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7/31/2019 09 ATRS _Std
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Presentation outline
Overview of Plant Controls
Functions of ATRS
Structure of ATRSProgram Structure of ATRS and
Turbine protection
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OPERATOR
INSTRUMENTATION & CONTROL
PLANT
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UNIT CONTROL
BOILER TURBINE GENERATOR
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MEASUREMENT
CLOSE-LOOP
CONTROL
OPEN-LOOP
CONTROL
PROTECTION
MONITORING
INSTRUMENTATION
ANDCONTROL
INSTRUMENTATION
ANDCONTROL
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ADVANTAGES OF AUTOMATION
OPERATING PERSONNEL FREED FROM ROUTINE TASKS.
INCORRECT INTERVENTIONS IN THE PROCESS AVOIDED.
STRESS ON EQUIPMENT REDUCED.
PLANT OPERATIONS GEARED FOR MAXIMUM
EFFICIENCY.
INCIPIENT FAULTS RECOGNISED QUICKLY.
ON FAULT OCCURRENCE, IMMEDIATE AND LOGICAL
INTERVENTION POSSIBLE.
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A. CONTROL SYSTEM:
ANALOG(CLOSE LOOP)
- ELECTROHYDRAULIC CONTROLLER (EHC)- TURBINE STRESS EVALUATOR (TSE)
- LOW PRESSURE BYPASS CONTROLLER (LPBPC)
- GLAND STEAM PRESSURE CONTROLLER (GSPC)
BINARY(OPEN LOOP)
- AUTOMATIC TURBINE RUN UP SYSTEM (ATRS)- AUTOMATIC TURBINE TESTER (ATT)
B. MONITORING & MEASUREMENT SYSTEM
- TURBINE SUPERVISORY INSTRUMENTATION (TSI)
- MEASURMENT OF PARAMETERS LIKE, TEMP.,PRESS.,LEVEL etc.
C. PROTECTION SYSTEM
TURBINE C&I PACKAGE CONSISTS OF THE FOLLOWING SYSTEMS:
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HIERARCHY OF CONTROL
UNIT
CONTROL
GROUP CONTROL(WHEN, HOW MANY,WHICH)
SUB-GROUP CONTRL-1 SUB-GROUP CONTRL-2
CONTROL INTERFACE
SWITCH GEAR (MCC)
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TASKS PERFORMEDTASKS PERFORMED:
SWIFT,ACCURATE AND OPTIMUM STARTUP ( INCLUDING
SYNCHRONISATION AND LOADINING) OF TURBINE
MAINTAINING OIL SUPPLY
BUILDING UP AND MAINTENANCE OF VACUUM
FEATURES :FEATURES : BASED ON FUNCTIONAL GROUP CONTROL PHILOSOPHY
EACH FUNCTIONAL GROUP ORGANISED AND ARRANGED IN SUB-GROUP CONTROL,
SUB-LOOP CONTROL, AND CONTROL INTERFACE
OPERATING MODES AVAILABLE:
- MANUAL MODE ( OPERATOR GUIDE)- AUTOMATIC MODE
- STEP BY STEP MODE
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ATRS
STRUCTUREOIL SYSTEM, VACUUM SYSTEM, TURBINE etc.
GC
SGC SGC
SLC SLCSLC
CI
SGC
CI
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GROUP CONTROL: Decides WHEN, HOW MANY & WHICH SGC
shall be operating and stopped.
SUB GROUP CONTROL: Contains the sequential logics for switching
drives ON and OFF. Perform sequence in STEPS, issue commands and
get Checkbacks.
SUB LOOP CONTROL: can be switched ON & OFF manually.Receive commands from GC, SGC and also Manual
CONTROL INTERFACE: Standard Interface between the command
transmitters and receivers in the plant, undertakes all necessary signal
processing and monitoring.
SYSTEM OPERATION MODES:
AUTOMATIC,SEMI AUTOMATIC,OPERATOR GUIDE
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ADVANTAGES OF ATRSADVANTAGES OF ATRS
ELIMINATES HUMAN ERROR PROVIDES MAXIMUM PROTECTION AGAINST MALFUNCTIONS
OPERATORS TASK LESS ARDUOUS
ENABLES SAFE, SMOOTH, STRESS CONSISTANT AND OPTIMUM
WARM-UP, ROLLING AND SYNCHRONISATION OF TURBINE IN
LEAST POSSIBLE TIME INCREASES PLANT AVAILABILITY
REDUCES STARTING TIME WITHOUT IMPAIRING LIFE
MEETS EMERGENCIES AUTOMATICALLY
ALL PLANT OPERATING CONDITIONS CATERED TO BY CRITERIA
DEPENDANT PROGRAMMING
INCREASED OPERATING FLEXIBILITY, SAFETY AND RELIABILITY
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Start up and Shutdown sequence performed in reliableway
Protect drives and related auxiliaries
Uniform and sequential information to operator aboutthe process
Distinct information about the nature and location offaults
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STEP 01
STEP 02
&
START DRIVE A
DRIVE A ON
MONITOR &
BLOCKING TIME
MONITOR &
BLOCKING TIMEOPEN DMPR A
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AUTOMATIC TURBINE RUN-UP SYSTEM
SUB GROUP CONTROL ( SGC):
SGC executes commands to bring the equipment upto a particular
defined status.
