Control & Instrumentation Commissioning - an Overview

8/13/2019 Control & Instrumentation Commissioning - an Overview

http://slidepdf.com/reader/full/control-instrumentation-commissioning-an-overview 1/36

Suresh SharmaBHEL -PEM-C&I, NOIDA



COAL TO ELECTRICITY

BOILER

GENERATOR

TRANSFORMER

TRANSMISSION

TOWER

COAL

HANDLING

PLANT

COAL

MILL

CONDENSER

PUMP

TURBINE

ESP

C

H

I

M

N

E

Y

ID

FAN

ASH

HANDLING

PLANT

PA

FAN

FD

FAN

GENERATOR

CW

PUMP

Cooling

Tower

C

O

AL

STEAM

WATER

FLUE GASES

WET ASH

FLY ASH

PRI AIR

SEC AIR

TO ATMOSPHERE

COOLING WATER

FURNANCE

ASH

POND

ELECTRICITY



SAFE OPERATION OF PLANT

LOWEST COST OF GENERATION

LONGEST EQUIPMENT LIFE

MINIMUM ENVIROMENTAL FFECTS

MAXIMUM EFFICIENCY

ENERGY CONSERVATION



IT IS APPLIED TO OPERATE VARIOUS COMPONENTS /

DEVICES (FINAL CONTROL ELEMENTS) OF PLANT WITHIN

SAFE OPERATING ZONE IN ORDER TO GET THE DESIRED

PARAMETER .



IT IS APPLIED TO GET THE PROCESS INFORMATION OF

DESIRED PARAMETERS (e.g. PRESS , TEMP , FLOW, LEVEL,

PH , CONDUCTIVITY ETC) TO FACILITATE THE CONTROL /

MONITORING OF THE PROCESS.



PRIMARY INSTRUMENTS :

o THEY SENSE THE PROCESS

o THEY ARE MOUNTED IN FIELD

o Ex – SWITCHES , TRANSMITTERS , GAUGES.

SECONDRAY INSTRUMENTS :

o THEY RECEIVE THE SIGNAL FROM PRIMARY

INSTRUMENTS.

o MOUNTED ON CONTROL PANEL .

o Ex - INDICATOR,RECORDER, TEMP SCANNER .



PRESSURE MEASUREMENT : PT,PS, DPT,

DPS

TEMPERATURE MEASUREMENT : RTD, TC

FLOW MEASUREMENT : FI, FS, FT

LEVEL MEASUREMENT : LI, LS, LT

POWER MEASUREMENT

VOLTMETER AMMETER WATTMETER ENERGYMETE



• TO ENSURE QUALITY OF DM WATER TO BOILER .

• TO PREVENT COROSSION .

• TO REMOVE IMPURITIES TO PREVENT SCALE

DEPOSIT IN THE BOILER TUBE .

• TO PREVENT SILICA DEPOSIT ON THE BLADES OF

TURBINE .

HOTWELL CONDUCTIVITY CEP DISCH PH, CONDUCTIVITY, Na

DEA O/L PH, DISS O2

ECO INLET PH, COND, HYDRAZINE

DRUM WATER COND, PH, SILICA

MAIN STEAM COND, PH, Na



MEASUREMENT OF OXYGEN, CARBON MONO

OXIDE IN FLUE GASES FOR PROPER &

OPTIMISATION OF COMBUSTION OF FUELS IN

BOILER .

MEASUREMENT OF SULPHER DIOXIDE, NITROGENOXIDES, DUST DENSITY IN FLUE GASES TO

MINIMISE THE ENVIROMENTAL EFFECTS .



PUMPS / FANS / BLOWERS Unidirectional Drives

MOTORISED VALVES Bidirectional Drives

- WITHOUT INTEGRAL STARTER

- WITH INTEGRAL STARTER

- WITH SMART ACTUATOR

CONTROL VALVES – Analog drives

- PNEUMATIC ACTUATOR

- ELECTRIC ACTUATOR

- HYDRAULIC ACTUATOR



INTERLOCK & PROTECTION ARE USED FOR SAFE START

UP / OPERATION / SHUTDOWN / TRIP OF ANY EQUIPMENT

OR AUXILLARY , EXAMPLES:

o CW PUMP , ID FAN , FD FAN, BOILER FEED PUMP, CEP,

MILL , PA FANS , PUMPS ,

o LP / HP HEATERS ,

o AIR HEATERS ,

o REHEATER PROTECTION ,

o VALVE & DRAINS etc.



