHSS03 module

works with the IMFCS01 Frequency Counter module.

I/O Expander Bus

The I/O expander bus is a high speed, synchronous, parallel bus. It provides a

communication path between controllers and I/O modules. The I/O expander bus

parallel signal lines are located on the module mounting unit backplane. Inserting a

rack-mounted controller and I/O modules into the mounting unit connects them to the

expander bus.

I/O Module

An I/O module interfaces and processes field device input and output signals. There

are several different I/O module types available. Table 1 lists the available module

types and gives a brief description. All I/O modules share the same layout and

connection, configuration, and mounting methods. Refer to the Harmony Rack Input

/ Output data sheets for individual I/O module capabilities.

Modular Power System

The Modular Power System III (MPS III) is specifically designed for powering

Harmony rack modules and associated field mounted devices. The MPS III can

provide 5, +15, and 24 VDC system power as well as 24, 48, and 125 VDC for field

powered devices. Special features of the MPS III include: power factor correction, on-

line power supply replacement, power and cooling status monitoring, and adaptability

to various power input sources.

The MPS III supplies 5 VDC, +15 VDC, -15 VDC, 24 VDC, 48 VDC, and 125 VDC

power to Harmony rack components of the Symphony Enterprise Management and

Control System. Figure 1 shows MPS III power system architecture.

In Figure 1, the 5, +15 and -15 VDC lines shown entering the system power bus bar

are the operating voltages for rack I/O devices. The 24VDC (25.5 VDC actual

voltage) line shown entering the system power bus bar is I/O power for field devices.

Additionally, the power system can provide various combinations of 24, 48, and 125

VDC field power. The major MPS III components consist of a power entry panel,

power chassis, power trays, system fan, and bus monitor.

Bus Monitor

The bus monitor checks status and generates a Power Fail Interrupt (PFI) signal in

the event of a 5, +15, or -15 VDC bus failure. The bus monitor is located on the back

of the power chassis.

Control NET

Control Network, Cnet, is a high-speed data communication highway between nodes

in the Symphony Enterprise Management and Control System. Cnet provides a data

path among Harmony control units (HCU), human system interfaces (HSI), and

computers. High system reliability and availability are key characteristics of this

mission-critical communication network. Reliability is bolstered by redundant

hardware and communication media in a way that the backup automatically takes

over in the event of a fault in the primary. Extensive use of error checking and

message acknowledgment assures accurate communication of critical process data.

Cnet uses exception reporting to increase the effective bandwidth of the

communication network. This method offers the user the flexibility of managing the

flow of process data and ultimately the process. Data is transmitted only when it has

changed by an amount which can be user selected, or when a predetermined time-

out period is exceeded. The system provides default values for these parameters, but

the user can customize them to meet the specific needs of the process under control.

Harmony rack communications encompasses various communication interfaces as

shown in Figure 1: Cnet-to-Cnet communication, Cnet-to-HCU communication, and

Cnet-to-computer communication.

Control Network

Cnet is a unidirectional, high speed serial data network that operates at a 10-

megahertz or two megahertz communication rate. It supports a central network with

up to 250 system node connections. Multiple satellite networks can link to the central

network. Each satellite network supports up to 250 system node connections.

Interfacing a maximum number of satellite networks gives a

system capacity of over 62,000 nodes. On the central network, a node can be a

bridge to a satellite network, a Harmony control unit, a human system interface, or a

computer, each connected through a Cnet communication interface.

On a satellite network, a node can be a bridge to the central network, a Harmony

control unit, a human system interface, or a computer.

Harmony Control Unit

The Harmony control unit is the fundamental control node of the Symphony system.

It connects to Cnet through a Cnet-to-HCU interface. The HCU cabinet contains the

Harmony controllers and input/output devices. The actual process control and

management takes place at this level. HCU connection to Cnet enables Harmony

controllers to:

1. Communicate field input values and states for process monitoring and control.

2. Communicate configuration parameters that determine the operation of functions

such as alarming, trending, and logging on a human system interface.

3. Receive control instructions from a human system interface to adjust process field

outputs.

4. Provide feedback to plant personnel of actual output changes.

Human System Interface

A human system interface such as a Signature Series workstation running Maestro

or Conductor Series software provides the ability to monitor and control plant

operations from a single point. It connects to Cnet through a Cnet-to-computer

interface. The number of workstations in a Symphony system varies and depends on

the overall control plan and size of a plant. The workstation connection to Cnet gives

plant personnel access to dynamic plant-wide process information, and enables

monitoring, tuning, and control of an entire plant process from workstation color

graphics displays and a pushbutton keyboard.

Computer

A computer can access Cnet for data acquisition, system configuration, and process

control. It connects to Cnet through a Cnet-to-computer interface. The computer

connection to Cnet enables plant personnel, for example, to develop and maintain

control configurations, manage the system database, and create HSI displays

remotely using Composer™ engineering tools. There are additional Composer and

Performer series tools and applications that can access plant information through a

Cnet-to-computer interface.

Cnet-to-HCU Communication Interface

The Harmony control unit interface consists of the INNIS01 Network Interface Module

and the INNPM12 or INNPM11 Network Processing Module (Fig. 4). This interface

can be used for a node on the central network or on a satellite network (Fig. 1).

Through this interface the Harmony control unit has access to Cnet and to

Controlway at the same time. Controlway is an internal cabinet communication bus

between Harmony rack controllers and the communication interface modules. The

HCU interface supports hardware redundancy. Redundancy requires a full set of

duplicate modules (two INNIS01 modules and two INNPM12 or INNPM11 modules).

The secondary network processing module (INNPM12 or INNPM11) continuously

monitors the primary through a direct ribbon cable connection. A failover occurs

when the secondary detects a primary module failure. When this happens, the

secondary assumes responsibility and the primary is taken offline.

Cnet-to-Computer Communication Interface

The Cnet-to-computer interfaces are the INICI03 and INICI12 interfaces. The INICI03

interface consists of the INNIS01 Network Interface Module, the INICT03A Computer

Transfer Module, and the IMMPI01 Multifunction Processor Interface Module. The

INICI12 interface consists of the INNIS01 Network Interface Module and the INICT12

Computer Transfer Module

Cnet-to-Cnet Communication Interface

The Cnet-to-Cnet interfaces are the INIIR01 Remote Interface and the INIIL02 Local

Interface. Figure 2 shows the remote interface and Figure 3 shows the local

interface.

The local interface supports hardware redundancy. Redundancy requires a full set of

duplicate modules (four INNIS01 modules and two INIIT03 modules). The secondary

INIIT03 module continuously monitors the primary over dedicated Controlway. A

failover occurs when the secondary detects a primary module failure. When this

happens, the secondary assumes responsibility and the primary is taken offline.

Cnet-to-Cnet Local Transfer Module

The INIIT03 Local Transfer Module serves as the bridge between two local Cnet

communication networks. It holds the node database and is responsible for

transferring all messages between networks.

Messages include exception reports, configuration data, control data, and system

status. This module directly communicates with the INNIS01 module of the central

network and of the satellite network simultaneously. The INIIT03 module is a single

printed circuit board that occupies one slot in the module mounting unit. The circuit

board contains microprocessor based communication circuitry that enables it to

directly communicate with its two INNIS01 modules and to interface to Controlway.

Harmony Sequence of Events(SOE)

Harmony sequence of events (SOE) provides distributed event monitoring, recording,

and reporting capabilities for the Symphony Enterprise Management and Control

System. An SOE event is a transition of a digital signal from either on to off or from

off to on. A series of SOE modules collect and time-stamp these digital transition

events which are then made available to the system. Figure 1 shows the distributed

sequence of events system architecture.

An SOE module consists of a single printed circuit board that occupies one slot in a

module

mounting unit (MMU). In general, jumpers and switches on the printed circuit board

and jumpers and dispshunts on the termination unit configure the module and its I/O

channels. A cable connects the SOE module to its termination unit. The physical

connection points for field wiring are on the termination unit.

Server Node

The INSOE01 Server Node consists of the INNIS01 Network Interface module, the

INSEM01 Sequence of Events Master module, and the INTKM01 Time Keeper

Master module.

INSEM01

The INSEM01 Sequence of Events Master module communicates with the INNIS01

Network

Interface module and the INTKM01 Time Keeper Master module. The INNIS01

module is the

front end for all Cnet (control network) communication interfaces and is the intelligent

link

between a node and Cnet. The INSEM01 module communicates directly with the

INNIS01 module.

The INSEM01 module is responsible for managing the distributed sequence of

events system,

which includes managing:

1,500 points coming from the SOE I/O modules in up to 1,000 Harmony

control units (HCU).

256 complex triggers with 16 operands each.

3,000 simple triggers.

The INSEM01 module monitors Harmony control units for data on an exception

report basis, collects and sorts data it acquires, and provides SOE data to human

system interfaces for report

presentation after some predefined trigger condition occurs. Digital state transitions

are collected

at the HCU level by IMSED01 and INSET01 modules, then forwarded to the

INSEM01 module.

The INSEM01 module records the information and sorts it according to time in an

internal database. When a trigger condition occurs, the human system interface is

notified and data transfer occurs.

INTKM01

The INTKM01 Time Keeper Master module provides time information to the

INSEM01 module

and to the rest of the distributed SOE system through the time synchronization link.

The

INTKM01 module connects to an external receiver using IRIG-B time code link. The

module transmits absolute time to the rest of the system using the RS-485 time

synchronization link.

The INTKM01 module cable connects to an NTST01 termination unit. In this case,

the termination unit provides the connection point for the external receiver signals

and also the time synchronization link.

IMSET01

The IMSET01 Sequence of Events Timing module processes up to 16 digital field

inputs, and

receives and decodes the time synchronization link information sent by the INTKM01

module for a Harmony controller. The controller utilizes function code 241 (DSOE

data interface) to interface SOE data from the IMSET01 module to the INSEM01

module, and function code 242 (SOE digital event interface) to configure and access

the IMSET01 module input channels. Each channel is optically isolated, and can be

individually programmed for 24 VDC, 48 VDC, 125 VDC, and 120 VAC input.

The module communicates with its Harmony controller over I/O expander bus. Only

one

IMSET01 module can operate on an I/O expander bus segment. The module cable

connects to

NTST01 and NTDI01 termination units. The NTST01 unit provides for time

synchronization link termination. The NTDI01 unit provides for field wiring

termination.

IMSED01

The IMSED01 Sequence of Events Digital Input module is similar to the IMSET01

module except that it only processes up to 16 digital field inputs for the Harmony

controller. It does not process time synchronization link information. The controller

utilizes function code 242 (SOE digital event interface) to configure and access the

IMSED01 module input channels. Up to 63 IMSED01 modules can operate on an I/O

expander bus segment along with one IMSET01 module. The NTDI01 termination

unit provides for field wiring termination.

Composer™ System

Composer provides a comprehensive set of engineering and maintenance tools for

the Symphony Enterprise Management and Control System. Composer is designed

to operate on the Microsoft® Windows NT® 4.0 (service pack four or later) platform.

The working environment provided by Composer simplifies the configuration and

maintenance of Symphony systems. The base product contains all the functionality

necessary to create and maintain control system configurations. Applications provide

users with the ability to graphically develop

control system strategies, develop and maintain global configuration databases, and

manage system libraries of reusable software components.

Composer is designed to be compatible with INFI 90 OPEN system configurations

and is capable of importing existing WinTools configurations. Once imported, these

configurations can be fully integrated into Composer and utilize all its features.

Composer Applications

The base Composer product contains all the functionality necessary to develop and

maintain Symphony

control system configurations. There are two primary applications: explorer and

automation architect.

Explorer

The primary application of Composer is the explorer. Explorer presents the

Symphony system architecture and provides an intuitive means for organizing,

navigating and locating system configuration information. Explorer presents a user

with two main windows: system architecture and the object exchange.

System Window

The system architecture window functions similar to Microsoft’s file explorer. The left

pane of the window displays a hierarchical representation of the Symphony system.

When a system object is selected, the right pane displays a detailed view for the

selected object.

The system window supports two views: the document view (Fig. 1)and the data

browser view (Fig. 2). When the system window is in the document view, it will show

the configuration documents that are associated with the system object that the user

has selected. Configuration documents support long file names and can include

control logic documents, human system interface displays, or documents created by

other applications such as CAD packages or spreadsheets.

Figure 1. System Architecture - Document View

Figure 2. System Architecture - Data Browser View

The ability to associate any documents with the system architecture is an important

feature. This allows any information, such as P&IDs, cabinet arrangement drawings

or field wiring drawings, to be managed by the configuration server and therefore

accessed by Composer client applications. All that is required to edit any of these

documents is to double click on the document. Composer’s explorer will

automatically launch the appropriate application for the document selected.

When the system window is in the data browser view, the right pane of the system

architecture window will display tag information associated with the system object the

user has selected. All tag information presented, is retrieved from the configuration

server database that is managed by the Composer server.

When working in the data browser view, users can view, define, and modify tag data

for the whole system. This central repository of data is managed by Composer’s

configuration server for all tag data in the entire system. The data for each tag is

added to the configuration server database as each tag is defined. This eliminates

the need for users to enter the same information more than once. Some notable

features of the data browser view are the ability to:

_ Edit tag objects in a datasheet or property page view.

_ Filter the database. Filtering makes configuration easier and faster by eliminating

unnecessary

information from view.

_ Import and export tag data.

_ Navigate directly from a tag to its related configuration document.

_ Perform automatic search and replace operations based on complex queries.

Object Exchange

The object exchange (object library) window presents the user with a view of the

reusable components

that can be used to create control system configurations (Fig. 3). Objects are

organized in folders. Standard system components such as function codes and

standard shapes and symbols are organized under the system folder. Users are able

to use these components but since they are part of the standard system objects

supported by Composer, users are not permitted to delete these items from the

object exchange.

To support reuse, the object exchange provides library management features such

as cutting, copying, and pasting of objects between different projects. This makes it

easy for systems engineers to share objects among projects.

Automation Architect

The automation architect provides for the visual creation, editing, monitoring, and

tuning of control logic. High-level control strategies can be created by dragging and

dropping function codes from the object exchange to the control logic document.

Figure 3. Object Exchange

Control strategies are represented graphically by the automation architect. Rather

than textually programming strategies, the automation architect represents

predefined control strategies as function blocks. By connecting function blocks

together (Fig. 4), users are able to specify the signal flow of a control strategy and

visually define the control strategy.

Figure 4. Automation Architect

The automation architect stores configuration information in control logic documents.

Control logic documents support grouping of multiple logic sheets in a single

document. This permits users to group sheets of logic together using process

partitions. For example, a single control logic document could be used to define the

control strategy for a mix tank. Each control loop or motor control sheet associated

with the mix tank could be assigned to the control logic document. Partitioning control

logic in this manner is more process object oriented and intuitive to process

engineering personnel (Fig. 5).

The monitoring and tuning capabilities (Fig. 6) of the automation architect provide the

ability to troubleshoot and maintain an operational system using the same

information used to create the system. By using the monitoring functionality, it is

possible to obtain dynamic operating values from the Symphony system. These

values are automatically presented on the same control logic documents that were

used to configure the module. Composer’s tuning functionality allows the change of

logic parameters as permitted by the controller. The control logic document in the

Composer application and in the module are dynamically updated when tuning

changes are made so that the documentation for the system accurately reflects the

current configuration of the controller.

Figure 6. Monitoring and Tuning Capabilities

Control Logic Templates

Two of the primary goals of Composer are to reduce the cost of implementing control

strategies and improve the quality of Control strategy software. To realize these

goals, Composer supports a new type of document called a Control Logic

Template.Control Logic Templates (Fig 7.) define reusable standard control

strategies that are typically used to develop a process automation system, and can

be thought of as blueprints that define the structure of a control strategy. They are

maintained by the object exchange and can be used to quickly define control logic

documents.

The Control Logic Template Linking functionality allows users to define logic that is

controlled by the template or can be modified within a logic document. Any

subsequent changes made to a template can then be propagated to logic

documents. When a template updates its documents it will preserve logic additions

that the user has made to the document. This template management functionality

provides efficient maintenance and utilization of reusable standard control logic.

EMERGENCY TRIP SYSTEM (ETS)

Sagardighi Thermal Power Project (2 × 300MW) uses PLC based Emergency

Trip System (ETS) to ensure fast turbine tripping in case of some specified abnormal

conditions occur in the main plant. The PLC is a (90-70) series of GE Fanuc .It takes

different data continuously from many field instruments acting as trip device,

processed signals from main control system (in SgTPP main control system is DCS

manufactured by M/s. ABB Ltd.), Digital Electro-hydraulic system which govern

opening/closing of turbine main stop valves & control valves, Turbine Supervisory

Instrumentation that monitors healthiness of turbine and Instrumentation & Control

power cabinet which supplies power to the control cabinet of DCS and ETS as well.

Each unit of the plant contains separate ETS panel to process. The decision

taken by ETS PLC is through Triple Modular Redundant (TMR) which sends trip

signals to tripping device attached to turbine main stop valve and turbine control

valve by voting 2 out of 3 processed signals. TMR avoids any chance of tripping due

to wrong signal coming out from one of any 3 inputs.

INPUT/OUTPUT OF ETS: There are two terminal blocks at the back panel of ETS,

D1 and D2. All the inputs from various systems and field terminate at D1 and all the

processed output signal goes out from ETS via D2. The output signals serves two

purposes, i) goes to tripping devices and ii) others go to DCS for viewing different

alarms like PLC failure, power failure etc. For all the tripping signals there is

individual display at Power Generation Portal (Front end graphic software used for

main plant operation). All the inputs to the ETS are made into three separate inputs

by using diode and put into three separate Input modules. The Input modules are 06

nos. and driven by 24V DC. All the Input modules are IC660TBD024M and are sink

type in nature. Each Input module has 32 channels so as to handle 32 inputs at the

same time. There are 08 nos. of output modules used in each ETS. They are also of

24V DC type. Four of them are of sink type (IC660TBD024M) and others are source

(IC660EBD025V) type. Two sink type output modules & two source type output

modules combine to make 32 nos. of output data and rests make another 32 nos. of

output data. Each unit is called a `H` type formation of output and combined digital

output energies corresponding output relays.

CPU, BUS & BUS CONTROLLERS: ETS system has three individual PLC units.

Each PLC is having separate power supply units, one CPU (CPM790) and Three Bus

Controllers (BEM791). As each input to the ETS system is made into three and is fed

to three PLCs so there are three buses for whole communication. Each CPU takes all

the three inputs from all the three buses. To achieve this kind of arrangement Each

CPU requires three Bus Controllers. So, each bus passes through three bus

controllers of different PLC, two input modules and three/two output modules. There

is one 150Ω resistance used at each termination of three individual busses. Diagram

below shows how architecture has been done between bus controllers of different

PLC, 6nos. of DI & 8nos. of DO.