The commands are executed in a predefined sequence in the form of
steps.
Desired number of criteria act as preconditions before the SGC can
take off or execute its defined sequence. The functional group continues to function automatically all the time
demanding enabling criteria based on the process requirements and
from other FGs, if required.
In case the desired criteria is not available, the system would
automatically act in such a manner as to ensure the safety of the mainequipment.
The sequence is programmed in the processor. The process signals
are acquired through the input modules and are available on the bus.
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AUTOMATIC TURBINE RUN-UP SYSTEM
WAITING AND MONITORING TIME FOR STEPS:WAITING AND MONITORING TIME FOR STEPS:
Waiting Time :
It implies that the subsequent step will not be executed unless the
specified time elapses. If no waiting time is specified, the next step
gets executed as soon as the enabling criteria are fulfilled.
Monitoring Time :
It is the time required for executing the command of any step as well
as the time required for appearance of criteria for the next step.
Under healthy conditions it should happen within the specified time,
otherwise an alarm is initiated. Whenever there is uncertainty
regarding the time required for completing a particular task, such
as warming-up, pulling vacuum etc., the monitoring time is blocked.
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02
FROM STEP 1STEP CRITERIA FOR STEP -2
BYPASS CRITERION
PROGRAM LOOP
WAIT
50s
MO TIME
20sCOMMAND
1
2
&
&
1
&
STEP 2 ( START UP PROGRAM) WITH 2 STEP CRITERIA, 2 COMMAND
OUTPUTS AND A MONITORING & WAITING TIME .
WITH ADDITIONAL PROGRAM LOOP CONTROL AND A BYPASS
CRITERIA FOR STEP 1
WAITING OR MO TIME CAN BE PROGRAMMED FOR 0.1 SEC TO 999
MIN.
NOS. 1-49 USED FOR START-UP, 51 TO 99 FOR SHUTDOWN PROGRAM.
EXAMPLE
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AUTOMATIC TURBINE RUN-UP SYSTEM
WAITING AND MONITORING TIME FOR STEPS:
ATRS can be switched on at any stage after
completing certain tasks manually, if so desired. In
such cases, the SGC program quickly scans throughthe steps and starts executing from the stage upto
which the tasks have been completed manually.
This is achieved by incorporating suitable
overflow /bypass conditions in the logic.
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AUTOMATIC TURBINE RUN-UP SYSTEM
ATRS CONTROLS:11. ATRS is organised in the following four Sub-Groups :
Oil supply
Evacuation
Turbine
HP CONTROLFLUID
2. SGC issues commands either to the SLC or directly to
the drive through the Control Interface.
3. Each of these SGCs has its subordinate SLCs and CI
modules. These SGCs in conjunction with the turbinegoverning system , TSE and the auto-synchroniseraccomplish the function of start-up of the TG set.
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AUTOMATIC TURBINE RUN-UP SYSTEM
CONTROL INTERFACE (CI) :
Each remote controlled drive has a dedicated CI module which acts asa standard interface between the transmitters and receivers in the plant
and undertakes all necessary signal processing and monitoring.
The CI module receives manual commands from the process
keyboard/inserts, active protection signals and enabling signals from
the protective logic, as well as automatic control commands from the
SGC/SLC. It interlocks the input commands according to their priority and
validity and then passes actuation signals to the interposing relays in
the switch-gear.
The status checkbacks received from the switchgear or actuators are
monitored, processed and transmitted to VDU/desk tiles, the protective
logic and the SGC.
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AUTOMATIC TURBINE RUN-UP SYSTEM
CONTROL INTERFACE (CI) : (Continue--)
These modules have the firmware which defines the standard
function of the module and its signalisation mode as well as the
programmable logic for the drive protection and the permissive
interlocks. The drive level automation tasks related to the respective
drive is realised through the programmable logic.
The module has hardwired inputs and outputs for connection of
feedback signals and commands to the switchgear together with local
bus interface for signal exchange via the system bus.
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AUTOMATIC TURBINE RUN-UP SYSTEM
ATRS STRUCTURAL SYSTEMATRS STRUCTURAL SYSTEM::
ATRS IS ORGANISED IN THREE SGCs :
1. SGC-TURBINE :
SGC Turbine acts directly on the following systems :SGC Turbine acts directly on the following systems :
Sub-loop Control (SLC) Drains.
Warm up Controller.
Starting Device of turbine governing system.
Speed & Load Setpoint devices of turbinegoverning
system.
Auto-synchroniser.
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AUTOMATIC TURBINE RUN-UP SYSTEM
ATRS STRUCTURAL SYSTEMATRS STRUCTURAL SYSTEM::
2. SGC-OIL SUPPLY :
SGC oil supply directly acts on the following systemSGC oil supply directly acts on the following system :
Sub-loop control (SLC) turning gear.
SLC auxiliary oil pump 1.
SLC auxiliary oil pump 2.
SLC emergency oil pump. SLC jacking oil pump.
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AUTOMATIC TURBINE RUN-UP SYSTEM
ATRS STRUCTURAL SYSTEMATRS STRUCTURAL SYSTEM::
3. SGC-CONDENSATE & EVACUATION :
SGC- Condensate & Evacuation directly acts on the following systems :
Sub-loop Control (SLC) condensate extraction
pumps.
Starting ejector, if provided.
Main ejectors / vacuum pumps (as applicable). Vacuum breaker.
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AUTOMATIC TURBINE RUN-UP SYSTEM
ATRS STRUCTURAL SYSTEMATRS STRUCTURAL SYSTEM::
3. SGC-HPCF :
SGC- HPCF acts on the foll :
Sub-loop Control (SLC) HPCF
SLC HPCF pumps
HPCF pumps
HPCF re-circulation pumps LPCF temp control valve
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AUTOMATIC TURBINE RUN-UP SYSTEM
3. SGC-HPCF :
Both CF PUMPS GET SWITCHED ONTHRU SLC. IN CASE
RUNNING PUMP DOES NOT DEVELOP THE REQUIREDPRESS, THE STANDBY PUMP GETS SWITCHED ON
AFTER GETTING THE REQUIRED CF PRESS SLC
HEATING IS PUT ON & CF CIRCULATION PUMP WHICH
FEEDS THE REGENERATION CKT IS ALSO PUT ON. TEMP
CONTOL VLV IS PUT IN AUTO MODE TO REGULATE THETEMP.
CF TEMP IN THE TANK IS MAINTAINED BETWEEN 55 TO
57 C BY SWITCHING ON/OFF THE CF HEATER THRU
THE SLC. IN CASE CF TEMP IN HTR EXCEEDS > 65 C
THE HEATER IS SWITCHED OFF IN SHUTDOWN PROG ALL THE PUMPS ARE SWITCHED
OFF AND SLC IS PUT OFF. SLC HEATING IS KEPT ON TO
MAINTAIN THE TEMP REQUIRED FOR THE NEXT
STARTUP.
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TURBINE START-UP / SHUT-DOWN CONTROL,
OVERVIEW
SUB-GROUP ( TURBINE START-UP / SHUT-DOWN)SUB-GROUP ( TURBINE START-UP / SHUT-DOWN)
SUBLOOP
DRAIN
VALVE
SUBLOOP
LP-WATER
INJECTION
MECHANICAL
HYDRAULIC
CONTROL(MHC)
ELECTRO-
HYDRAULIC
CONTROL(EHC)
SEAL
STEAM
CONTROL(SSC)
TURBINE
TRIP
SYSTEM(TTS)
TURBINE
STRESS
EVALUATOR
LP WATER
INJECTION
AUTOMATIC
SYNCHRONIZER
DRAIN
VALVES
GENERATOR
MAIN CKT.
BREAKER
THYRISTOR
VOLTAGE
REGULATOR(TVR)
CRITERIA
CRITERIA
AUTO-ON/OFF
AUTO
ON/OFF
AUTOON/OFF
MANUAL
ON/OFF
MANUALON/OFF
MANUALOPEN/CLOSE
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4 6 8 7 5
1
3
2
1. PUSHBUTTON SHUTDOWN
2.PUSHBUTTON STARTUP OR OPERATION
3.PUSHBUTTON AUTOMATIC ON/OFF
4.LAMP SHUTDOWN PROGRAM5.LAMP STARTUP OR OPERATION PROGRAM
6.LAMP AUTOMATIC OFF
7.LAMP AUTOMATIC ON
8.LAMP FAULT
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2 3 4
1. PUSHBUTTON MANUAL ON/OFF
2.LAMP SLC OFF
3.LAMP FAULT
4.LAMP SLC ON
1
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3 4 5
1. PUSHBUTTON OFF (CLOSE)
2. PUSHBUTTON ON (OPEN)
3. LAMP OFF (CLOSE)
4. LAMP FAULT
5. LAMP ON (OPEN)
1 2
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PROTECTION SYSTEMFOR
STEAM TURBINE
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TURBINE PROTECTION SYSTEM
TASK PERFORMEDTASK PERFORMED :
PROTECTS TURBOSET FROM INADMISSIBLE OPERATING
CONDITIONS
PREVENTS DAMAGE IN CASE OF PLANT FAILURE
FAILURE OCCURRENCE REDUCED TO MINIMUM
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TURBINE PROTECTION SYSTEM
ADVANTAGESADVANTAGES :
DETECTION OF UNIT IRREGULARITIES
PREVENTION OF UNIT OVERSTRESSING DUE TO TRIPS
RELIEF OF OPERATING PERSONNEL FROM QUICK AND
CORRECT DECISION TAKING
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TURBINE PROTECTION SYSTEMTURBINE PROTECTION SYSTEM
HYDRAULIC
TRIP SYSTEM
ELECTRICAL
TRIP SYSTEM
EXTENDED
TURBINE PROT.