5 6 4

Bus-1 Bus-1

PLC A PLC B PLC C DI DI DO DO DO

3 1 2

Bus-2 Bus-2

PLC A PLC B PLC C DI DI DO DO DO

7 8

150Ω 150Ω resistor

Bus-3 Bus-3

PLC A PLC B PLC C DI DI DO DO

Bu

s Co

ntro

ller 1

Bu

s Co

ntro

ller 1

Bu

s Co

ntro

ller 1

Bu

s Contro

ller 2

Bu

s Contro

ller 2

Bu

s Contro

ller 2

Bus C

on

troller 3

Bus C

on

troller 3

Bus C

ontro

ller 3

HOW TMR & DUAL OUTPUT WORKS: As discussed earlier every single input is made triple using a diode and fed to single

PLC via bus and bus controllers and each bus passes through two input modules

handling 1-32 nos. and 33-64 nos. of data. Each PLC CPU is configured with

different addresses but same programmable logic is loaded into every PLC. The

addresses given in the CPUs are also reflected to bus controllers also. So through

bus controller arrangement every PLC knows what happens to the other PLCs. If one

digital input changes its state the Triple Modular Redundant will vote out any

possibility of getting state change to its corresponding output channel.

The output modules are of `H` type combination. Each `H` consists of two source

type output modules and two sink type output modules. First `H` can handle 1-32

nos. of output and second `H` can handle 33-64 nos. of output. PLCs can generate

dual output source and dual sink corresponding to each output relay which energizes

actuator associated to the electro-hydraulic governor to make the turbine valves

quick close.

REASONS FOR TURBINE TRIP BY ETS : The emergency trip system

(ETS) of steam turbine is able to start automatically the closing loop while trouble

occurring with turbine, tripping occurring with generator and tripping occurring with

main fuel of boiler, thus to fast close the steam inlet valves (main stop valves and

control valves). The ETS is composed of mechanical-hydraulic and electrical-

hydraulic parts. That means the trouble can be detected in mechanical mode and

electrical mode. But the closing of steam inlet valves are controlled by the hydraulic

control and protection system finally.

Mechanical-hydraulic emergency tripping: The emergency governor is a

mechanical detector for overspeed trouble. In case the speed of turbine reaches

n≥3300rpm, a stop ring will be flies out by the action of centrifugal force to actuate

the emergency tripping device. The emergency tripping device changes the moving

direction of the trip valve in tripping isolation valve group to drain the HP control oil.

After the HP control oil is drained, the overspeed limiting control oil is also drained

though the check valve. As a result the control oil pressure in dump valves for

servomotors of steam inlet valves disappears and the dump valves are open. Then

the pressure oil in both upper and lower chambers of servomotors is connected to

the drain port through the opened dump valves to fast close the steam inlet valves.

After full closing the main stop valves the limiting switch signal will be sent out to the

check valves through electric control loop.

Electric-hydraulic emergency tripping: This is an electric mode to detect the

trouble occurring with turbine, the tripping occurring with generator and the tripping

occurring with main fuel of boiler and also to send out the electric tripping signal to

the mechanical tripping electric magnet 3YV at the same time.

As soon as the electric tripping signal is sent to the mechanical tripping electric

magnet 3YV, the latter will be energized to actuate the emergency tripping device

through linkage mechanism. The following process will be performed as same as

described in Mechanical-hydraulic emergency tripping system.

Electric tripping signals: The electric tripping signals of ETS for the steam

turbine are as follows:

1. Overspeed Trip: In case the speed of turbine rises to 3300 rpm and above,

the overspeed relays in overspeed monitoring channels of ETS are actuated

and the tripping signal is sent out after processing by the ETS in 2 out of 3

logic through the output contact.

2. Low Lube Oil Pressure Trip: In case the oil pressure in lube line

P≤0.0392MPa (which is the setting value for pressure switch), three pressure

switches PSA4~PSA6 in lube oil low pressure tripping device will be reset and

three normally-closed(NC) contacts will send out the tripping signal after

processing by the ETS in 2 out of 3 logic.

3. Low Control Oil Pressure Trip: In case the oil pressure in fire-resistant

oil line P≤7.8MPa, three pressure switches in resistant oil manifold supplied by

the DEH manufacturer will be reset and three normal-open(NO) contacts will

send out the tripping signal after processing by the ETS in 2 out of 3 logic.

4. Condenser Low Vacuum Trip: In case the pressure in condenser

P≥19.7kPa, three vacuum switches in condenser low vacuum tripping device

are actuated and three normal-open(NO) contacts will send out the tripping

signal after processing by the ETS in 2 out of 3 logic.

5. Axial Position High Trip: In case the shaft displacement related to thrust

bearing increases (≥ 1.2mm or ≤ -1.65mm), the contact of the axial

displacement emergency relay in dual-channel axial displacement monitor will

send out the tripping signal after processing by the ETS.

6. Main Fuel Trip: The steam turbine will suffer tripping by trouble with main

fuel of boiler, and the signal will be supplied by the Furnace Safeguard

Supervisory system (FSSS).

7. Generator Failure Trip: The steam turbine will suffer tripping by trouble

with generator, and the signal will be supplied by the generator protection

system.

8. Shaft Vibration High Trip: The TSI (Turbine Supervisory

Instrumentation) will send out the shaft vibration in X axis at any of #1~#6

bearings is too high (≥ 0.25mm) or the shaft vibration in Y axis at any of #1~#6

bearings is too high (≥ 0.25mm). Above mentioned combination logic has been

conducted in the TSI and a contact signal is sent out by the TSI to the ETS for

turbine tripping.

9. EHG Failure Trip: This is the turbine tripping signal supplied by the DEH

(Digital Electro-hydraulic System) and contains the turbine overspeed

monitored by DEH, DEH speed signal trouble and etc. It is used to output the

shut-down contact signal for turbine tripping.

10. Differential Expansion High Trip: The TSI (Turbine Supervisory

Instrumentation) will send out the HP/IP differential expansion trip signal if it is

≥ 7μm or ≤ -4μm or LP differential expansion ≥15μm. Above mentioned

combination logic has been conducted in the TSI and a contact signal is sent

out by the TSI to the ETS for turbine tripping.

11. Remote Manual Trip: There is one manual push button in Central Control

Room. If any case somebody presses it sends one tripping signal to ETS and

ETS makes the turbine trip.

12. Generator Cooling Water Loss Trip: In case the cooling water flow for

generator ≤ 35 T/H, three Differential Pressure switches (DP set at ≤ 29.4kPa)

meant for generator cooling water flow low trip are actuated and three normal-

close contacts will send out the tripping signal after processing by the ETS in 2

out of 3 logic.

13. Exhaust Temperature High Trip: In case the HP exhaust temperature

≥420˚C main plant control system will send trip signal by itself using the help

of three temperature detector to ETS where it will be activated by 2 out of 3

logic.

FURNACE SAFEGUARD SUPERVISORY SYSTEM

The Triguard SC300E is a high integrity safety system designed especially for use in

processes with high demands on the availability, reliability and fault-tolerance of the

control system; emergency shutdown systems, interlock systems, burner control,

turbine control, fire and gas detection and protection systems.

The Triguard SC300E safety controller is designed with Triple Modular Redundant

(TMR) hardware system. This hardware architecture is combined with Software

Implemented Fault Tolerance (SIFT) to achieve extremely high operational

availability and function on demand performance.

The three key aspects of Triguard SC300E, that permit system availabilities in

excess of 99.999% (about 1 hour’s downtime in 11 years) to be realized, are:

• Triple Modular Redundant architecture - TMR

• Software Implemented Fault Tolerance - SIFT (with HIFT output voter)

• On line hot repair facility

Architecture

Theory of operation

At the input modules, field signals are filtered and then split, via isolating circuitry,

into three identical signal processing paths. Each path is controlled by a

microcontroller that coordinates signal path processing, testing and signal status

reporting to its respective processor, via one of the I/O communications buses. Once

each processor has a copy of the input state it votes on that data against the input

states presented by the other two processors. The voted result is then used in the

application logic. Once the application has been processed, the results of the

application logic are again compared with the other two processors. These voted

results are then written to the output cards by the processors. The output modules

share the same microcontroller architecture as the input cards, a single result is

presented to the field by passing the three processor signals through a hardware

2oo3 voting circuit.

Processor modules

The SC300E processors have been designed around Intel microprocessors. Key

features of the processor modules are:

• Intel 32 bit microprocessor

• Support for up to 1Mb of battery backed static RAM for application logic storage.

Error detection and

correction circuitry is used to monitor all data accessed from the RAM. Onboard

lithium batteries

provide a backup supply to the RAM for up to 6 months in the event of system

power failure.

• Up to 2 Mb of EPROM programmed with Triguard SC300E’s real time operating

system. EPROM can

also be used for the storage of application logic.

• Buffered I/O communications bus via a special 96 way DIN41612 connector

permitting the live

insertion of a processor module.

• Real time calendar clock circuitry used for data logging to a resolution of 10 ms.

The size of a

processor’s sequence of events log is typically 5000 events.

• Two 8 Mbps, read-only, serial communications links used by a processor to read

I/O and diagnostic

information from its two processor neighbours.

• Front panel mounted RS232 serial communications port used for engineering

diagnostic purposes.

• Watchdog circuitry and front panel mounted control switches and indicators.

Common interface

All I/O modules in the Triguard SC300E share a common system interface as

depicted byFigure 1-4.

LOCAL IGNITION CONTROL SYSTEM

The local ignition control system is designed by Eastern Boiler Control Co., Ltd

specifically for INDIAN SAGARDIGHI 2×300MW power plant.

The boiler designed by Dong Fang Boiler Group Co., Ltd specifically for INDIAN

SAGARDIGHI 2×300MW power plant includes:

a. Four (4) Elevations of tangential fired oil compartments, which one include: one

(1) light oil gun and one (1) heavy oil gun.

b. Four (4) Elevations of tangential fired coal compartments.

Each oil burner is equipped with a Class 3 Special igniter, as defined by NFPA.

This is a high energy spark type igniter for direct ignition of the atomized oil

burner during oil burner light off.

First, the light oil gun will be lit off by igniter with the commands from operator,

then the heavy oil gun will be lit off by the light oil gun with the commands from

operator.

The igniter is also brought into service when the oil atomizer is shutdown and

purged (scavenged) to remove oil from the atomizer, the oil being lit by the igniter

as it is ejected from the atomizer by the purge (scavenged) steam. These typical

functions will be completed in FSSS (or BMS) logic.

In remote operation mode, the local ignition control system, accepted the

command from FSSS (or BMS) which is a part of DCS, send drive signals to local

devices of oil burner.

In local operation mode, the local ignition control system, accepted the

commands from operator, send drive signals to local devices of oil burner.

2 System function

The local ignition control system consists of sixteen (16) local control cabinets and

sixteen sets of local devices for oil burner.

2.1 Local devices of a oil burner

For each oil burner, includes:

Heavy oil gun insert/retract actuator drove by instrument air

With a single solenoid valve and insert/retracted limit switches (DPDT)

Light oil gun insert/retract actuator drove by instrument air

With a single solenoid valve and insert/retracted limit switches (DPDT)

Igniter insert/retract actuator drove by instrument air

With a dual solenoid valve and insert/retracted limit switches (DPDT)

High Energy Igniter (HEI)

Light oil shut-off valve

With a dual solid valve & pneumatic actuator & opened/closed limit switches (DPDT)

Light oil purge valve

With a single solenoid valve & pneumatic actuator & opened/closed limit switches

(DPDT)

Light oil atomization valve

With a dual solid valve & pneumatic actuator & opened/closed limit switches (DPDT)

Heavy oil shut-off valve

With a dual solid valve & pneumatic actuator & opened/closed limit switches (DPDT)

Heavy oil purge valve

With a single solenoid valve & pneumatic actuator & opened/closed limit switches

(DPDT)

Heavy oil atomization valve

With a dual solid valve & pneumatic actuator & opened/closed limit switches (DPDT)

2.2 The signals from the ignition control system to DCS:

Light oil valve opened

Light oil valve closed

Light oil atomization valve opened

Light oil atomization valve closed

Light oil purge valve opened

Light oil purge valve closed

Heavy oil valve opened

Heavy oil valve closed

Heavy oil atomization valve opened

Heavy oil atomization valve closed

Heavy oil purge valve opened

Heavy oil purge valve closed

Igniter insert

Igniter retracted

Light Oil gun insert

Light Oil gun retracted

Heavy Oil gun insert

Heavy Oil gun retracted

Local operation requirement

HEI sparking

2.3 The signals from DCS to the ignition control system:

Local operation permission

Open command to Light oil valve

Close command to Light oil valve

Open command to Light oil atomization valve

Close command to Light oil atomization valve

Open command Light oil purge valve

Close command to Light oil purge valve

Open command Heavy oil valve opened

Close command to Heavy oil valve closed

Open command Heavy oil atomization valve opened

Close command to Heavy oil atomization valve closed

Open command Heavy oil purge valve opened

Close command to Heavy oil purge valve closed

Insert/ retract command to Igniter

Insert/ retract command to Light Oil gun

Insert/ retract command to Heavy Oil gun

Energize HEI transformer

Flame on

3.2 Igniter and oil gun insert/retract actuator

The heavy oil gun insert/retract actuator is controlled by a solenoid 5/2 valve. Once

operated the “insert” valve will remain in its operated position after the pulse has

been removed and until the retract solenoid is operated.

The light oil gun insert/retract actuator is controlled by a solenoid 5/2 valve. Once

operated the “insert” valve will remain in its operated position after the pulse has

been removed and until the retract solenoid is operated.

The HEI igniter insert/retract mechanism is controlled by a single acting solenoid 3/2

valve which is energized to insert the igniter pod.

In the oil corner start or stop sequence, neither heavy oil gun or light oil gun need to

be insertd or retracted. When advancing command which will be sent to the solenoid

5/2 valve, the oil gun is insertd via the insert/retract actuator drove solenoid 5/2 valve,

the oil gun is retracted via the insert/retract mechanism drove by instrument air.

Before energizing the HEI transformer, the igniter pod must to be insertd. When

advancing command which will be sent to a solenoid 3/2 valve, the igniter is insertd

via the insert/retract actuator drove by instrument air. When the advancing command

is missing, the igniter will be retracted to the original position.

3.3 High energy igniter (HEI)

The HEI is used to ignite oil gun in power plant station.

It includes:

HEI transformer

Igniter pod

Special cable assembly between HEI transformer and igniter pod (about six 6

meter long0

The igniter pod moves with the igniter insert/retract actuator. Its length depends

on the light oil gun requirements. Before sparking in the start or stop sequence,

the igniter pod need inserted in the atomizing area of light oil gun. After the

sparking, the igniter pod must be retracted from the flame area as a protection

against heat overload.

HEI transformer accepts the energizing signal. A high tension capacitor in the HEI

transformer is charged up with energy and then released via a special cable

assembly to the igniter pod. The resultant arc discharge converts the energy into

heat which ignites the fuel.

3.4 Oil corner shut-off valve. Atomization valve & Purge valve

Both light oil shut-off valve and heavy oil shut-off valve drove by instrument air, which

we supplied, is controlled by solenoid 5/2 valve. When opening command is sent to

the solenoid valve, the valve is opened via the pneumatic actuator. When closing

command is sent to the solenoid valve, the valve is closed via the pneumatic

actuator.

Both light oil atomization valve and heavy oil atomization valve drove by instrument

air, which we supplied, is controlled by solenoid 5/2 valve. When opening command

is sent to the solenoid valve, the valve is opened via the pneumatic actuator. When

closing command is sent to the solenoid valve, the valve is closed via the pneumatic

actuator.

Both the light oil purge valve and heavy oil purge valve is controlled by single

solenoid coil (solenoid 3/2 valve). When opening command is sent to the solenoid

valve, the purge valve is opened via the pneumatic actuator. When missing the

opening command, it is closed automatically.

Main performance parameter of heavy oil shut-off valve or light oil shut-off valve as

below:

Control voltage:240VAC 50Hz

Instrument air pressure:0.4~0.8 MPa

Medium temperature: ＜250

Atomization/purge steam temperature: 220~250

Medium pressure: ＜3.2MPa

Main performance parameter of heavy oil atomization valve or light oil purge valve as

below:

Control voltage:240VAC 50Hz

Instrument air pressure:0.4~0.8 MPa

Medium temperature: ＜250

Atomization/purge steam temperature: 220~250

Medium pressure: 0.78~1.27 MPa

Main performance parameter of heavy oil purge valve or light oil purge valve as

below:

Control voltage:240VAC 50Hz

Instrument air pressure:0.4~0.8 MPa

Medium temperature: ＜250

Atomization/purge steam temperature: 220~250

Medium pressure: 0.78~1.27 MPa

UPS GENERAL DESCRIPTION

UPS（Uninterruptible Power System） supplies reliable and interference-resistant

AC power for computer control, SCADA, DCS, important protection, measuring meter

and solenoid valve etc.

UPS system composition in power house

1 Stabilizer panel

2 Isolation transformer panel

3 #1UPS Main panel

4 #2UPS Main panel

5 Distribution feeder panel

UPS equipment：

1. 100% Static inverter

2. 100% Static switch

3. Manual bypass switch

4. 100% UPS System battery bank

5. 100% high-frequency switch module charger

6. Step-down transformer with associated Switchgear

7. voltage stabilizer and standby power switch

8. battery panel

9. UPS AC feeder panel

UPS System description

1. The capacity of the power house UPS system is 2X80KVA for each set. The input

voltage of UPS is AC 415V ±10%, 50HZ, the output of the UPS is AC 240V, 50HZ.

The UPS is normally supplied by a 415V emergency PMCC circuit. When the 415V

emergency PMCC fails, the UPS will be supplied by its DC 1.2V, 100Ah battery bank.

Total no of batteries are 272 per UPS set. When both static inverters of UPS fail, the

supply of UPS will be automatically transferred to auto bypass.

2. Two inverters are in operation on normal condition, each carries 50% UPS load.

On failure of any inverter, its load gets automatically transferred to the other inverter

through static transfer switch. If one inverter is out of service for any reason, then the

second inverter will be working with 100% UPS load. On failure of this inverter，the

auto bypass A.C. source will supply 100% UPS load automatically through static

transfer switch.

UPS Battery Bank

UPS Technical Data

AROS 80KVA Major Technical Data：

Operating Condition 80KVA

Operating Temperature -5/50

Storage Temperature -20/70

Relative Humidity 5-95%

Total Efficiency >96% （ECO-MODE operation >98）

Average MTBF >350,000 hours

Noise 65dBA

Dimension（W×D×H）MM 800*740*1400

Weight KG 520

Rectifier Input Data

Input Voltage 415V/AC±20%

Input Frequency 50Hz/60Hz±10%

Input Power Factor >0.95

Inverter Electrical Data

Output Voltage 240V

Output Voltage Fluctuation Range ±1%

Output Voltage’s Spontaneous

Response Feature

±3%（load 0-100％ 10ms resume）

Output Voltage Distortion

--100% Non Linear Load

<1%

<2%

Output Frequency 50

Frequency Adjustable Range ±0.001

Conversion Efficiency 96%

Output Wave Form Positive Sine Wave

Overload 110％ load 5 hours；125％load 15mins.；

150％load 60secs.

Crest Factor 5:1

Inverter’s Short Circuit Resistance 5.0

Static Bypass Data

Overload Capacity 2000%，100ms

Efficiency 99%

Real Time Transfer

-from mains to inverter

-from inverter to mains

0 sec.

0 sec.

ALARM MESSAGES

A list is given below of the alarm messages displayed on the first line of the display

panel, the alarm number in brackets shows the priority level.

5.1 DISTURBANCES ON BYPASS LINE

Alarm present when there are disturbances on the bypass line of the voltage peaks

or harmonic distortions type, while voltage and frequency are correct. CAUTION. In

this case the inverter is not synchronised with the bypass line, hence if the bypass is

forced with the switch SWMB or the remote controls or panel there could be wrong

switching between voltages in counterphase.

5.2 BY-PASS MANUAL, SWMB - ON or cable defect

Manual BY-PASS SWMB Switch inserted and therefore return to normal operation is

prevented. Load is fed by the input of the BY-PASS line and therefore isn't secured

by the continuity unit. “ cable defect" only for UPS in parallel version, logic has

revealed an error in signals exchanged between the UPSs connected in parallel, and

has therefore switched the entire system to BY-PASS.

5.3 BYPASS VOLT. FAIL or SWBY, FSCR OFF

Alarm is present if:

- bypass line input voltage is wrong,

- bypass line turn-on switch SWBY is open,

- SCR fuse of the bypass line is open or burnt out following output short circuit.

5.4 MAIN LINE VOLTAGE FAIL or SWIN OFF

Input voltage is wrong and battery is discharging.

The alarm appears if:

- input voltage or frequency are without range ,

- SWIN power switch is open,

- the rectifier does not recognize the voltage due to internal anomaly;

5.5 PREALARM, LOW VOLTAGE ON BATTERY

The alarm is present if:

- the battery voltage is lower than calculated to supply approximately 5 minutes

duration or the residual ;

- autonomy time is lower than the time set for the pre alarm.

5.6 BATTERY DISCHARGED OR SWB OPEN

The logic of the UPS has carried out A BATTERY TEST, during presence of mains

feeding, the voltage of the battery was lower than the estimated value (see menu 3,2

BATTERY TEST).

5.7 LOW VOLT. SUPPLY or OVERLOAD [W]

This alarm is present if one of the following conditions is verified:

- voltage of feeding in input is insufficient to feed load, (see general characteristics);

- load of output, in active power W, is higher than the nominal value .

5.8 OUTPUT OVERLOAD

Indicates that the power absorbed by the load at the output is greater than allowed

rated power, hence the indicated value expressed in %VA exceeds 100%. The same

alarm is activated also when the peak absorbed current of the load exceeds the

maximum admitted. When this alarm is on it is necessary to reduce the load,

otherwise the system automatically goes on bypass within a time period inversely

proportional to the amount of the overload.

5.9 BY-PASS FOR VA OUTPUT < AUTO_OFF VALUE

This alarm is present when power in %VA, absorbed by the load is lower than the set

value of" AUTO-OFF".The value of %VA for AUTO-OFF is set to 0 in the factory

(therefore this alarm condition can't happen).

UPS , Stabiliser panel, AC Distribution panel

Multi Flame Detector Control Unit & Flame scanner UVISOR MFD is an advanced flame detector control unit designed for utility and

industrial multi-burner furnaces to detect and discriminate the operating burner flame.

UVISOR MFD behaves as a true “Two-Systems-in-One”, processing simultaneously

the flame signals carried by two scanner heads regardless the sensor spectral range

(Ultraviolet or Infrared) or the electrical signal type (amplitude/frequency modulated

signal or pulse rate signal).

It can achieve a stable flame-on status and a reliable discrimination at various load

rates thanks to a proven algorithm, which analyses the flame’s flicker spectrum and

tunes consequently the basic parameters of the amplifier. The UVISOR MFD

provides the “Individual channel maintenance power-off” utility thus to offer a cost

effective application options where simultaneous and independent control for burner

and pilot flame or two burners flame scanners are required.

UVISOR MFD process simultaneously flame signals from two scanners on two

separate channels. Each channel can be configured to use two different techniques

to detect the flame. Based on the detector types, these techniques are:

• Flicker frequency receiver

• Pulse counter receiver

The two-channel can be used independently one from the other to drive the

associated flame relay, they can also be connected in logical OR/AND to generate

one unique flame status.

Whether the two channels are logical interconnected (AND & OR) the second

channel relay is available to output a secondary flame on status.

Each channel can be independently tuned. Four set up files per channel can be

selected from remote (BMS) to get the best tuning at the various burner/boiler

operating condition. Tuning parameters are secured on non-volatile memory.

Acquisition, processing, display and control functions of the UVISOR MFD are

microprocessor based.

Safety and reliability of the flame control process is assured by the hardware and

firmware Fail-Safe characteristics and by the diagnostic tasks constantly operating.

UVISOR MFD provides enhanced feature to ease the tune-up, to supervise the flame

quality, to speed-up diagnosis:

− Separate analogue output. One for each flame detector.

− Automatic parameter setting.

− Connection to a local Monitoring Station through RS232 which features:

− Real time flame signal trends and archive on scroll diagram.

− View, upload and download parameters from/to the unit.

− Download new firmware releases.

− Flame flickers spectrum analysis (with burner on/off and difference plot out).

− Connection to a remote SCADA through RS485 network based on MODBUS

standard.

− Separate raw signal from the scanner heads suitable for PC standard Sound-

Board. Unconditioned flame signal is rendered for further flame performance

analysis.

− One thermocouple input and related alarm output to measure and prevent the hot

side of the scanner from overheat.

Technical specifications

1Power supply

Power Supply Voltage - 120+220Vac +/- 20% 45+65Hz

- 30VA (6A/5ms in-rush current)

- 24Vdc +/- 20%

- 22W

Fuse rating - AC Power supply 2AT 250V

- DC Power supply 4AT

- Relay outputs 6A

2 Outputs

Contacts rating Channel 1, 2 Flame relay and watch dog

- 1 SPDT standards VDE0110

- 250 Vac 3A cosf ≥ 0.4 750W cycles ≥

250 Vdc 300 mA 66W

Temperature alarm

- 1 SPST standards VDE0110

- 100 Vac 0.3A cosf ≥ 0.4 30W cycles ≥1E5

Scanner Power Supply - 24Vdc refereed to common for bias and blind

- Short circuit and overload protected

Bias Contact Power Supply - 24Vdc refereed to common for contact bias

- Short circuit and overload protected

Nr. 2 Analogue outputs - Configurable as follow:

0÷10V (R out = 600 Ω )

4÷200mA ( R load < 500 Ω)

Flame signal reading +/- 30 dB

Galvanically isolated

Protected against short circuit

Flame raw signals Two (2) 0 dBV output level.

3 Inputs

Channel Set up Selection - Nr. 2 inputs opto coupled for each channel allow to select four

different set

Off: < 5 Vdc

On: < 16 Vdc (4.5 mA typical). Vin max. 24Vdc

Thermocouple - Nr. 1 Thermocouple input type “J”

4 Mechanical Specification

Dimensions - Europe Single Standard

- Height: 3 Units, 5.06” (128.4 mm)

- Width: 21 TE, 4.19” (106.3 mm)

- Depth: 6.3” (160mm)

- Protection CEI EN 60529: IP20

Weight - 1.2 Kg

Installation - 19” Rack mounting (See section…)

Hardware Block Diagram

Legend

1 LED CH-1 When on it indicates the CH.1 flame relay energized

2 LED CH-2 When on it indicates the CH.2 flame relay energized

3 DISPLAY Alphanumeric 2*16 characters LCD. Graphic

4 MENU KEYPAD Allow to brows the MFD option and program the

operating parameters

5 DB9

CONNECTOR

“COM”

RS232 isolated serial output

When “NET” LED (8) is on the RS232 is accessing

the network

6 SET UP MODE

TOGGLE

Enabled/disabled set up function. When LED is

flickering set-up is enabled

7 SAFE LED When on it indicates the MFD has no failure and the

relevant Watch Dog relay is energized

2 UVISOR FLAME SCANNERS UR600

Scanner UR 600 is in explosion proof construction, CESI certificate No. AD 83.062

ext. 02/89 EExd, according to CENELEC Standards EN 50.014-1977 (CEI 31/8/78)

and EN 50.018-1977 (CEI 31/1/78), FM and CSA. The case has an IP66 (NEMA 4X)

degree of protection in accordance with IEC standards 144-1963.

The Scanner UR 600 IR houses a glass lens, a PbS photoresistor sensing element

and a signal conditioning / pre-amplification PCB. Terminals to the control unit are

screw type.

The Scanner UR 600 is also available in special versions with rigid or flexible probe

capable to collect signals in the nearest of the flame inside the combustion chamber,

and suitable for installation in corner-fired application.

• SCANNER UR 600

In both the direct view and extended version, the flame detection and discrimination

is bases on the capability of the scanner UR 600 Model IR to sense the IR

wavelength.

The PbS photo resistor sensitive element reacts to the dynamic characteristics of the

intensity of IR radiations issued mainly by the flame in the zone where primary

combustion takes place (flame root).

The pre-amplification circuit, hosed in the scanner head, conditions the electrical

signal to be transferred to a remote location where the control unit MFD.SA is

installed.

• SELF-CHECKING

The MFD.SA control unit cyclically executes a self-checking task. In case an error is

detected the watchdog is reset and a message appears. The IR PbS photo resistor is

an intrinsically fail-safe device; it reacts to the flame presence only, providing an AC

signal (flickering) to the MFD.SA, which energizes the flame relay.

The MFD.SA performs the self-check removing the bias voltage from the sensor

element. No electromechanical shutter is involved.

The following checks are made:

- Self-checking loop integrity.

- Ripple detection.

During self-check an error message IRSC is generated if the flame signal does not

go to zero within a selected time, while the error message IRBL is generated in case

of short circuit on the self-checking loop.

During self-check an error message IRSC is generated if the flame signal does not

go to zero within a selected time, while the error message IRBL is generated in case

of short circuit on the self-checking loop.

Self-check continues testing the programmable cut-off filters.

Four combinations of pass-band are set and for each one of them the filter behaviour

is checked.

In case of fault a specific error message appears and the Flame signal is forced OFF.

Also in this case, the control is repeated cyclically and the normal situation is

restored in case of Flame detected and successful tests.

DEH System With the progress of computer technology, the Distributed Computer System (DSC)

control based on microprocessors is more and more widely used. The emergence of

digital electro-hyraulic (DEH) control systems has broken the fact that the adjustment

of steam turbine could only be finished by the special steam turbine maintainers who

were heat engineers more often than not. Meanwhile, for turbine operators, besides

the technological process of the control system, computer knowledge is also very

important. Aiming at the new generation 300MW DEH control system that is jointly

developed by Dongfang Steam Turbine Works (DFSTW) and ABB SYMPHONY, this

instruction book presents the basic concepts of steam turbine control system, the

configuration of DEH, and the primary functions, operation specifications, and

installation and debugging methods of a control system.

Control System Principle

For our D300N steam turbine generator unit, the high-pressure (hereafter referred to

as HP) steam admission is controlled by 2 HP stop valves (hereafter referred to as

MSV) and 4 HP control valves (hereafter referred to as CV), and the intermidiate-

pressure (hereafter referred to as IP) steam admission is controlled by 2 IP stop

valves (hereafter referred to as RSV) and 2 IP control valves (hereafter referred to as

ICV). All the above 6 admission control valves are driven by hydraulic actuators to

meet the requirements of short action time and high positioning accuracy.

Normally the working rotation speed of the steam turbine is 3000r/min; however,

when the load in the grid varies, the actual rotation speed will change with it. The

speed measurement part of the steam turbine control system will measure the actual

speed and compare it with the rated speed 3000r/min, and then, through frequency

difference amplification and regulator servo control, control the opening extent of CVs

and ICVs to form a negative feedback of rotation speed, which will keep the rotation

speed within a preset range.

All the above-mentioned 10 admission valves are driven by oil servo motors that

adopt HP fire-resistant oil as working medium. Except the six control valves (CVs and

ICVs) that are controlled continuously by using servo valves and microcomputer

interface of DEH, the rest two RSVs and two MSVs are controlled by solenoid valves

and DEH interface in a two-digit way.

In order to guarantee a safe operation, several redundant protection sleeves are

available in the hydraulic system:

Emergency tripping devices and testing solenoid valves;

HP and LP stop solenoid valves;

Overspeed restriction solenoid valve.

For the oil sources of HP fire-resistant oil, 2 redundant pressure oil pumps are also

available to guarantee a continuous oil supply. For detail, see the specifications for

hydraulic system.

The combined start by HP and IP cylinders is a traditional mode. With this method,

the steam simultaneously enters into HP cylinder (intermediate pressure cylinder) by

way of CV (ICV) from superheater (intermediate superheater) and finally brings the

steam turbine to a rated operating state. During the start, in order to reduce the

throttling loss from ICV, the influence resulting from intermediate superheater needs

to be reduced. Under their respective working pressures, the ratio of the flow

capacity of CV to that of ICV is 1:3.

During the start, in general a full-admission method (throttle regulation) will be

adopted for the HP cylinder, so that the heat exposure will be uniform and thus the

heat stress will be reduced to the minimum. Under normal operation, because the

temperature field in the cylinder is roughly stable, a partial admission method (nozzle

regulation) will be adopted for the HP cylinder, so that the throttling loss can be

reduced and the efficiency can be improved.

During the start, because the physical dimensions of rotor and cylinder are very large

and the temperature of the heating surface builds up quickly, staying at certain points

during speed raising and load up is required to reduce the heat stress of steam

turbine. This is called warm-up of turbine.

A rotor has its inherent natural frequency of vibration. During the rotating of a rotor,

when the exciting frequency resulting from the eccentric mass occurring prior to

reaching equilibrium is in agreement with the natural frequency of vibration,

resonance will occur; at this point the rotation speed is called critical speed of

rotation. The resonance amplitude will increase with time, and too large a amplitude

will destroy the steam turbine generator unit; therefore, it is required that the steam

turbine shall rush through the zone in which critical speed of rotation occurs.

In general a steam turbine generator unit is required to operate in a grid.

Synchronous grid-connection means a process in which a steam turbine generator

unit is connected to an electric grid after it reaches its running rotation speed. The

conditions for synchronous grid-connection are that the switch is closed and the

potential difference of phase between both sides (generator, electric grid) of oil switch

is equal to zero, that is, both sides have the same phase sequence, voltage,

frequency, and phase.

The EHC adopts ABB’s advanced open industrial control system,

SYMPHONY ,which includes 1 printer, 1 application operating station (with the

functions of operator station (hereafter referred to as OIS) and engineering work

station (hereafter referred to as EWS)).

OIS is a major device used to conduct a human-computer dialogue between power

plant operators and steam turbine control systems.

The printer is used to record all kinds of inportant data and keep them in the archives

when necessary.

EWSs facilitate the design, debugging, and revising of control logic.

The DEH adopts two-circuit AC 240VAC UPS for power supply and has redundancy

design in the interior. The internal power supply of SYMPHON is realized by Industry

Power Module (hereafter referred to as IPM). One advantage is that the failure of one

power supply module will not affect the whole power supply; and the design is also

featured by good heat dispersion, simpleness, flexibility, safety, and high quality.

Every card has a power supply with both master and auxiliary IPMs.

Based on a design concept of decentralized control, the control system exercises its

automatic control by using a hydraulic servo system with SYMPHONY function

module configurations. The package unit consists of serialized standard hardware

modules, each of which can complete its respective functions independently and can

communicate with each other.

Major functions of the control system are as follows:

Automatic setting of static relation of servo system;

Remote latching-on prior to start;

Automatic thermal condition judgement;

HIP CV start mode

Full-range automatic closed-loop control of rotation speed from hand-turning speed

to rated speed;

Overspeed control and overspeed protection functions available;

Able to realize rapid synchronous grid-connection with the interface of automatic

synchronization installation;

Flexible selection between power control and valve position control and free

switching;

Valve management functions available;

On-line HIP SV and HIP CV activity tests available;

Able to realize remote spray oil testing and automatic latching-on after testing;

On-line HP tripping solenoid valve testing available;

Mechanical and electric overspeed testing available;

Throttle Pressure Control (TPC), load control, and valve position control functions

availale;

DEH-controlled SV and CV leak testing available

Cooperating with CCS to realize RUNBACK functions;

Cooperating with CCS to finish unit-boiler coordination control;

Sound parameter monitoring functions available;

ATC control available.

1 Automatic setting of static relation of servo system

Prior to the start of a unit, the static relation setting for servo valves, LVDTs, and

servoboards must be completed to guarantee the control accuracy and linearity of all

servoactuators so that the unit's requirement for the static relation of the servo system

can be met. Such valves as CV, ICV, and MSV can be checked simultaneously or

respectively. The process goes on at the OIS display.

1 The setting of static relation for a servo system prior to the start of a unit must fulfill

the following conditions:

Latching-on is available for the steam turbine.

All valves have been closed.

No steam is allowed in front of a SV; otherwise, when the valve is under check and

the rotation speed of the unit is greater than 100r/min, DEH will conduct tripping

automatically. In other words, the rotation speed of the steam turbine must be less

than 100r/min.

2 Calibration procedures

a) Enter into OIS "STEAM TURBINE VALVE CALIBRATION" picture, and select

"SINGLE CALIBRATION PERMIT" or "DOUBLE CALIBRATION PERMIT" (Both can be

selected simultaneously for off-line calibration, but only one of them can be selected for

on-line calibration).

b) When "SINGLE CALIBRATION PERMIT" is lit, only the valves of odd number can be

selected for calibration; when "DOUBLE CALIBRATION PERMIT" is lit, only the valves

of even number can be selected for calibration. Select the valve to be checked, the

corresponding key is lit.

c) After selecting the valve for check, begin to check the corresponding servoboard, and

at this time the "CHK" light on the servoboard begin to flicker (down flicker frequency is

slow but up flicker frequency is fast), meanwhile the "VALVE CALIBRATION IN

PROGRESS" light also begin to flicker (the same flicker frequency with that of "CHK"

light).

d) When "CHK" light and "VALVE CALIBRATION IN PROGRESS" light are normally on,

the check is over.

e) Again click the "single CALIBRATION" or "double CALIBRATION" buttons to quit from

the check mode, and at this time the "CHK" light is off and the "VALVE CALIBRATION

IN PROGRESS" light turns grey.

f) After finishing the check, inspect the static relation. Through the OIS station send out

a valve opening instruction, then check whether the opening instructions and the actual

valve opening meet the static relation's requirements; if not, conduct setting again

according to the above steps.