PROT. CRITERIA
FROM OTHER AREA
- OVER SPEED
TRIP DEVICE1/2
- VACUUM TRIPDEVICE
- HAND TRIPLEVER(LOCAL)
1/2
- MANUAL
REMOTE TRIP( UCB)
- LOW VACUUM
TRIP
- LOW LUBE OIL
- FIRE PROT.
TRIP-BRG METAL
TEMP
-AXIAL SHIFT
-HP/IP TOP/BOT
DIFF TEMP HI
- LP EXH. STM.
TEMP. > MAX
-GENERATOR
PROTECTION
- MASTER FUEL
TRIP RELAY
ENERGISED
- BOILERPROTECTION
OPTD.
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TURBINE PROTECTION SYSTEM
GENERALGENERAL :
The electrical trip system comprises of two identical and independent
relay based trip channels viz. electrical trip channels 1 & 2.
Both channels are connected to different (two) trip solenoid valves.
All command signals for turbine trip are hooked up with both the
channels.
Actuation of any of the channels energises the respective trip solenoid
which in turn trips the turbine.
Each channel is realized in a local bus. Both the local buses are
completely independent of each other and input modules, processor
module and output modules reside on each.
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TURBINE PROTECTION SYSTEM
GENERALGENERAL :
Trip signals from the sensors / field instruments are conditioned anddistributed to both the channels (local buses) via hardwired modules.
Realisation of 2 out of 3 trip logic is carried out in the local bus. On
detection of a fault in any one of the input signals to a channel, the
configuration for that channel changes from 2 out of 3 to 1 out of 2 and is
annunciated. Further failure in a channel changes the configuration to 1out of 1.
Trip signal from each of the local buses acts on 3 relays in 2 out of 3
combination.
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TURBINE PROTECTION SYSTEM
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TURBINE PROTECTION SYSTEM
TRIPPING CRITERIATRIPPING CRITERIA:
1. CONDENSER VACUUM VERY LOW :
This is a back up protection to the hydraulic low vacuum trip
device.
The protection acts if absolute pressure in the condenser rises
above 0.3 Kg/cm2 (abs).
2. LUBE OIL PRESSURE LOW :
The protection acts if the lube oil pressure before thrust bearing
decreases to 1.2Kg/cm2 . The trip signal is initiated by three pressure transmitters in 2-out-of-3-
logic.
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TURBINE PROTECTION SYSTEM
TRIPPING CRITERIATRIPPING CRITERIA:
3. FIRE PROTECTION :
The protection acts in the event of any of the following
conditions :
i) Fire protection switch, either in unit control room
or in
machine hall, operated.
ii) Level in main oil tank falls to a very low value,
indicating
substantial leakage of oil from the system.
The command signal under condition (ii) is initiated from
three level transmitters in 2-out-of-3 logic cofiguration.
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TURBINE PROTECTION SYSTEM
TRIPPING CRITERIATRIPPING CRITERIA:
4. HP EXHAUST STEAM TEMPERATURE HIGH :
The HP exhaust steam temperature protection circuit causes the exhaust
sections of the turbine, the blading and the extraction points against
overheating. Under extreme operating conditions the HP turbine can be run at low flow rate
and simultaneous relatively high back pressure. This prevents the steam from
expanding, which causes the exhaust steam temperature to rise ( > 5000C).
The temperature is measured by means of three thermocouples and protection
criteria is derived in 2 out of 3 logic.
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TURBINE PROTECTION SYSTEM
TRIPPING CRITERIATRIPPING CRITERIA:
7. GEN. PROTECTION OR MFT- RELAY ENERGISED :
In the event of generator faults under Class-B trip both the turbine trip
channels are actuated to trip the turbine. In such a case the generator
protection acts through Reverse Power Relays.
In the event of generator faults under Class-A trip or in the event of boiler
"Master fuel trip relay" energised, command signal for turbine trip shall
act simultaneously and independent of other equipment trip out sequence.
8. OPERATION OF REVERSE POWER RELAY :
The command signal is initiated with a time delay of 10 seconds after any of
the two reverse power relays have operated.
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