2 Automatic thermal condition judgement

A steam turbine's start process is also a heating process for both the steam turbine and

its rotor. In order to reduce the heat stress resulting from start, for different initial

temperature, different start curve shall be adopted.

Every time when latching-on is conducted for DEH, the thermal state of the turbine is

automatically determined based on the temperature of the inner upper wall of the HP

inner casing at the control stage of the unit. If the temperature signal from the upper wall

fails, it wall be replaced by that of the lower wall automatically.

T≤150°C Cold state;

150°C<T<300°C Mild state;

300°C≤T<400°C Hot state;

400°C≤T Extremely hot state.

3 Automatic remote latching-on prior to start

Prior to start, first generate an latching-on instruction through OIS; then reset the testing

valve block to make the emergency tripping device engaged. After latching-on, a HP

safe oil pressure is established, and all SVs and CVs are in a close state.

Permissive conditions for latching-on:

Tripping of steam turbine;

All valves in a full close state.

Push the "RESET" button in the OIS "AUTOMATIC CONTROL" menu, then the HP

tripping solenoid valve acts, the oil pressure in the upper chamber of the slide valve on

the emergency governor gear is established, and HP security oil is established; at this

time the OIS "AUTOMATIC CONTROL" menu displays the "RESET" status of the steam

turbine.

4 Startup and operating mode

1 Prewarming of HP cylinder

Prior to start, prewarming can be conducted through introducing HP by-pass steam to

the HP cylinder by way of RFV prewarming valve and HP cylinder's steam outlet.

Drivers send out a prewarming instruction to open the prewarming valve RFV, close the

vacuum valve VV, and close the HP exhaust check valve. When the temperature of the

HP cylinder reaches the specified value, keep warming for an hour, and close RFV, so

the prewarming of HP cylinder is completed.

2 HP SV (HP stop valve) prewarming

Operators send out a prewarming instruction to open 10% of the HP SV in one side and

introduce main steam into the two SVs; when the temperature of the valve bodies

reaches the specified value, the prewarming is over and the HP SV shall be closed.

3 Startup mode

3.1 Intermediate pressure (IP) cylinder start

After the prewarming is completed and the start condition is available, open VV. Select

the "STARTUP MODE" button in OIS, and then select the "IP CYLINDER STARTUP"

mode. The IP control valve will be open gradually and the speed of the unit will be

raised to 3000r/min. After grid connection, the unit has an initial load. Set up the target

load and load rate. Push the "PROCEEDING/HOLD" button. At this time a

"PROCEEDING" status displays on the menu and the unit begin to raise its load. In

order to keep the reheating pressure constant, the lower by-pass system begins to

close gradually; when the lower by-pass system is fully closed, HP and IP cylinder

switching can be conducted. Push the "CYLINDER SWITCHING" button, the switching

of HP and IP cylinder begins, that is, the IP control valve opens gradually. In order to

keep the throttle pressure constant, the higher by-pass system begins to close. When

the steam admission ratio of HP cylinder to IP cylinder reaches 1:3, it is thought that the

switch is over. HP and IP control valves participate in control simultaneously. When the

cylinder switching is in progress, the load control will be cancelled and the VV will be

closed.

3.2 Combined start by HP and IP cylinders

When the by-pass system has performance problems or hot state and extremely hot

state are used for start, a combined start mode by adopting HP and IP cylinders can be

adopted; at this point HP and IP control valves are opened simultaneously.

5 Speed control

Prior to the grid-connection of steam turbine generator unit, DEH is a rotation-speed

closed-loop isochronous control system. Its set point is the setting rotation speed.

Through the calculation of PID regulator, the servo system uses the difference of setting

speed and actual speed to control the opening of the oil servo motor, making the actual

speed vary with the setting speed. As per different start modes, the oil servo motor is

ICV or CV and ICV.

After a target speed is set, the setting speed automatically approaches the target speed

with a setting acceleration rate. When the speed reaches the critical speed zone, the

acceleration rate will be automatically changed into 400r/min/min. During speed raising,

often the steam turbine needs to be heated in medium or high speed to reduce heat

stress.

1 Target rotation speed

Except the target rotation speed set up by operators through OIS, under the following

conditions, DEH automatically set up the target speed:

When the steam turbine is just engaged, the target is the current rotation speed;

When the oil switch is just disconnected, the target is 3000r/min;

In a manual state, the target is the current rotation speed;

When the turbine has tripped, the target is zero.

When the target exceeds the upper limit, it has been changed into 3060 or 3360r/min;

In a self-start mode, the target depends on ATC;

In synchronization, the target varies with the change of the synchronous fluctuation

signals (rate of change 60r/min/min).

When the target is set in the critical range by mistake, it has been changed to a specific

critical value.

2 Acceleration rate

Set by operator, within (0~400) r/min/min;

Under a self-stardup mode, 120, 180, 360r/min/min;

Within the critical speed range, 400r/min/min.

3 Critical speed of rotation

The calculated values of combined critical speed are:

First-order: 1399r/min electric machine rotor first order

Second-order: 1679r/min HIP rotor first order

Third-order: 1753r/min LP rotor first order

Fourth-order: 3465r/min electric machine rotor second order

In order to avoid the critical speed of rotation, DEH sets up two critical speed zones, the

range of which is about ±50r/min different from the calculated values of the critical

speed. If the measured critical speed is greatly deviated from the calculated value, the

critical speed zone value and the critical speed plateau value must be revised.

Warm-up of turbine

The warm-up rotation speed depends on the specific unit, and each unit has its own

warm-up speed. When the target rotation speed is reached, the speed raising can be

ceased for warm-up. If intermitting is required during speed raising, the following

operations can be conducted:

When not in an ATC mode, the operator sends out a "HOLD" instruction;

When in an ATC mode, the operator sends out a "HOLD" instruction after the system

quits from the ATC mode.

Within the critical speed zone, the hold instruction is invalid, and only the target rotation

speed can be modified.

Note: during the warm-up, the resonant frequency with rotor and blades must be

avoided.

4 3000r/min constant speed

When the steam turbine's speed is stabilized above 3000±2r/min, all systems conduct

an inspection for grid connection. A pseudo grid connection test is conducted for the

generator to check the reliability of the automatic synchronous system and the accuracy

of adjustment. During the test period, the isolating switch on the side of generator power

grid is disconnected and a pseudo grid connection test signal is sent out. As the normal

condition, the automatic synchronous system changes the frequency and voltage of

generator through DEH and generator excited system. When the synchronization

condition is met, the oil switch is closed. Because the isolating switch is disconnected,

actually the generator is not grid-connected.

As a result, during the pseudo synchronization testing, when DEH receives the pseudo

grid connection test signals and the oil switch is closed, it does not judge that the

generator is grid-connected. In this way, an initial load resulting from grid connection

and the resultant speed rising can be avoided.

During speed rising, warm-up is required. Push down the "HOLD" button in the

"AUTOMATIC CONTROL" menu of OIS. At this point, the OIS menu displays a "HOLD"

status, and the rotation speed keeps constant for warm-up. If the unit is stepping across

the critical zone, the operation of clicking "HOLD" button will be invalid.

Attention: in some works, for no DI signal of pseudo grid connection is sent to DEH,

during the test no grid connection signals can be sent to DEH; otherwise, DEH will think

that the unit has been grid-connected and thus turn up the control valve with an initial

load, which will result in considerable rise of rotation speed.

6 Synchronous grid-connection control

When the rotation speed of steam turbine is about 3000r/min, if DEH receives the

synchronous request signals from an automatic synchronization installation, automatic

synchronization functions can be input through OIS; at this point DEH can receive the

rotation speed increase or decrease instructions of the automatic synchronization

installation, control the rotation speed, make it in agreement with the grid frequency.

The speed rate is 60r/min/min. At this point, the generator voltage (including amplitude

and phase) is controlled by the exciter control system. When the grid connection

condition is available, the generator will be grid-connected.

In case of one of the following instances, the synchronization mode will be cancelled.

Rotation speed: less than 2985 r/min or greater than 3015 r/min;

Manual status;

Rotation speed failure;

Have been grid-connected;

Tripping of turbine.

7 Control after grid connection (non CCS mode)

When a steam turbine generator unit is just grid-connected, DEH will immediately

increase the setting value, which will make the generator carry an initial load and thus

avoid the occurrence of reverse power. At the beginning of grid connection, DEH will

use the throttle pressure to correct the increased setting value, instead of inputting load

feedback.

Setting value = original value +3+f (p0).

At the beginning of grid connection, the target is also equal to the setting value.

1 Load up

After the steam turbine generator unit is grid-connected, in order to realize the primary

frequency adjustment, rotation speed feedback is available for the control system.

During testing or with a base load, load control can also be input. During inputting load

control, the target and setting value find expression in the form of MW. After the power

control is cancelled, the target and setting value find expression in the percentage of the

total flow under the rated pressure.

After the target is set, the setting value will approach the target value with a set change

rate, and along with it the generator power or throttle pressure will change gradually.

During the load up, often the steam turbine needs to be heated to reduce heat stress.

2 Target

Except the target set up by operators through OIS, under the following conditions,

DEH automatically set up the target:

When the power control is just input, the target is the current load (MW);

When the generator is just grid-connected, the target is the setting value for initial

load (%);

In a manual state, the target is the reference quantity (%) (valve total flow

instruction);

When the control is just cancelled, the target is the reference quantity (%);

When the turbine has tripped, the target is zero;

Under the mode of control of CCS, the target is CCS setting (%);

When the target is too large, it shall be replaced by the upper limit value.

3 Load rate

Set by operator, within (0~100) MW/min;

During Single / Sequential

Valve switching, 5.0MW/min.

4 Warm-up of turbine

During the load up of steam turbine, in view of such factors as heat stress and

expansion difference, in general warm-up is required. If the load up is required to pause,

the following operations can be conducted:

When not in a CCS mode, the operator sends out a "HOLD" instruction;

When in a CCS mode, the operator sends out a "HOLD" instruction after quitting it from

the CCS mode.

5 Power control

The power controller is a PI controller, used to compare the setting value and the actual

power and output CV and ICV instructions after calculation.

Power control input conditions:

With a grid-connected unit, the load varying between 6.0MW~310MW;

Normal power signal;

No CCS control input

No TPC action;

No quick release action;

No primary frequency adjustment action;

No high load restriction action;

No low load restriction;

The system in an automatic mode

When all the above conditions are met, click the “IN” button in the "AUTOMATIC

CONTROL" menu of the OIS to input power control.

Power control canceling conditions:

Operators clicking the "OUT" button in the "AUTOMATIC CONTROL" menu of OIS;

Load less than 6.0MW or greater than 310MW

Abnormal power signal; Tripping of steam turbine; Change to a manual mode; High load restriction action; Low load restriction; Quick release action; When reaching the sliding pressure point; TPC action; Primary frequency adjustment action; Tripping of oil switch; CCS control input. When there is power control input, the set point is denoted as MW. When PI isochronous control is adopted, the steady-state load is equal to the set value. 6 Primary frequency adjustment When a steam turbine generator unit is grid-connected, in order to ensure that the power supply quality meets the requirement of the grid frequency, in general primary frequency adjustment functions is required to input. When the rotation speed of the unit is within the dead zone, the frequency adjustment setting is zero, and the primary frequency adjustment fails to actuate. When the rotation speed is beyond the dead zone, the primary frequency adjustment acts and the frequency adjustment setting changes with the speed variation as per the diversity factor. The diversity factor of primary frequency adjustment is adjustable within a range of 3%~6%. Its factory set value is 4.5%. The adjustment dead zone is adjustable within a range of 0~30r/min. The factory set value for frequency dead zone is ± 10/min. When controlled by CCS, the frequency adjustment dead zone changes itself into ± 30r/min. The diversity factor and frequency adjustment dead zone of primary frequency adjustment can be displayed in the "AUTOMATIC RESTRICTION" menu of OIS. Primary frequency adjustment function input condition: The system being in a automatic state;

After the load greater than 10% of the rated load for the first time.

8 CCS control

DEH can cooperate with CCS to complete the coordination control of unit and boiler.

Under the CCS control mode, DEH is one of actuator of CCS. DEH automatically

cancels the power control and, according to the instructions given by CCS, control the

opening of all valves. DEH can give a proper judgment or restriction to CCS instructions

in terms of higher limit, lower limit, and rate of change. The signal transmission between

DEH and CCS is tabled as below:

No. Signal name Signal

direction

Signal category

1 CCS control request CCS→DEH Digital signal

2 CCS instruction CCS→DEH 4∽20mA Analog

signal

3 CCS control input DEH→CCS Digital signal

4 Valve position of steam

turbine

DEH→CCS 4∽20mA Analog

signal

Here, it is required that during CCS input the "CCS CONTROL REQUEST" signal shall

be normally available; otherwise, DEH decides that CCS proper has canceled it and as

a result DEH changes from a CCS control mode to a valve position control mode.

When DEH receives the "CCS CONTROL REQUEST" signals, we can click the "CCS

INPUT" button in the "AUTOMATIC CONTROL" menu of OIS, and the menu will display

"CCS INPUT". Under the CCS control mode, the DEH target is equal to the CCS setting

value. At this point, the target follows the increase and decrease of CCS setting signals

and the actual load also changes accordingly. Under the following conditions, cancel

CCS:

Operators clicking the "OUT" button in the "AUTOMATIC CONTROL" menu of OIS;

TPC action;;

Manual mode;

Tripping of oil switch;;

Without "CCS CONTROL REQUEST" signals;

Runback action.

All signals between DEH and CCS connected with hard wires.

9 Valve management

The philosophy for valve management is to require that within its whole range of operation a

steam turbine can select its mode of regulation as desired and realize a undisturbed switch

between throttle control (corresponding to single valve operating mode) and nozzle control

(corresponding to sequence valve operating mode). When a throttle steam distribution mode is

adopted, the rapid start-stop and varying duty of steam turbine will not go so far as to produce

oversized heat stress, so that the unit life loss can be reduced; however, within a normal load

range when a nozzle governing variable-pressure operation mode is adopted, the unit has the

best economical efficiency and operational flexibility.

During the start, speed raising, grid connection, and with low load phases, in general

the throttle control mode, i.e., the "single valve" control mode, is adopted. With this

mode, the steam flow enters into the HP control stage in a full circle, which makes the

cylinder and rotor be heated and expanded uniformly, and as a result the heat stress

resulting from start and the mechanical stress resulting from rotor blade regulation can

be effectively lowered.

Under a normal power, a nozzle control mode, i.e., the "sequence valve" control

mode， is adopted to acquire relatively high thermal efficiency.

DEH has valve management functions, that is, it can realize the undisturbed switch

between throttle control and nozzle control. Operators are able to select the steam

distribution mode of a steam turbine's control valves, and the concrete steam

distribution mode depends on the start operation mode of the steam turbine.

When the unit's load rises to a certain degree, input power control, and click the

"SEQUENCE VALVE" button in the "AUTOMATIC CONTROL" menu of OIS to display

"SINGLE / SEQUENTIAL VALVE SWITCHING". About 10 minutes later, the switching is

over. After the switching, the load shall be stable. Then switch back to the single valve

control mode. The load shall be stable. If input pressure control, and repeat the above

process, then after the switching process is over the load shall be stable. If the start is

conducted at a hot state or extremely hot state, the sequential valve mode will be

adopted forcefully. After the unit throw off the load, it will automatically set the operation

mode as sequential valve mode. If at this point you want to switch back to the single

valve mode, grid connection with an initial load is required before the switching between

single / sequential valves.

10 Overspeeds

Overspeed control and overspeed protection are available for DEH.

1 Overspeed control

1.1 Load rejection

For the time constant of the rotor of a high-capacity steam turbine is commonly very

small, the time constant of the cylinder volume is often very large. When load rejection

occurs, the rotation speed rises very quickly. If the control only relies on the system

itself, the maximum speed may exceed the action speed of the protection system and

as a result bring about steam turbine intercepting. For this reason a set of load rejection

overspeed limit logic must be set up.

If the oil switch is disconnected and load rejection occurs, both DEH hardware and

software circuits act simultaneously. The overspeed limit integrated package and the

fast solenoid valves of all oil servo motors will act quickly to close CVs and ICVs;

meanwhile the target rotation speed and setting rotation speed are changed into

3000r/min. 2 seconds later, all solenoid valves are reset, and the control valves are

restored to be under the control of servo valves, and the control turns back to normal

speed circuit control. Finally, the rotation speed of steam turbine is stabilized at

3000r/min, so that a rapid grid connection is available after the emergency disappears.

1.2 103% Overspeed

Overspeed has a large influence on the life of a steam turbine. Except in the overspeed

test, at no time the rotation speed is allowed to exceed 103% (for the max. grid

frequency is 50.5Hz, that is, 101%)

Under the condition of no overspeed test, once the rotation speed exceeds 103%, the

overspeed limit integrated package and the fast solenoid valves of all oil servo motors

will act quickly to close CVs and ICVs. When the rotation speed is lower than 103%, all

solenoid valves are reset, the control valves are restored to be under the control of

servo valves, and the control turns back to the normal speed circuit control.

1.3 Acceleration limit

In DEH there also sets up a acceleration limit circuit. When the rotation speeds of two

consecutive cycles show a difference of 10r/min, the circuit will close both CV and ICV

quickly; when the rotation speed difference is <10r/min, all solenoid valves are reset.

2 Overspeed protection

If a steam turbine's rotation speed is too high, the steam turbine will be damaged due to

the action of centrifugal stress. Although overspeed limit functions are available for DEH

to avoid steam turbine overspeed, in the event of a failure of speed restriction,

exceeding the preset speed will result in tripping, and all the stop valves and control

valves will be closed as quickly as possible

For the purpose of safe operation, there set up several layers of overspeed protection in the

system:

DEH electric overspeed protection 110%;

Mechanical overspeed protection

In addition, the following tripping functions are also available for DEH:

Mannual tripping by operator;

Sending out tripping signals by emergency stop cabinet ETS.

3 Overspeed test

Operators conduct test operation on the "OVERSPEED TEST" menu of OIS.

3.1 Mechanical overspeed test

First shift the overspeed test switch on the "OVERSPEED TEST" menu of OIS from

"NORMAL" to "MECHANICAL", then click the " MECHANICAL OVERSPEED TEST" button,

and a "TEST PROCEEDING" status will be displayed. Set the target rotation speed as

3360r/min and the speed rate as 100r/min/min for speed raising. When the speed rises so far

as to result in tripping, intercept the unit and display both the intercept speed and top speed.

After the test is over, reset the top speed, shift the overspeed test switch from the

"MECHANICAL" to "NORMAL" to quit the unit from the mechanical overspeed test.

3.2 Electric overspeed test

Shift the overspeed test switch on the "OVERSPEED TEST" menu of OIS from "NORMAL" to

"ELECTRIC", then click the "ELECTRIC OVERSPEED TEST" button, and a "TEST

PROCEEDING" status will be displayed. Set the target rotation speed as 3310r/min and the

speed rate as 100r/min/min for speed raising. When the rotation speed rises to exceed 110%,

the overspeed protection system acts, intercepting the unit and displaying the intercept

rotation speed and top speed. After the test is over, reset the top speed, shift the overspeed

test switch from the "ELECTRIC" to "NORMAL" to quit the unit from the Electric overspeed

test.

11 Valve activity test

When a unit is in normal operation, activity tests to check MSVs, RSVs, CVs, and ICVs can

be conducted regularly to avoid jamming of these admission valves. Activity tests can be

conducted for CVs and SVs respectively.

Permissive conditions for valve activity test:

All SVs are full open;

Non CCS mode;

Automatic mode.

On the OIS menu, enter into the "VALVE TESTING" menu, shift the test switch from

"TESTING PERMIT" to "TESTING", click the button of the valve for activity test and begin the

valve activity test. At this point the valve begins to be closed with a certain speed rate. When

the closing reaches 85% opening extent, the valve reopens the position prior to testing. The

test is over.

After the activity test is over, shift the test switch from "TESTING PERMIT" to "NORMAL".

12 Spray oil testing

When the rotation speed is in the order of 3000r/min, DEH can complete the spray oil

extruding test for the centrifugal stop ring of emergency overspeed governor through resetting

testing valve combinations, so as to prevent the centrifugal stop ring from jamming due to

long-term motionlessness.

When an injection test is conducted, first the isolated solenoid valve in an intercepting

isolation valve block is powered up, which isolates the emergency tripping device from the

system. Then the spray oil solenoid valve of the emergency overspeed governor is powered

up, which makes the emergency tripping valve trip. Because the stop valve has been isolated

from the system, the unit will not trip. After the emergency tripping device trips successfully,

DEH engage it through resetting the solenoid valve. After the latching-on is available, the

isolation solenoid valve loses electricity, so the isolation is canceled, the system is restored to

normal, and the spray oil test is over.

Permissive conditions for spray oil testing: the rotation speed shall be within

2985r/min~3015r/min and all the indicators of the unit are within the testing allowed range.

First in the "SPRAY OIL TESTING" menu of OIS change the test switch from "TESTING

PERMIT" to "TESTING", and then click the "SPRAY OIL TESTING" button to input spray oil

testing. The screen displays that the spray oil testing is in progress: isolation solenoid valve

4YV is electrified; after ZS4 enters into the testing position, it sends out messages; after DEH

receives the signals, spray oil solenoid valve 2YV is electrified, injects oil, and flies the

centrifugal stop ring; when DEH receives the intercepting signals of ZS2, it judges that the

spray oil testing is successful; then spray oil solenoid valve 2YV losses its electricity, the

steam turbine generator unit is reset, isolation solenoid valve 4YV losses its electricity, ZS5

returns to normal, and the spray oil testing is over.

13 HP tripping solenoid valve testing

The HP tripping solenoid valves consist of four solenoid valves, of which two valves are connected in series

and the other two valves are connected in parallel. The design is based on a principle of stop for electricity

failure, that is, the sole electricity failure of any solenoid valve will not result in the intercept of the unit;

therefore, HP tripping solenoid valves can be tested on-line one by one. The test results can be reflected by

the action of two pressure switches PS4 or PS5. When a test for 6YV or 8YV is conducted, the middle oil

pressure will be lowered, at this point the pressure switch PS4 will send out a message to show that the

solenoid valve under testing has valid action; when a test for 7YV or 9YV is conducted, the middle oil

pressure will increase, at this point pressure switch PS5 will send out a message to show that the solenoid

valve under testing has valid action.

After the latching-on for the unit is conducted, a HP tripping solenoid valve test can be

conducted.

Enter into the "TRIPPING SOLENOID VALVE TESTING" menu in the OIS, and change the

test switch from "TESTING PERMIT" to "TESTING". Press the "HP INTERCEPT TESTING"

button, and then select solenoid valves 6YV, 7YV, 8YV, or 9YV for testing. The positions of the

corresponding solenoid valve in the menu will turn red. After the test is over, the red color will

disappear. If the testing succeeds, a "SUCCESS" message will display; if the testing fails, a

"FAILURE" message will display.

14 Valve leak test

When the steam turbine runs idle at the rated speed of rotation and the steam pressure of

boiler meet some specific conditions, DEH can control the unit for SV leak testing and CV leak

testing.

When a SV leak test is conducted, all RSVs and MSVs shall be fully closed and the steam

turbine's rotation speed shall be lowered quickly. DEH works out an acceptable rotation speed

according to the current main stream pressure and confirms that the rotation speed of the unit

can be lowered below the above acceptable rotation speed, by means of which it decides

whether the SV is tightly closed.

When a CV leak test is conducted, all CVs and ICVs shall be fully closed and the steam

turbine's rotation speed shall be lowered quickly. DEH works out an acceptable rotation speed

according to the current main stream pressure and confirms that the rotation speed of the unit

can be lowered below the above acceptable rotation speed, by means of which it decides

whether the CV is tightly closed.

Permissive conditions for valve leak testing: automatic mode; latching-on available for the

steam turbine; rotation speed within 2985r/min~ 3015r/min; tripping of oil switch; in the "LEAK

TEST" menu in the OIS the test switch is in the "TESTING" position instead of "TESTING

PERMIT" position.

1 SV leak test

The turbine speed is stabilized at 3000r/min. In the "LEAK TEST" menu in the OIS, click the

"SV TESTING" button, and the button displays "TESTING PROCEEDING" and the color is

red. The control mode changes from "AUTOMATIC" to "MANUAL", all SVs are closed, and the

rpm drops. Display the steam turbine race time record.

2 CV leak test

The turbine speed is stabilized at 3000r/min.. In the "LEAK TEST" menu in the OIS, click the

"CV TESTING" button, and the button displays "TESTING PROCEEDING" and the color is

red. The control mode changes from "AUTOMATIC" to "MANUAL", all CVs are closed, and

the rpm drops. Display the steam turbine race time record.

3 When the rotation speed reaches the acceptable value, click the "OFF TEST" button to

terminate the leak test. After the test is over, the unit trips for shutdown and restart is required.

15 Automatic limit functions

DEH is featured by automatic limit function, which is used to keep the power, throttle pressure

or valve position within certain limits.

DEH can set up the maximum and minimum load limits to limit the generator's developed

power. The value is given by the operator in the OIS.

When the difference between the measured power and given power exceeds the predeterined

value, DEH automatically cancels the power control loop and changes into a valve position

control mode to ensure the safety of the unit.

DEH also has low throttle pressure protection control function (TPC function). When the

throttle pressure drops to the set value (set by operator throught OIS), the throttle pressure

limit loop is brought into operation, outputting instructions to reduce steam valve opening so

as to limit load and help the boiler to restore its throttle pressure as quickly as possible. At this

point, the power control circuit is automatically cancelled.

DEH can also set up a maximum valve position limit to restrict the steam turbine's valve

position within a certain range. The value is set by the operator in the OIS.

1 High load limit

Operators can set up the high load limit in the "AUTOMATIC LIMIT" menu in the OIS (20~

330MW) to ensure that the DEH setting value is always smaller than the limit. After the

system is powered on, the high load limit is automatically set up as 330MW. If at this point the

load is higher than the limit, it will be automatically reduced to the limit.

2 Low load limit

Operators can set up the low load limit in the "AUTOMATIC LIMIT" menu in the OIS (0~

20MW) to ensure that the DEH load is always greater than the limit. After the system is

powered on, the low load limit is automatically set up as 3MW.

3 Valve position limit

Operators can set up the valve position limit in the "AUTOMATIC LIMIT" menu in the OIS

within (0~120)%, and after the system is powered on, the limit will be automatically set up as

120%.

Additional tripping through DEH:

Some additional tripping have been incorporated through DEH system which DEH can

generate alone by sensing data directly to it. The tripping are as follows:

1. Any turbine bearing metal temperature trip which is > 115°C

2. Any thrust bearing temperature high trip > 110°C

3. Turbine Over speed trip > 3300rpm

4. Main Steam temperature low trip < 430°C

5. EH safe oil pressure low

6. Manual trip push button

7. EHG failure trip (it includes any malfunction in turbine main steam valves operation or any

power supply failure to DEH system like 48V DC) 8. Any ATR trip Which includes:

a) any brg metal temp trip

b) Any thrust brg temp trip

c) Any brg drain oil temp trip > 75°C

d) Rotor position trip +1.2 / -1.65

HART System HART stands for Highway Addressable Remote Transducer. It is an open protocol

developed in the late 1980's to facilitate communication with Smart field devices. HART

communication occurs between two HART-enabled devices, typically a field device and

a control or monitoring system. Communication occurs using standard instrumentation

grade wire and using standard wiring and termination practices.

HART provides two simultaneous communication channels: the 4-20mA analog signal

and a digital signal. The 4-20mA signal communicates the primary measured value (in

the case of a field instrument) using the 4-20mA current loop - the fastest and most

reliable industry standard.

MACHINE MONITORING SYSTEM(MMS)

Beijing ENVADA’s EN9000 device is an online vibration monitoring and protection

system for rotating machinery. It takes vibration and keyphasor data from PA fan, FD

fan, ID fan, CEP, BFP, CWP, ACWP and all mills and generates annunciation for all

vibration risk limit. MMS produces tripping signals equipment safety. The system

continuously measures and monitors the main mechanical safety parameters of the

device.

2. EN9000 Characteristics

The EN9000 uses the latest microelectronic technologies to ensure a highly

integrated, strong anti-interference capability with high reliability and ease of

installation.

The doubly redundant power supply guarantees the normal working of the system

at any time so long as commercial electric power is available.

Each module supports hot plug & pull operation. Maintenance is achieved by

module convenient replacement.

Each module is provided with a built-in microprocessor. The modules are

independent and cause no interference to other modules.

The system integrates the vibration monitoring protection and fault diagnosis

functions. All settings can be defined remotely and transferred by software download but

each channel can be set and adjusted directly on the machine. The software provides

rich functionality, with user definable display area, sensor sensitivity, alarm values,

alarm delays, alarm logic and zero point definition. The delayed access and password

protection are built in to prevent faulty operation and protect the fixed values from

unauthorized operation.

The values and development trends of each channel can be observed on the host

machine screen. Waveform and frequency analysis is provided to automatically

diagnose common rotating machinery problems, including unbalance, rotor/stator

rubbing, uneven expansion, abnormal axial position, oil whirl/whip, etc.

The common system computer vibration analysis and fault diagnosis software

provides flexible data management, real-time status monitoring, complete signal

analysis, detailed fault diagnosis and dynamic balancing.

Classification of EN9000 system modules

EN9000 system is of modular design that meets a wide range of needs. The

system is expandable. The EN9000 modules are as follows:

EN9000/RX unit

EN9000/1X power supply module

EN9000/40 vibration and displacement module

EN9000/30 rotational speed module

EN9000/20 keyphase module

EN9000/50 8-channel process module

EN9000/60 20-channel process module

Power Supply Module: Each EN9000 power supply module is a

half-height module and must be installed into the special

purpose slot on the left side of the chassis. Two identical power

supply modules are installed inside EN9000 chassis to provide

a two-way redundant supply.

The power supply module is installed at the lower left

corner of EN9000 chassis, and it converts

the AC voltage provided from the terminal

board on the back of the chassis to the

DC voltage ( +5V DC, +15V DC, - 24V

DC) required for the normal working of

other EN9000 modules. The external AC

supply voltage should be specified at the

time of order may be 115V AC±15% or

230V AC±15%.

Vibration sensing module: The 4-channel vibration and displacement module is

numbered as EN9000/40 (it corresponds to i/o module: EN9000／04) and is able to

monitor the radial vibration, radial clearances and axial displacement of rotating

machinery in real time. It can be used on all sizes of rotating machinery and can be

installed into EN9000 chassis to be used together with the power module and Host

Machine Module.

The 4-channel vibration and displacement module monitors the input signals from 4

sensors. It performs the following functions:

- It buffers the voltage output from the sensor signals

- It records the 4- 20mA transducer current output from the sensor signals

- It displays the status of the sensor and its channel through the LED on the

front panel

- It transmits the monitored values and set values of the 4 channels to the

central LCD.

What is critical is that the relay will trip the protection switch to shut down the

rotating machinery when the warning criteria are exceeded.

Important signal out from MMS panel:

Alarm signals of different Equipment:

1. All ID fan, FD fan, PA fan radial bearing, thrust bearing, motor drive bearing, non-

drive bearing alarms are set at 7.1mm/sec.

2. All ID fan, FD fan, PA fan radial bearing, thrust bearing, motor drive bearing, non-

drive bearing tripping are set at 10mm/sec.

3. All BFP, CEP motor drive ,motor non-drive, pump drive and non-drive bearings

alarm has been set at 80 microns.

4. All BFP, CEP motor drive ,motor non-drive, pump drive and non-drive bearings

tripping has been set at 150 microns.

5.All mills Reductor vibration alarms set at 5.6 mm/s.

TURBINE SUPERVISORY INSTRUMENTATION(TSI)

TURBINE SUPERVISORY INSTRUMENTATION is abbreviated to TSI. As the turbine capacity and

the turbine capacity keep creasing, and the thermal system becomes more and more complicated,

smaller stage clearance and the gland clearance are chosen in order to higher the thermal economy

of unit. Since the speed of turbine is quite fast, the rotating parts and the static parts are possibly

scrap without right operation or control, which may result in serious accidents like blade cracking,

shaft bending, thrust pads burning, etc.. In normal operation, the mechanical parameters of the axial

displacement, the thermal expansion, the differential expansion, the rotating speed, the libration, the

main bearing eccentricity and etc., should be monitored and be protected. The main valve will close

automatically to stop the unit when the monitored parameters over the limit.

3500 series: SgTPP is using 3500 series Bently Nevada vibration monitoring

system. This comes with rack configuration system. One dedicated rack is there for

analyzing all turbine shaft vibration.

Designed using the latest in proven microprocessor technology, the 3500 is a full-

feature monitoring system. In addition to

meeting the above stated criteria, the 3500 adds benefit in the following areas:

• Enhanced Operator Information

• Improved integration to plant control computer

• Reduced installation and maintenance cost

• Improved reliability

• Intrinsic Safety option

Enhanced Operator Information: The 3500 was designed to both enhance

the operator's information and present it in a way that is easy for the operator

to interpret. These features include:

• Improved Data Set

- Overall Amplitude

- Probe Gap Voltage

- 1X Amplitude and Phase

- 2X Amplitude and Phase

- Not 1X Amplitude

• Windows® Based Operator Display Software(System1 software)

Improved integration to plant control computer:

• Communication Gateways supporting multiple protocols

Reduced installation and maintenance cost:

• Reduced cabling costs

• Improved space utilization

• Easier configuration

• Reduced spare parts

Improved reliability:

• Redundant power supplies available

• Triple Modular Redundant (TMR) monitors and relay cards available

• Redundant Gateway and Display Modules permitted

The following modules may be installed in the 3500 rack:

Power Supply: The Power Supply is a half-height module available in AC and DC

versions. One or two power supplies can be installed in the rack. Each power supply

has the capacity to power a fully loaded rack. When two power supplies are installed in

a rack, the supply in the lower slot acts as the primary supply and the supply in the

upper slot acts as the backup supply. If the primary supply fails, the backup supply will

provide power to the rack without interrupting rack operation. Any combination of power

supply types is allowed. Overspeed Detection and TMR Monitors require dual power

supplies.

Rack Interface Module: The Rack Interface Module is a full-height module that

communicates with the host (computer), a Bently Nevada Communication Processor,

and with the other modules in the rack. The Rack Interface Module also maintains the

System Event List and the Alarm Event List. This module can be daisy chained to the

Rack Interface Module in other racks and to the Data Acquisition / DDE Server

Software. The 3500 Monitoring System Computer Hardware and Software Manual

shows how to daisy chain the Rack Interface Modules together. Rack Interface Modules

are available in Standard, Triple Modular Redundant and Transient

Data Interface versions.

Communication Gateway Module: The Communication Gateway Modules are full-

height modules that allow external devices (such as a DCS or a PLC) to retrieve

information from the rack and to set up portions of the rack configuration. More than one

Communication Gateway Module can be installed in the same rack. Communication

Gateway Modules are available

for a variety of network protocols.

Relay Module: Relay Modules offer relays that can be configured to close or open

based on channel statuses from other monitors in the 3500 rack. Relay modules are

available in 4 channel, 16 channel, and 4 channel Triple Modular Redundant The TMR

Relay Module is a half-height 4-channel module that operates in a Triple Module

Redundant (TMR) system. Two half-height TMR Relay Modules must operate in the

same slot. If the upper or lower Relay Module is removed or declared as not OK, then

the other Relay Module will control the Relay I/O Module.

Keyphasor Module: The Keyphasor Module is a half-height module that provides

power for the Keyphasor transducers, conditions the Keyphasor signals, and sends the

signals to the other modules in the rack. The Keyphasor Module also calculates the rpm

values sent to the host (computer) and external devices (DCS or PLC) and provides

buffered Keyphasor outputs. Each Keyphasor Module supports two channels and two

Keyphasor Modules may be placed in a 3500 rack (four channels maximum). If two

Keyphasor Modules are used, they must be placed in the same full-height slot and will

share a common I/O module.

3500/22M Transient Data Interface

The 3500 Transient Data Interface (TDI) is the interface between the 3500 monitoring

system and Bently Nevada’s System 1® machinery management software. The TDI

combines the capability of a 3500/20 Rack Interface Module with the data collection

capability of a communication processor such as TDXnet.

TDI operates in the RIM slot of a 3500 rack in conjunction with the M series monitors

(3500/40M, 3500/42M, etc.) to continuously collect steady state and transient waveform

data and pass this data through an Ethernet link to the host software. Static data

capture is standard with the TDI, however using an optional Channel Enabling Disk will

allow dynamic or transient data to be captured as well. TDI has made improvements in

several areas over previous communication processors in addition to incorporating the

Communication Processor function within the 3500 rack.

TDI provides certain functions common to the entire rack, however the TDI is not part of

the critical monitoring path and has no effect on the proper, normal operation of the

overall monitor system. One TDI or RIM is required per rack. The TDI occupies only a

single slot in the rack and is always located in Slot 1 (next to the power supplies).

For Triple Modular Redundant (TMR) applications, the 3500 System requires a TMR

version of the TDI. In addition to all the standard TDI functions, the TMR TDI also

performs “monitor channel comparison”. The 3500 TMR configuration executes

monitoring voting using the setup specified in the monitor options. Using this method,

the TMR TDI continually compares the outputs from three (3) redundant monitors. If the

TMR detects that the information from one of those monitors is no longer equivalent

(within a configured percent) to the remaining two, it will flag the monitor as being in

error and place an event in the System Event List.

Rack Configuration Software

Rack configuration soft ware is a Windows based easy to install to the racks of 3500

system host software. All the racks like power module, RIM, Transient Data Interface ,

keyphasor module, vibration module etc can be configured remotely through RS232 or

10/100 T base Ethernet port.

For all the shaft vibration, bearing vibration, differential expansion, keyphasor,

eccentricity range is defined through this Software.

Alarm values and danger limit is defined to trigger relay attached to individual back pne

module.

TMR Relay module can be configured to incorporate more than one parameter to have

different alarm and trip events.

Type of Racks used and signals out

1. Speed module: It is a two channel speed module which senses speed of turbine and

relay out the zero speed of turbine to auto start of Turning gear.

2. Over speed module: There are three nos of 3500/53 overspeed module. They are

single channeled. Each module is configured to have a high limit relay out of 110% of

normal turbine speed i.e. 3300rpm. Three nos of output goes to ETS to trip turbine if

speed exceeds the high value.

3. Rotor position monitoring module: This is a 4 channel proximity monitoring module

which measures the rotor position. The danger limit is set as (≥ 1.2mm or ≤ -1.65mm).

The trip signal is generated through relay module.

4. Differential Expansion Module: This is a 4 channel position monitoring module which

measures HIP differential expansion & LP differential expansion & two nos of casing

expansion. Turbine trip due to differential expansion high is clubbed together and

programmed in relay module.

5. Vibration monitoring module : There are 6 nos of 3500/42 proximity module for

measuring X and Y direction vibration of each turbine shaft and bearing. The 4-20 mA

signal out is taken to DCS and turbine trip due to high shaft vibration logic is built using

Composer.

6. Eccentricity measurement: This is also a proximity module whose corresponding

sensor is mounted on front pedestal of turbine.

HPLP Bypass

HP bypass controller

The Sulzer HP bypass controller is an integrated system with the functions signal

conditioning, control and valve positioning (Figure 1). The type of operator interface can

be tailored to the needs of the individual plant. The below described functions for start

up as well as for shut down are fully automated.

With a few standardized interface signals the Sulzer bypass controller can be tied easily

into an overall plant automation. The duty of the HP bypass controller can be

summarized for the different operating conditions as follows:

Boiler start up

The controller has to control and increase the boiler steam pressure according to the

steam production of the boiler. The bypass has to divert the steam flow to the reheater,

thus ensuring a proper steam flow through superheater and reheater. The bypass

controller has to control the temperature of the steam to the reheater whenever steam is

flowing through the bypass.

Turbine start up

The HP bypass controller has to control the steam pressure until the boiler master

controller can take over the pressure control.

Load operation

The bypass is closed but the controller is ready to prevent excessive live steam

pressure or excessive pressure gradients.

Turbine load rejection/trip

The controller opens the bypass valves, if necessary with the help of the quick opening

devices, in order to prevent excessive live steam pressure and controls the pressure

until the turbine picks up load again.

Safety Function

Regulations of various countries allow the use of the HP Bypass valves as safety valves

for the HP part of the boiler without any additional conventional safety valves on the HP

side. for this the HP Bypass has to be equipped with a hardwarewise fully independent

safety system. Functionally this system is fully integrated into the bypass controller to

ensure smooth transients between safety and control function.

Figure 2 shows the main elements of a two line HP bypass with the main control

functions:

Pressure controller temperature controller injection water isolation valve control safety

function

1.2.1 Pressure control

Figure 3 shows in more detail the structure of the pressure controller and the pressure

setpoint generator. The different functions and operating modes of the pressure

controller are represented again in the start up diagram of Figure 4.

At the begin of a cold start the minimum opening (Ymin) is active. It ensures

immediately after ignition an open path and therefore a steam flow through the

superheater and reheater.

When there is enough steam production to reach a predetermined minimum pressure

(pmin) the controller begins to control the live steam pressure by opening the bypass

valves.

When the valve positions reach a predetermined value Ym (determined by the desired

steam flow during boiler start up) the setpoint generator begins to increase the pressure

setpoint in accordance with the steam production of the boiler, but with a limited

maximum gradient.

Once the target pressure for starting the turbine (psynch) is reached, the setpoint

generator switches to (fixed) pressure control. As the turbine starts to accept steam the

bypass will start to close until the turbine consumes all the steam produced by the boiler

and the bypass is fully closed.

As soon as the bypass is closed the pressure setpoint tracks the actual pressure plus a

threshold dp which keeps the bypass closed (follow mode). The maximum gradient of

the pressure setpoint is still limited. If the life steam pressure exceeds this gradient, the

bypass will start to open and the controller returns to pressure control mode. The

pressure is controlled by the bypass until normal operation has been restored and the

bypass is closed again.

1.2.2 Temperature control

Regarding temperature control it should be mentioned here only that accurate control of

the steam temperature under all operating conditions requires a controller well matched

to the wide range of operating conditions of a HP bypass (low load, quick opening at full

load, etc.). Accurate control of the temperature under all this operating conditions is an

important life conserving factor for the heavily stressed walls of the valves and piping.

1.3 LP bypass controller

The Sulzer LP bypass controller is an integrated system with the functions signal

conditioning, control and valve positioning (Figure 5). The type of operator interface can

be tailored to the needs of the individual plant. With a few standardized interface signals

the Sulzer bypass controller can be tied easily into an overall plant automation.

Although independent in operation from the HP bypass controller the LP bypass

controller must operate in conjunction with the HP Bypass system and allow the excess

steam flow which is not admitted to the turbine to pass to the condenser.

1.3.1 Pressure Control

The duty of the LP bypass pressure controller for the different operating modes can be

summarized as follows:

Boiler start up

The controller has to control the steam pressure in the reheater system. The injection

controller has, when ever the LP bypass is open, to control the desuperheating of the

steam so that it can be accepted by the condenser.

Load operation

The bypass is closed but the controller monitors the reheat steam pressure in order to

open and control the pressure whenever an unacceptable pressure increase is

monitored.

Condenser protection

Whenever the condenser is not able to accept the steam or the injection water system is

unavailable, the controller has to close the bypass through a separate safe channel in

order to protect the condenser.

During load operation the first stage pressure of the turbine serves as load signal for the

setpoint generator which generates a load dependent (sliding) pressure setpoint.

With large bypass valves, their flow capacity at high reheater pressure can exceed the

absorption capacity of the condenser. For such cases the steam flow to the condenser

must be limited by the bypass controller.

If power operated reheater safety valves are provided (e.g. Sulzer MSV valves),

coordinated operation of the reheater safety valves with the LP bypass can further

improve plant operation for the case of turbine trip or load rejection at high load. The

Sulzer LP bypass controller can provide the necessary signals for operation of the

reheater safety valves.

1.3.2 Injection water control

Because the steam conditions after the LP bypass de superheater are usually near or at

saturation condition, the temperature after the de superheater cannot be used as control

signal. The necessary injection water flow and valve position of the injection valve must

therefore be calculated from the steam flow and steam conditions. The steam flow is in

turn a function of the steam conditions and the valve position of the bypass valve. The

LP bypass controller provides the necessary computing functions to perform this

calculations and uses the calculated injection water demand as setpoint for the water

flow controller.

Software description (Version 2.5)

The parametrization software „PASO“ is used for adjustments and diagnosis of the

positioner PVRxx. PASO is a comfortable user environment for easy adjustments, which

can be done by keyboard or mouse. The communication with the positioner PVRxx is

done by a serial interface RS232.

The PASO can be used only in conjunction with the positioner PVRxx. The software

description of the positioner PVRxx must be studied precisely in beforehand, and its

instructions must be followed.

2.4 Connection to the P-card

The connection between the PC, the installed PASO and the positioner PVRxx is done

with the serial interface RS 232. For this, you must connect the enclosed cable into the

desired port on your PC and into the RS 232 connector on the positioner PVRxx. If

necessary the comunication port (COM1, 2) can be changed in the dialogue box

“Configuration”.

Local control and monitoring for hydraulic supply unit

SHV200/350/450AS

3.1 Application

The hydraulic supply units HV200AS, HV350AS and HV450AS provides pressurized

oil for the operation of hydraulic actuators. The hydraulic supply units are each

equipped with two main pumps, a pump for the filter circuit and a cooling fan. The

controller is installed in a local control cabinet on the hydraulic supply unit.

The controller monitors the hydraulic supply unit by pressure transmitter,

temperature transmitter and level transmitter. The controller activate the control

devices as accumulator charging valves, main-pump motors, filter-pump motor, and

cooling-fan motor and the heater (optional). The operation and display elements on

the control cabinet are necessary for the commissioning and are indicating detail

faulty operation on hydraulic supply unit.

The control cabinet is fully wired and tested at factory. The customer has only to

connect electric supply and I/O signals.

Optionally one regeneration station can be connected to the control cabinet. One

powered and fused output to the regeneration station (optional) is available at the

control cabinet.

3.2 Signals

3.2.1 Operating and display elements

Operational and fault conditions are displayed on the display elements in the cabinet

door. Fault messages are always stored. When the fault is cleared the hydraulic

supply unit will start operation automatically again. The fault message will be kept

stored until the operator has checked locally the hydraulic supply unit and reset the

fault message with the pushbutton (Reset).

Fig. 1 Control cabinet operating and display elements

Tag Operation and display Operation /

alarm

Inscription

on Display

Color

S411 Local operation key switch Man/Auto

S412 Lamp check pushbutton Lampcheck

S413 Alarm reset pushbutton Reset

S414/H471 Pump 1 on/off pushbutton Pump 1 run Pump 1 green

S415/H472 Pump 2 on/off pushbutton Pump 2 run Pump 2 Green

S416/H473 Filter pump on/off

pushbutton

Filter pump

run

Filterpump green

S417/H474 Cooling fan on/off

pushbutton

Cooling fan

run

Fan green

S418/H475 Heater on/off pushbutton Heater on Heater Green

H451 Protective switch tripped or Alarm MCC Red

supply fault

H452 Pressure too low, more than

2 minutes

Alarm P << red

H453 Pump changed after fault Alarm P1 <> P2 red

H454 Level low in tank Alarm L < red

H455 Pressure high Alarm P > Red

H456 Temperature too high Alarm T >> Red

H478 Nitrogen pressure low in

accumulator

Alarm N2

pressure

red

H457 Hydraulic supply unit in

operation

HV auto HV auto green

H = Lamp; S = Switch

3.2.2 I/O Signal

Following signals are available at control cabinet output terminals:

Tag Signal Contacts Abreviatio

n

Remark

K457 HV collective

alarm

SPDT HV fault Alarm

K461 HV automatic

operation

SPDT HV auto Message

K462 Pressure too low SPDT P too low Alarm

K463 Pressure too low 8xSPST

(NO)

P too low block the positioners

Signal (HV collective fault) is set when one of the following faults occur:

Protective switch tripped or supply fault (MCC)

Pressure too low, more than 2 minutes (P<<)

Pump change after fault (P1<>P2)

Level low in tank (L<)

Pressure high (P>)

Temperature too high (T>>)

Nitrogen pressure low in accumulator (N2 pressure)

Transmitter fault

1 Controller

The controller is switched to automatic mode (HV auto) as soon as the power supply is

switched on. The controller monitors and controls the hydraulic supply unit.

By remote control inputs the controller can be switched off (HV off impulse) and on

(HV on impulse). Only when signal off (HV off) is present continuous, the controller is

blocked in the off condition, also after a restart of the controller due to reset of power

supply

2 Main pumps

The main pumps supply the hydraulic oil from the tank to the accumulator. Running of

the main pumps are displayed on control panel (Pump1) (Pump2).

As soon as the controller is switched to automatic mode (HV auto) both pumps are

started, in order to reach the operating pressure as quickly as possible. The start up

of the second pump is delayed by 3 seconds. After the monitor “Press auxiliary pump

off” is crossed the standby main pump is switched off. The selected main pump

remains running.

If the pressure falls below “Press auxiliary pump on”, the standby main pump will be

switched on again, to increase the pressure again as quick as possible. The standby

pump is switched off again once the monitor “Press auxiliary pump off” has been

exceeded. If the pressure falls below “Press auxiliary pump on” three times in a row

without attending monitor “Press valve up”, a pump change is carried out and the fault

message (P1<>P2) is displayed.

If there is a fault on the selected main pump, automatic switch-over to the standby

pump takes place and the fault message (P1<>P2) is displayed.

If pressure drops below “Pressure too low” with 2 pumps running and does not recover

within 2 minutes, both pumps will be switched off and the fault message (P<<) is

displayed.

A similar sequence takes place when starting from the zero pressure condition. If the

“Pressure too low” is not crossed within two minutes both pumps will be switched off

and the fault message (P<<) is displayed.

For safety and protection reasons the main pumps are always switched off at

following fault conditions:

Level low in tank (L<)

Temperature too high (T>>)

Pressure high (P>)

When above fault conditions are cleared the main pump are switched on again. At

fault (P>) the main pump is switched-over in addition and the fault message is

(P1<>P2) is displayed.

To check, if both pumps are ready for operation, the main pumps are switched over

automatically each 3 days.

3 Accumulator charging valves

The accumulator charging valves control the accumulator pressure of hydraulic supply

unit.

As soon as the main pump is started, the corresponding accumulator charging valve is

activated. When the pressure reach “Press valve up” the accumulator charging valve is

de energized and the oil from the main pump flows back to the tank. If the pressure in

the accumulator falls below “Press valve down” the accumulator charging valve is

energized again and the oil from the main pump is charging the accumulator.

If accumulator charging is shorter than 12 second three times in a row the fault

message (N2pressure) is displayed. Remark: The nitrogen must be filled in at

depressurized accumulator. Please see instructions.

4 Filter pump

In controller automatic mode (HV auto) the filter pump is continuous in operation.

Running of the filter pump is displayed on control panel (Filter pump). The filter pump is

switched off at fault level low in tank (L<).

5 Cooling fan

The cooling fan is switched on when the oil temperature exceed “Temperature high”.

As soon the temperature falls below the threshold the cooling fan is switched off

again. Running of the cooling fan running is displayed on control panel (Fan).

6 Heater (Optional)

For low ambient temperatures the hydraulic supply unit can be optionally fitted with a

heater. The heater is switched on if the oil temperature falls below “Temperature low”.

Running of the heater is displayed on control panel (Heater).

For safety and protection reasons the heater will be switched off at following fault

conditions:

Level low in tank (L<)

Temperature too high (T>>)

When above fault conditions are cleared the heater is switched on again.

4 Power supply cabinet PVN10

Application

The power supply cabinet PVN10 is used as central supply for several local positioners

for hydraulic actuators with proportional valve.

The power supply cabinet contains one or two power supplies depending, if the

infeeding voltages is designed redundant or non redundant. The power supply cabinet

contains for each power supply one primary circuit breaker and eight output circuit

breaker for power supplying of the positioners.

Function

Each primary power supply is feed to AC-DC converters.

The outputs are short-circuit protected via circuit-breaker and can be interrupted

individually.

The output voltage of the power supply cabinet is monitored for total loss of power and

in addition for redundancy failure by redundant power supply. The failures are indicated

on the alarm relay with potential-free SPDT contacts. The alarm relay drops by any of

the above mentioned failures.

Technical Data

Electronics

Input voltage

Alternate current (AC) 85...264 VAC

Direct current (DC) 90...350 VDC

Input frequency

AC-supply 45...65 Hz

Input fusing primary 16 AT

Device fusing 12 AT

Rated power 480 W

Operating temperature -25...+50°C

Storage temperature -40...+85°C

Output voltage Vout VDC

Internal adjustable +22,5...+28,5 VDC

Output fusing

AC/DC type 8AT (each output)

Output current limitation 102 %

Derating power at >60°C 2,5% / °C

Application note

Attention: The cabinet must not be placed in direct sunlight, in order that the internal

temperature in the cabinet does not exceed the maximum permitted.

If the reference ground „M“ of the PVR10 cabinet is galvanically isolated from the

master process controller, the reference ground „M“ of PVN10 power supply cabinet has

to be connected with protection earth PE, otherwise that connection must be removed.

CCTV SYSTEM

Closed circuit television system for Sagardighi (2×300MW) power plant is designed

with full digital plan. The project is for 2×300MW subcritical burning-coal steam turbine

power unit. The closed circuit television system is installed to monitor and control #1

unit area, #2 unit area and common system area. The system is composed of the

following units: front camera unit, transmission unit, network unit, as well as the unit for

system center management, control, video record and display.

Closed circuit television system is composed of four units: 55 cameras, network transmission unit, control unit, display and record unit. Each unit includes more concrete equipments or parts. System structure schematics is as following:

Video Streamers

COLOR DOME

Control Center

`

deco

der

Video

Streamers

Switch

Color CCD Camera

Video

Manager

NetWork Record Server

CLIENT 2

To 2# lvs

CLIENT 1

To 1# lvs

1#Unit 2#Unit Common System

All functions are designed with modular. User can modify and expand its functions

according to actual demand. The system can set up different user levels, provide simple

and practical man-machine interface with graphic window, which is extremely

convenient for system administrator's operation. At the same time, using customer -

service network topology structure, the system administrator can easily add or subtract

the actual number of motoring places, and can conveniently change the definite position

of central monitoring workstation, which enhances the system utilize efficiency, and

enable the whole closed circuit television system serve the power plant with high effect

and great flexibility.

Camera

Camera part is the front part of the TV monitoring system and “eyes “of the whole

system. Its function is as follows:

Camera is selected to suit to the indoor environments and

agree with industry standard.

The selected cameras have backlight compensation function

according to the size and contrast ratio of the subject in the

whole image, the compensation electrical level needed is

calculated automatically. Even at some positions of

monitoring point the backlight phenomenon is difficult to be

avoided, the compensation function of a poor light of camera

can enable the system to produce the satisfied image, too. When the camera is shot by

strong light, the camera can not be damaged or focus light, and the image is neither

lost. By selecting the camera with the low intensity of illumination, and the super strongly

dynamic CCD can also take relatively clear pictures in the area of faint light source.

The built-in synchronizer of the camera can select the synchronous way or outer

synchronous way according to the conditions, and under any circumstance the image

scroll won’t take place in order to keep the video signal vertical and in same phase.

Specification of System Equipments

The camera of this system design selects 11 integrative and intelligent high-speed

dome type cameras (ENVD2450M is Day/Night, Color &B/W versions) and 44 color

CCD cameras (LTC0455/51 is Day/Night, Color &B/W versions) of BOSCH, which

guarantees high performance, high sensitivity effect and high quality pictures. The

cameras with Pan/Tilt and zoom lens were selected to achieve a broad field-of-view

angle and basically have no dead angle in main workshop area and other system areas.

Thus we can monitor a long distance object, and save the number of cameras. Under a

bad environment for monitoring, the outdoor camera housing (PT5723-3) with sun

shroud, thermostatic fan & heater and wiper functions was used against adverse

circumstance.

There are three cables for dome type camera (ENVD2450M), which includes power

cable (AC24V), video cable (SYV 75-3) and RS485 control cable. An outdoor dome can

be assembled for the dome type camera, which can be installed in wall-installation way

or in hanging installation way with corresponding support. The video signal of camera

and the RS485 control signal of decoder are directly sent to the video Streamer (VIP

X1). The camera power source AC240V of unit control room is transported to monitoring

spots, then is transformed to AC24V as power source of equipments.

The color CCD camera (LTC0455/50) with electric zoom lens (LTC 3384/21) is

installed in outdoor camera housing or indoor full function camera housing. The camera

housing is installed on electric Pan/Tilt (LTC9420/11). The decoder (LTC8566/50)

provides power source for camera, lens control and Pan/Tilt control. The camera video

signal and RS485 control signal of decoder are directly sent to the video Streamer (VIP

X1). The camera power source AC240V of unit control room is transported to decoder

which will provide power source for front equipments.

RUNBACK ( RB )

Runback function principle. RB is the short form of Runback which means the main auxiliary fault-trip due to unit’s actual power limitation. Control system still force to decrease the unit target load rate. This function called auxiliary unit fault load reduction. The perfect RB control strategy is established on the basis of coordinated control system. Every system must be internally coordinated (coordinated control system) and such ensure the balanced transition of the operation condition. The external coordinated control system such as FSSS, SCS, DEH, works very fast to stable the load to be decreased to unit output for premises of scope. The condition to Runback-

I. Unit is on coordinate mode.

II. Power load < 180 MW.

III. Runback push button is put into service. Runback items running condition. The unit designs have 6 kinds of items:

a) Load < 180 MW, two ID fans in operation, and one ID fan trip.

b) Load < 180 MW, two FD fans in operation, and one FD fan trip.

c) Load < 180 MW, two PA fans in operation, and one PA fan trip. d) Load < 270 MW, 4 Mills in operation, and 1 mill trip. e) Load < 220 MW, 3 Mills in operation, and 1 mill trip. f) Load < 180 MW, 2 Feed water pump in operation, 1 Feed water pump trip.

When these conditions are fully qualified and any auxiliary trips then Runback happen.

i. The process after the Runback happened.

The unit is in coordinate mode & operation is in constant pressure mode, boiler adjusts power, turbine adjust main steam pressure. According to normal working condition the target load of boiler [ 4 mill for 230MW, 3 mill for 180MW, feed water pump RB for 150MW, PA fan RB for 160MW, FD/ID fan RB for 180MW] corresponding coal feeding flow works as reducing fastly the load order of the boiler load. And according to the turbine pressure the governing pressure valve is to be set up.

ii. After RB happened automatically shut down all the super heater and reheater attemperating water, motor valve & governing valve (4 mills except RB).

iii. After RB happen when 2 mills are running in every 10 seconds 1 mill automatically trip. Trip

mill sequence will be F,E,D,A,B,C. if the B or C flow mill is running then BC flow light-heavy oil gun automatically put into service.

iv. When load reduced to target value then automatically reset RB. Or after the load getting

stable – manually reset mode is closed. At this time the unit coordinate control & stable pressure mode , turbine adjust unit power mode .

Interlock protection

ID fan trip, at the same time FD fan. PA fan trip together close A/B fan interconnecting damper. FD fan trip, together open A/B fan interconnecting damper (except APH trip by same side)

Commissioning range Commissioning range including auxiliary unit systems:

a) Mill RB b) PA fan RB c) FD fan RB d) ID fan RB e) Feed water pump RB

Provided condition before commissioning

Condition before static test

Runback function control logic configuration complete. Unit is in stop state A/B ID Fan, A/B FD fan, A/B PA fan, A-F mill, A/B air heater main motor, A/B/C feed water

pump at testing start up position.

Condition before dynamic testing put into service

DCS , DEH, BPS, PRP systems are in normal working position, main power supply and the backup power supply are safe & reliable.

Boiler side main protection(MFT) turbine side protection(ETS) and generator main

protection are already input, moreover the functions are correct & reliable. RB function control logic configuration complete, moreover passes through static test

and confirm the corrections, and finished the 1st set up of all data.

During dynamic test the unit is operating with the rated load over 270 MW. Analog variable governing system all are under normal operation, control quality fulfills

the requirement.

Analog variable load disturbance test already finished. House power changeover test finished. Take the trend group of self-providing recording parameters on the DCS .

Testing parameters record: During testing must keep record of the following parameters. Unit target load, unit actual load, order unit actual power, main steam temperature, main steam pressure target value, main steam pressure actual value, reheat steam temperature, drum water level, furnace pressure, flue gas dust oxygen %, deareator pressure, deaerator water level, FD flow quantity, primary air pressure, boiler main control order, total air content, total coal feeding content, feed water content, main steam flow etc.

Commissioning sequence RB function test program divided into 2 parts, one is dynamic test & other is static functions inspection. The most important objective of static test are as follows:- after the RB function, must check the relating of the equipments, transfer of control mode, parameter change whether correct or not. Finding out these problems is the basic steps towards dynamic test. The target of dynamic test is actually finding out that after RB, checking RB function is either reasonable or not, and every parameter is either appropriate or not, through such tests these will be further optional. And these

things ensure the safe & stable operation of the unit.

Static Test When unit is shutdown, then talking turns of simulation runback condition , check

operation load loop, moreover initially set up the load order change velocity according to the design data.

After checking the runback working condition and other control system such s FSSS

interlock system device, confirm the correction of the logic

Runback function process Passing through one kind of malfunction like simulating the control system status automatic reduction (runback) condition, except running one auxiliary unit. RB logical signal send by the main control system, FD fan, Boiler main control ,FSSS system. FSSS system requires to cut off mill and put into oil gun. RB load order repairs boiler load order. Passing through the firing rate control system, the boiler output reduce very fast , which is corresponding to the RB target value. During load reducing process the main steam pressure control system of turbine main control and the main parameter control system coordinate of MCS , these are the main parametrer of the unit, must be restored internally, and not endanger to the safe running of unit.

Dynamic operation test a) 4 mill RB test

4 mill running, the unit load stable at 270-300 MW. Turbine, boiler main control, burner, feed water pump, steam temperature and other

auxiliary control system put into service automatically. Any 1 mill stops by manual. Unit is on coordinate mode, load order automatically decrease 230MW, and decrease load

rate is 80 MW / min. Observe unit running condition, record every system curve. After unit operation getting stable , restart the stopped mill. During the test parameters must monitor- FD fan current, ID fan current , furnace

pressure , drum water level, burner condition, main steam temperature, reheat steam temperature.

Important things to remember:

i. Attentively monitoring boiler burner condition. If the boiler pressure deteriorate then must intervene MFT manually.

ii. Monitoring drum water level and steam temperature. For unit’s maintenance operation if

necessary then intervene MFT manually.

iii. If main steam pressure unable to maintain then further decrease target load by manual.

b) 3 mill RB test:

3 mills in operation. Unit load stable at above 220MW. Unit, boiler main control, burners, feed water pump, steam temperature and other auxiliary

control system function all are put into service. Stop one mill by manual. Alarm display “full RB”. When unit is on coordinate mode, the load order automatically decrease to 180MW. The load

rate is 80 MW /min. Automatically close every superheater, reheater, desuperheating water motor operated valve

and governing valve. Moreover BC &DD light-heavy oil gun automatically put into service.(If

light-heavy oil gun automatically put into service during the operation of B & C mill, then DD light-heavy oil gun automatically put into service )

Observe unit running condition, record every system curve, After unit operation is stable, restart the stopped mill. During the test parameters must monitor-- FD fan current, ID fan current

furnace pressure, drum water level, burner condition, main steam temperature, reheat steam temperature. Important things to remember:

i. Attentively monitoring boiler burner condition. If the boiler pressure deteriorate then must

intervene MFT manually . ii. Monitoring drum water level and steam temperature. For unit’s maintenance operation if

necessary then intervene MFT manually. iii. If main steam pressure unable to maintain then further decrease target load by manual.

FD fan RB test Unit load stable between180-300MW Unit, boiler main control, burners, feed water pump, steam temperature and other

auxiliary control system function all are put into service. Until the load and steam pressure getting stable manually trip one FD fan. Alarm display “FD fan RB”. No. 1 mill automatically trip, after 10 seconds no.2 mill also trip, only left 3

rd mill for

operation. When unit is on coordinate mode , the load order automatically decrease to 180MW.

The load rate is 150 MW /min. Automatically close every superheater, reheater, desuperheating water motor

operated valve and governing valve. Moreover BC &DD light-heavy oil gun automatically put into service.(If light-heavy oil gun automatically put into service during the operation of B & C mill, then DD light-heavy oil gun automatically put into service )

MIS SYSTEM (PGIM)

1. MIS overview

A plant wide Fiber-optic 1 GBPS (minimum) high speed backbone Network & workgroups is realized in the power plant. This network is used by different users of the plant for over viewing selective Plant Graphics & data on real time basis, historical data & trends and MIS reports such as Plant Generation, Unit Heat rate, Auxiliary Power consumption, DM make up water consumption, Coal / Oil stock & consumption etc. and other day to day online maintenance, Inventory & purchase related functions.

By ABB understanding, MIS can be divided to 6 parts in this project:

Plant network

MIS-DCS interface(special for customer care)

Process monitor system

Performance calculation

Boiler life calculation

Maintenance & Inventory Management system

The following is for detail.

2. Plant network

In this project, ABB provides a typical 2 level ,star style, switch network. The first level is second level switch to core switch, this is backbone network with 1GBPS bandwidth. The second level is terminal PC to second level switch, each second level switch has 24 100M ports for user.

The plant network consists of:

1 core switch – WS-3750-24 + WS-3750-12G, from CISCO.

7 second level switches – WS-2950G-24-EI, from CISCO

Servers – Real Time Server, 2 Performance and life Server, CMMS Server – IBM

X346, from IBM

21 terminal PC(IBM) with UPS(APC), Printers(HP)

2 gateway PC(Advanced)

3 Firewalls(CISCO)

The 7 second level switches will be located in different building. They will connect to

core switch with 1G bandwidth as main network. 1 terminal PC will be used as shift in charge PC to show analysis data to operator. The other terminal PC will connect to second level switch in their building. 1 Firewall will be used to connect internet, it’s in Maintenance department. The 2 gateway PC will connect to DCS network with firewall isolation.

The PGIM database will be installed in RealTime Server(MIS Server) for process data management and store.

The Performance and life Server is for performance and life calculation. The input data

required for the calculation are read out from the PGIM database, calculated within the “Technical Calculation”, and then the results are written back into the PGIM real-time database.

3. MIS-DCS interface

For MIS-DCS interface, ABB provides 2 gateways for 2 units, the OPC protocol will

be used for connection between DCS and MIS. The 3 network adapters will be installed

in the gateway, 2 connect to DCS SW for redundant configuration, 1 connects to core

switch of MIS.

In the gateway, the OPC Scanner will be installed and configured to communicate

with PGP OPC Server (DCS side) as OPC Client; it gets process data and transfer data

to PGIM database. Firewall will be used to isolate MIS from DCS for preventing illegal

network access.

4. System protection

In the plant network, there is a very import task for network design – system protection.

Virus, illegal network access, etc., many things will menace to network system. We will use 3 security technology- Network firewall, Virus firewall and VLAN to protect network, servers and terminals. Network firewall

Network firewall is be used to isolate different part in network to prevent illegal network access. It

has 2 Ethernet ports, which have different security level. According security access rule, the data flow through the firewall can be just transferred from high security port to low security port. In fact, We’ll define DCS is high security system, MIS is low security system, so data can be just transferred from DCS to MIS, and cannot be transferred from MIS to DCS, so the DCS is safe. This philosophy realizes data protection for DCS.

There is also NAT technology in the network firewall, internal network use NAT to hide network

address from external network.. In this project, internet will not know MIS network address in power plant, and MIS will not know DCS network address, so, the vicious network attack will be disable due to there no object - object address is invisible.

Virus firewall

Virus firewall is to prevent virus. This is software with C/S structure, it will be installed across all network. The server of virus firewall will be updated automatically from internet, other terminal in the plant network will get the newest virus library from the server. In this way, network will keep away from virus. VLAN

VLAN technology is realized in switch, it like a independent network. In the network, we will define all Sever in special VLAN; access to these servers will be controlled by Access List in third level of switch. Whatever IP, other VLAN, who is not authorized, cannot access these server. Using VLAN, Virus firewall (mentioned above), these servers is safe surely.

5. Process monitor system

ABB will realize a process monitor system in MIS of this project for users to over view important, selective Plant Graphics & data on real time basis, historical data & trends, and results of calculation. The product is PGIM; it includes scanner, server and client.

Process data acquisition (scanner)

Scanners to acquire data from a number of different distributed control systems. In addition to this on-line data transfer, manual inputs into the system (for example for laboratory data) are also possible.

The scanners permit a preprocessing of process data. Based on the incoming values, it is possible to derive events (messages) or to sum quantities using limit value checks. Counters can be implemented which will integrate, for instance, the operating hours or determine a switching frequency. This occurs when the status of binary values change. This preprocessing can be extended at any time by linking with DLL modules (Dynamic Link Library).

Process Data Management (Server)

PGIM includes a process data server to store:

• Signal descriptions.

• Current process data (real-time data).

• Historical process data (long-term storage).

Process data includes these stored values:

• The time of acquisition.

• The physical value.

• Detailed status information (for example measured value disturbed).

This data is retrieved from the lower-level distributed control systems and generated in PGIM. The process data server is the central element of PGIM, from which all the other functions obtain their data. It provides a high degree of safety and processing speed.

Data can be compressed for long-term storage using, for example:

• Average value.

• Minimum value.

• Maximum value.

• Last value.

• Tolerance band methods.

The tolerance band procedure is the default method of compression.

With interface functions (API), the databases can be opened for read and write access from software applications. Common interfaces (such as OLE, SQL) ensure compatibility with the usual office environment, and common Microsoft-Office products.

Process Data Evaluation (Clients)

Networked computer systems are required for the management of process data on process data servers. They are also required for the distribution of data to the respective technical departments. Commercial PC’s can be used as client workstations for data evaluation, operation and configuration.

The interconnected client-server structure minimizes the data flow in the network. Various specialized clients (software applications) provide fast and individual services for the specific tasks of plant management.

6. Performance calculation

ABB provides “PGIM Technical performance Calculation” for performance calculation

in power plant to cover customer requirements.

The program “Technical performance Calculation” is used to determine online characteristic parameters of the essential plant components in energy supply plants and to compare these parameters with set points in order to achieve an improved operation of the plant. Variables such as efficiency, contamination factors, warming up ranges, etc. are calculated cyclically and compared to time-variant set points.

The calculation modules provided by ABB Utilities are implemented as C-functions and combined in a Dynamic Link Library (DLL). In addition to this, own modules can be generated by the user and included as a DLL. MS-Excel, which has access to the C-functions, is used as configuration surface.

The input data required for the calculation are read out from the Information Management System (PGIM), calculated within the “Technical Calculation”, and then the results are written back into the PGIM real-time database. The representation of the results is effected in the PGIM either in process displays or in line diagrams. Configuration of the Calculation Server (CalcServer) is effected via Excel. Subsequently, the finished configuration is transferred as a file to the CalcServer. Then there will be no feedback from the CalcServer to Excel until, e.g., the configuration is balanced or the calculations of the CalcServer are stopped. Thus, the CalcServer continues to be controlled via MS-Excel. However, Excel has not to be opened during the whole operating time of the CalcServer, but it can be quitted after configuration.

The scope of the performance calculation:

Class (I) - Equipment protection calculations (software generated alarms);

Class (II) - Plant/equipment efficiency, Heat rate calculations;

Class (III) – Others calculations.

The detail follows customer requirements in the part of technical protocol.

7. Boiler life calculation

ABB provides “OPTIMAX Boiler Life” for calculation of life of boiler. The “OPTIMAX Boiler Life” application is a product in the OPTIMAX product family. It

is used to calculate the total degree of exhaustion of thick-walled steam-generating components which are subject to pressure and temperature. The graphic Windows surface allows quick access to the results data of the individual components and thus allows an evaluation of the general state of the steam-generating plant.

The calculations are made under consideration of the preset parameters in TRD 301 and TRD 508 plants. The data required for the calculations such as pressure, temperature, wall temperature differential, are determined as a function of time and organized into classified data prior to further processing. Based on these calculations, maintenance intervals, for example, may be increased in an optimum fashion.

Scope of the Boiler Life calculation: • Drum (sphere, Cylinder) • Superheater header (inlet and outlet) • Reheater header (inlet and outlet)

Enterprise Asset Maintenance (MAXIMO)

Driven by the demanding and changing business practices requiring advance

technological solutions and the worsening situation caused by the limitations of old

technology and design concept, Sargardighi Thermal Power Plant had been reviewing

various solutions to meet business requirements and gain competitive advantages by

harvesting the technological advances. MRO SOFTWARE is offering a system blueprint

for the next generation Enterprise Asset Maintenance (EAM) System taking future

business and technological changes into consideration.

The proposed system acts as an operational system with management decision support

facilities. It meets the objective of providing timely and integrated information to

Engineering management and engineers to make sound decisions on strategic issues.

On the technical side, the system environment is flexible enough to take advantages of

technical advances to enables users to respond quickly to sudden and rapid changes of

business environments.

MAXIMO

Maximo is a computerized asset maintenance system that provides asset management,

work management, materials management, and purchasing capabilities to help

companies maximize productivity and extend the life of their revenue-generating assets.

Maximo allows your company to create a strategy for maintenance, repair,and

operations related to both Enterprise Asset Management (EAM) and Information

Technology Asset Management (ITAM).

Maximo stores and maintains data about your company’s assets, facilities, and

inventory. You can use this information to help you schedule maintenance work, track

asset status, manage inventory and resources, and analyze costs.

Maximo.s software suite can be configured to meet the needs of a variety of

different businesses, including:

Manufacturing and utilities production

Hotels, universities, and other facilities

Buses, trains, aircraft, and other fleet vehicles

Information technology (IT) assets

Maximo helps companies to improve the availability and performance of their

revenue-generating assets while decreasing operating costs, without

increasing safety issues. Maximo lets you:

Record service requests and all related records and communications from

the initial request to problem resolution. Track work orders and failures to better schedule preventive maintenance.

Track information technology (IT) assets and their configurations across a network.

Track inventory use to find optimum stock levels. The goal is to maximize availability

of items for upcoming work, while also reducing unnecessary inventory and

associated carrying costs.

Track purchasing of inventory stores and materials for work orders. To assist in

creating budgets, you can use Maximo to track costs for labor, materials, services,

assets, and tools used to complete work orders.

Reduce on-the-job injuries and accidents by identifying hazards in the workplace

and precautions needed to increase safety.

Maximo can automate processes that are repetitive or happen on regular intervals, for

example, preventive maintenance, periodic inspections, or reordering inventory items.

Maximo.s applications are grouped into modules. The applications in a module have

similar purposes, for example, applications related to purchasing are grouped together.

Some applications, such as Work Order Tracking, function individually, while others,

such as Precautions, create records designed to be used in conjunction with records

created in other applications. Depending on your job description and security

permissions, you may have access to some or all of the Maximo modules and

applications. Chapters that appear later in this guide describe the main modules and

applications in more detail.

2. Asset Management

As utilities refocus on the fundamentals, many are increasing their investment in work

management systems. The scope of work management projects is growing to include

supply chain management, condition-based maintenance, advanced planning and

scheduling for spare parts, automated workforce scheduling/optimization, and mobile

computing. All help to drive operational efficiency and raise the return on assets. Best

practices are being introduced and becoming integral to more efficient work

management in a number of ways. Best practices build integrity-based checks and

balances into the system. Standardizing processes throughout the enterprise improves

not only the asset performance but also worker productivity and safety.

Because power plant is an asset-intensive enterprise, asset performance is the basic

and key factor to ensure the successful management of a cetain enterprise. So how to

improve the asset management of a power plant is very important and the first task to

an excellent management.

Function Design

Track asset, associated costs, histories, and failures of a serialized piece of

asset as it moves throughout a plant or facility.

Build the asset hierarchy, an arrangement of buildings, departments, asset, and

subassemblies. It provides a convenient way to roll up maintenance costs so

that you can check accumulated costs at any level, at any time. It also makes it

easy to find a particular asset number.

Use the Drilldown to view location or asset information. You can locate and

select any piece of asset by scrolling down through a location hierarchy to a

particular location and then viewing the asset there, or by scrolling down through

an asset hierarchy.

Use Asset Modeling to determine relationships between a piece of asset, its

physical location and the systems with which it may be associated.

Create hierarchies identifying operating locations as part of multiple systems.

Asset can be used in more than one location.

Associate subassemblies (child asset) and/or spare parts (inventory items) with

the current asset record, thereby building the asset hierarchy.

View PMs (Preventative Maintenance’s) and service information for the selected

asset number.

Build failure code hierarchies to record asset problems for analysis. Set

measurement points, perform trending and defect analysis through Condition

Monitoring. This can display all the measurement points for the

selected asset, including: high and low warning and action values; value and

date of the last reading; date of the last work order generated in response to an

unacceptable reading. Readings that fall between the lower and upper warning

limits can be considered safe.

MAXIMO allows you to report actual meter values for multiple meters on the

current piece of asset. You can give meters more or less importance (weight) so

that it has a greater or lesser effect on the average units per day that MAXIMO

calculates. You can specify whether or not a meter should get updated when the

meter on the asset’s parent is updated.

MAXIMO provide Routes in the following ways: apply the route to a preventive

maintenance record to generate inspection-type work orders for all work assets

listed as stops on the route; apply the route to a work order, and generate child

work orders for each work asset listed as a stop on the route; create a route on

which you specify that child work orders generated for the route stops are

treated as "details" on the parent work order. When you print the parent work

order, you see the detail-type work orders as work order operations on the

parent work order. You can also associate job plan with route.

Use the Specification of asset to associate the selected asset to a specification

template, it helps classify assets into a hierarchy of up to five levels, making it

easier to locate asset.

Assign stores, repair shops, and vendors as location records to facilitate

continual tracking of asset as it is moved.

Analyze the potential for failure based on a piece of asset’s location and the

possible effects on systems with which it is associated. You can setup your own

failure code system for tracing and analysis.

Enquiry associate asset information, include cost, warranty, running status,

calculate total down time for a piece of asset.

Apply calendar to any asset, so you can estimate run time and planned down

time and idle time.

Interface and Field Design

You use the Assets application to create and store asset numbers and corresponding information, such as parent, location, vendor, up/down status, and maintenance costs for each asset.

Tabs in the Assets application let you build the asset hierarchy, an arrangement of buildings, departments, assets, and subassemblies. The asset hierarchy provides a convenient way to roll up maintenance costs so that you can check accumulated costs at any level, at any time. It also makes it easy to find a particular asset number.

The Assets application contains the following tabs:

List: to search Maximo for asset records.

Asset: to view, modify, add, or delete the main record for an asset.

Spare Parts: to create the asset hierarchy and view the subassemblies and parts of an

asset.

Specifications: to enter or view the specification for the asset as recorded in the

Classifications application.

GPS SYSTEM

CEMS

G-CEM1000 CO Monitor

Basic Principles The G-CEM1000 uses an in-situ probe set into a duct to measure CO concentration in the flue gases. The probe includes a section that allows the diffusion of flue gases into the measurement zone or the dispersion of zero/purge air out of the tube and into the duct. The analyser uses infrared gas cell correlation technology to determine the CO levels in the flue gases as they diffuse into the measurement chamber. The diffusion cell enables accurate measurements to be made in high flue gas dust levels exceeding several gram/m3. As with conventional cross-duct analysers, this probe configuration does not require the extraction of a sample from the gas stream and makes its measurement by analysing the way in which infrared radiation, transmitted through the measurement section of the probe, is modified by the gases present. The transceiver unit containing the infrared source and detector system, required to measure the received light energy after its passage through the gas, is totally isolated from the flue gas. There is, therefore, no contact between the analyser electronics and the flue gas. Correctly installed and commissioned, this provides the opportunity to achieve very low maintenance factors and totally eliminates any possibility of altering the composition of the flue gases to be measured. The probe is inclined downward at an angle of 5o to encourage condensation to gather at the lower end and then dissipate in the stack. For smaller duct sizes, the G-CEM1000 may be supplied with a shorter probe and in this case, as build-up of condensate should be less, the probe may be mounted horizontally. The general arrangement of the G-CEM1000 monitor is illustrated below in Figure 1.

The remaining components of the G-CEM1000 are :

A Power Supply Unit (PSU) to accept mains input voltages and provide 48V supply for the analyser. A Data Display Unit (DDU) into which is routed the cabling from the PSU & junction box. The unit incorporates a LCD and may be mounted local to the analyser or remotely. A Junction Box through which is routed the cabling from the analyser & DDU. The unit should be mounted local to the analyser. Although G-CEM1000 monitors can be used for process gas analysis, they have been primarily designed to monitor pollutant emissions from industrial stacks. Legislation governing such emissions usually requires data to be reported in very specific formats. G-CEM1000 analysers are therefore designed to fulfil this requirement without the need for external data manipulation. Although differing in detail from country to country, the essential demands of legislation are common world-wide. 2. Analogue and Logic Outputs The DDU is equipped with two 0/4-20mA analogue outputs, fully configurable from the keypad. Volt-free SPCO contact outputs (50V/1A) are provided for data valid and measurement alarm levels. 3. Analyser Protection G-CEM1000 monitors are designed for outdoor installation and all units are constructed to IP68 standards, designed for ambient temperatures from -20o to +60oC. For outdoor installation, an optional weather shield is recommended for the transceiver.

Measurement Principles CO absorbs infrared energy. The spectrum has the typical characteristics of a diatomic gas and comprises a number of fine absorption bands. The CO spectrum is centred on a wavelength of 4.7μm. This type of spectrum allows the principle of gas cell correlation to be employed in the spectrographic analysis to determine the concentration of gas present. If a sample of a high concentration of CO is inserted into an infrared beam, the fine absorption bands in the CO spectrum will reach a saturation point where they are capable of absorbing all the energy in the beam corresponding to those wavelengths. The presence of further amounts of gas will not result in any further absorption and thus attenuation of the infrared beam, whereas without the high concentration sample, even small amounts of CO would produce an attenuation of the beam. By taking a ratio of measurements of the attenuation of an infrared beam with and without a high concentration sample of the gas being measured, a function can be derived which is dependent solely upon the concentration of the gas to be measured.

Because the technique uses a sample of the gas itself as a highly specific filter, the measurement has extremely high immunity to other interfering gases. 2.1. Measurement Elements An infrared beam is generated from a small, black-body emitter. Radiation from this source is focussed by a lens onto a mirror. The reflected energy is received and focussed by a second lens onto a highly sensitive infrared detector. Immediately in front of the detector is a ‘band-pass’ filter for CO. Immediately in front of this filter is a wheel that generates two optical paths; one has a sealed gas cell containing 100% pure CO; the other optical path is clear. The wheel is rotated by a stepper motor at a constant speed of 1Hz, under the control of a supervisory processor. As each of the two channels sweeps across the infrared beam the processor digitises the detector output to produce two detector signals, D1 measurement and D2 reference. These values are used to compute parameters YCO that are unique functions of CO. Detector Operation The detector is a two-stage Peltier-cooled lead selenide element. Lead selenide has a very high sensitivity to infrared energy. However, in order to obtain the necessary response for the CO measurement at a wavelength of 4.7μm, the element must be cooled to a temperature of approximately -20oC. This is achieved by the encapsulated thermoelectric Peltier cooler. The detector element temperature is monitored by an integral thermistor. The thermistor resistance is monitored by the supervisory processor and is used to control the current, and hence the power, applied to the Peltier cooler to achieve a stable detector temperature at around -20oC. The detector itself is a photo-conductive device. A series of pre-amplifiers mounted within a shielded metal enclosure ensures a stable, fast response output suitable for digitisation by the processor. Stepper Motor Control The supervisory processor develops a frequency signal which is used to drive the stepper motor. Accurate timing of this signal ensures that the gas cell wheel operates at exactly 1Hz. By counting the pulses in the frequency drive to the motor the processor knows exactly when to digitise the detector output signal in order to obtain the two signals necessary for the calculation of CO concentration. Once each revolution, a small pin on the gas wheel interrupts an optical switch to act as a reference point for the processor to begin counting pulses for the next revolution of the wheel. Diagnostic Data Each second, detector values D1 measured and D2 reference, are measured and smoothed to maximise signal-to-noise ratio. From the smoothed values the following parameter is calculated : YCO = 80000 – SCCO . D1 measured/D2 reference where SCCO is a calibration constant.

This parameter is a unique function of CO and from it the processor computes the concentration level of CO in ppm in the measurement path.

G-CEM 4000 Multi-Gas Analyser G-CEM4000 Basic Principles The G-CEM4000 analyser uses an in-situ probe set into a duct to measure the concentration of gases of interest. Figure 2 illustrates the arrangement. The in-situ tube includes a section that allows the diffusion of flue gases into the measurement zone or the dispersion of purge or calibration gas out of the tube and into the duct. This section of the tube is the analysers’ measurement cell. The analyser is capable of simultaneous measurement of up to six different gases (plus water vapour as a seventh measurement if required). As with conventional cross-duct analysers, this probe configuration does not require the extraction of a sample from the gas stream and makes its measurement by analysing the way in which infrared radiation, transmitted through the measurement section of the probe, is modified by the gases present.

The transceiver unit containing the infrared source and detector system, required to measure the received light energy after its passage through the gas, is totally isolated from the flue gas. There is, therefore, no contact between the analyser electronics and the flue gas. Correctly installed and commissioned, this provides the opportunity to achieve very low maintenance factors and totally eliminates any possibility of altering the composition of the flue gases to be measured. The remaining components of a G-CEM4000 analyser are :

• The Gas Control Unit (GCU) that controls the input of zero and span calibration gases into the analyser. It contains the necessary compressed air filtration and drying

equipment to ensure high quality air supply for the zero calibration and probe purge functions. The analyser power supply and Station Control Unit (SCU) are also housed within the GCU. The function of the SCU is as an emissions data processing unit, communications centre for the monitor and controller of the zero and span calibration functions. The SCU also acts as a data logging device in which hours emission and diagnostic data is stored for retrieval in the case of loss of main data logging in the remote pc or DCS system.

• A Junction Box through which is routed the cabling from the transceiver and the

temperature, pressure and oxygen sensors and the cable to the GCU. The unit should be mounted local to the analyser.

• The Central Data Controller (CDC) that accepts data from 1 to 16 SCUs and

processes the data for onward transmission to a remote pc or SCADA system.

Normalisation Emission limits are always defined under standard conditions of temperature, pressure and air dilution (air dilution is defined using the waste gas CO

2 or O

2 concentration). Most

legislation also requires concentrations to be reported on a dry basis; i.e. water vapour in the flue gas is not permitted to dilute the measurement. The correction of the measurement from ‘as measured conditions’ to ‘standard’ conditions is known as ‘normalisation’. Like all cross-duct analysers, G-CEM4000 analysers measure concentrations of pollutant ppm (parts per million by volume) or %, under the conditions at the measurement position. This basic ppm measurement is always corrected for the duct pressure and presented as vpm by the analyser. G-CEM4000 analysers have the capability for the outputs and display

to be configured in vpm (or %) or mg/m3

(which is a mathematical conversion depending on the molecular weight of the gas being measured and the flue gas temperature), or in

mg/Nm3

(i.e. ’normalised’ to the required standard conditions). When the outputs are required to be normalised to a pre-defined O

2 concentration as

opposed to a CO2

level, then an external O2

4-20mA signal representing Oxygen levels can

be input into the G-CEM4000. All other normalising parameters i.e. pressure, temperature, and CO

2 are measured as standard by the G-CEM4000

D-CEM2000 Dust Monitor

Introduction Dust and smoke emissions have for a long time been recognised as major atmosphere pollutants, particularly since such emissions from stacks are clearly visible to an observer. There has been a requirement for monitoring, and quantifying these emissions, for some time and a variety of instruments have been marketed throughout the world for this purpose. Instruments in the past have, however, generally proved to be unreliable, falling rapidly into disuse or to be so expensive and complex as to be affordable only by the very large users, such as power stations. The CODEL D-CEM2000 seeks to overcome these

problems by providing a reliable, simple to use instrument with low maintenance requirements.

2.2. Transceiver Units Two identical transceivers are mounted on opposite sides of the stack. The transceivers each contain a sensing head comprising a light source, a detector and associated optical assembly; a calibration mirror and rotary valve and the electronics associated with control and measurement. Should the power fail, integral power-packs return the valves to a closed position to protect the sensing heads. 2.3. Signal Processor Unit (SPU) The D-CEM2000 SPU receives its 48V DC power from the SCU via the 4-core SmartBUS serial data link. Signals from the two transceivers are processed to derive the transmissivity values and compute the opacity output. Diagnostic communication is provided via the SCU and a laptop computer operating SmartCOM software. Gain adjustments for the transducer detector signals are provided by trim potentiometers in this processor. Details for adjustment can be found in Section 7. Commissioning. 2.4. Station Control Unit (SCU) The SCU provides 48V DC power for the analysers on its local data bus. Power input to the SCU is 86 to 264V AC maximum. The power supply is housed in one side of the SCU and the 48V DC power rail is fed through internally into the processor section of the device. The SCU is linked to the analyser by means of a 4-wire data bus (local data bus). This bus carries 48V power to the analyser as well as two serial communication lines referred to as MOSI (Master Out/Slave In) and MISO (Master In/Slave Out). On this data bus the SCU acts as the Master Device and the analyser as a Slave device.

Measurement Principle

Consider the two identical transceiver units positioned at either side of the flue (or duct), unit 1 and unit 2. The transmissivity of light from unit 1 to unit 2 (unit 1 transmitting) can be represented by the equation :

12 = K1 (D21/D11) where : K1 = gain constant to produce

= 1 (100% transmissivity, clean air condition) D11 = the detector output at unit 1 (internal reference level) D21 = the detector output at unit 2 The transmissivity of light from unit 2 to unit 1 (unit 2 transmitting) can also be represented by the equation :

21 = K2 (D12/D22) where :

K2 = gain constant to produce = 1 D12 = the detector output at unit 1 D22 = the detector output at unit 2 (internal reference level) This is demonstrated schematically in Figure 3.

Overall transmissivity of the system () can, therefore, be represented as:

= 12 . 21

= K1 (D21/D11) . K2 (D12/D22) which can be rewritten as :

= K1K2 (D21/D22) . (D12/D11) As the two bracketed terms above are measured from only one of the transceiver units, the output of the instrument is independent of drift of either detector.

V-CEM5000 Flow Monitor

Introduction

Correcting measurements to standard temperature, oxygen levels, etc., allows the density of emissions to be normalised (e.g. mg/Nm3), but in order to obtain a measurement of total emissions for pollution monitoring (e.g. kg/hr), it is necessary to measure flow. Many methods require direct contact with the hot dirty gases resulting in high maintenance costs and potential unreliability. The CODEL Model V-CEM5000 Gas Velocity Monitor utilises an infrared cross-correlation technique that requires no contact with the flue gases. The method used resembles flow measurement with chemical dye or radioactive tracers, where the velocity is derived from the transport time of the tracer between two measuring points a known distance apart. However, instead of an artificial tracer being added, the naturally occurring fluctuations of the infrared energy in the gas stream are used as the tracer. Fully purged transducers with no moving components make the system highly reliable and minimise maintenance requirements. The instrument is ideally suited to monitoring the flow rate of hot, dirty gases.

2.2. Transducer Units Each transducer unit consists of a broad band infrared detector, a lens to focus the radiation received on the detector and a pre-amplification circuit board, all housed within a fully sealed, epoxy-coated aluminium enclosure. The transducers are supplied with air purge units to maintain the cleanliness of the transducer windows.

2.3. Signal Processor Unit (SPU) The V-CEM5000 signal processor receives its 48V DC power from the SCU via the 4-core Smartbus serial datalink. Signals from the two transducers are processed and correlated to derive the transmission time of the gas flow from the first transducer to the second and thus compute the gas velocity. Diagnostic communication is provided via the SCU and a laptop computer operating SmartCom software.

3. Measurement Principle Gas flow is rarely laminar. Turbulence in the flow produces a series of swirling eddies and vortices that are transported with the bulk flow. Infrared radiation, emitted by a hot gas system, is characterised by a flickering signal resulting from the swirling effect of these vortices. Two infrared detectors, placed a small distance apart, will produce very similar flickering signals, but with a displacement in time equivalent to the time taken for the bulk gas flow to carry the vortices from the first detector to the second. The V-CEM5000 uses a cross-correlation technique to measure this time displacement and hence the flow. The two signals from the infrared transducer units are defined as A(t) and B(t) as shown below.

The time-of-flight (and hence the flow velocity) of the naturally occurring turbulent eddies within the flow stream can be determined by cross-correlating the two signals as shown in the following equation :

where is a variable time delay imposed on the signal A(t). Using this function a correlogram can be computed which has a maximum when the time-of-flight and ‘t’ are equal.

BOILER TUBE LEAKAGE DETECTION SYSTEM