RELAY BASED SYSTEM .

SOLID STATE .

PRO-CONTROL .

Max DNA .



MAN MACHINE INTERFACE

PLANT INFORMATION SYSTEM

AUTO CONTROL SYSTEM

INTERLOCK & PROTECTION

I

O

S

I

G

NA

L

S

D

P

U

I

O

I

O

I

O

I

O

I

O

I

O

I

O

I

O

I

O

I

O

D

P

U

D

P

U

Switch A

Switch B





Operator

Station # 1

RPUs (I/O + DPU + Network Components)

HUMAN MACHINE INTERFACE CATERING TO SG, TG, STATION C&I ANDELECTRICAL CONTROLS

maxNET

Operator

Station # 7maxSTORIAN

100MBps

Engg. Stn. PADO

STN

Colour Inkjet

A3/A4 – 3 Nos

NETWORK PRINTERS :

Laser B/W (A3/A4) – 2 Nos

FG #TURBINE FG #STN. C&IFG #BOILER

MOTORISED

VALVES/

DAMPERS

LOCAL JB

EP

POWER

AMP. MOTORS

PUMPS/

BREAKERS

~

CONTACT

INPUTS

CJC BOX

T/CsANALOG

(4-20mA)

RTDs

+-

LOCAL JBLOCAL JBLOCAL JB 10MBps

Remote

I/O (Not Applicable)

DBTC

Typical Unit Control Panel (Minimum)

ALARM A/M STN.SET

PT. STNPB STN.

CONT.SWITCH

ANA

IND.REC IND.

DIG. IND.

DPU

I/O Modules

DPU

I/O Modules

Time Sync. Signal

MASTER

CLOCK

SYSTEM

maxLINKInterface

Gateway to

off-site PLCs,

VMS, etc.

LVS (3 NOS.) 67”

DPU

I/O Modules

DPU

I/O Modules

C O N T R O L R O O M

E Q U I P M E N T R O O M

F I E L D

RPU # 1 RPU # n

ETHERNET SWITCH

ETHERNET SWITCH

RPU # 1 RPU # n

DPU

I/O Modules

RPU # 1 RPU # n

DPU

I/O Modules

INTEGRATED

ALARM ANNUNCIATOR

A3 - LASER(B/W)

A3 /A4 - Laser(COLOR) – 1 No.

HART

MANAGEMENT

SYSTEM

PLEASE REFER

PADO CONFIG

FOR DETAILS

Shift I/C







CENTRAL CONTROL ROOM

ELECTRONIC EQUIPMENT ROOM

UPS / BATTERY ROOM

SWAS ROOM

COMPUTER ROOM

HMI ROOM







COMPILATION OF C&I DOCUMENTS :

o PIDs OF RESPECTIVE UNITS .

o INSTRUMENT SCHEDULES OF RESPECTIVE UNITS .

o LOGICS

o WRITE-UPS

o DCS DOCUMENTS

o INSTRUMENTATION CABLE SCHEDULES AND

INTERCONNECTION .



CROSS- CHECKING OF ENGINEERING DRAWINGS :

o CABLE INTERFACE FROM DCS TO SWITCHGEAR/MCC FOR

CORRECTNESS OF TERMINATIONS .

o CABLE INTERFACE BETWEEN VARIOUS PANELS .

o CABLE INTERFACE WITH FIELD INSTRUMENTS AND DRIVES

o CHEKING OF INSTRUMENT SCHEDULES WITH RESPECT TO

VARIOUS PIDS .

o CHECKING OF LOGICS WITH RESPECT TO WRITE UPS .



AVAILABILITY BEFORE COMMISSIONING

o AVAILABILITY OF INSTRUMENT AIR IN FIELDS .

o CALIBRATION AND ERECTION OF FIED INSTRUMENTS .

o COMPLETION OF CABLING FROM FIELD/MCC/SWGR TO DCS

o

AVAILABLITY OF AIRCONDITIONING IN CONTROL ROOMPRIOR TO PANEL CHARGING .

o AVAILABILITY OF POWER SUPPLIES TO DCS PANELS AND

LOCAL INSTRUMENTS .



o MANPOWER AVAILBILITY FROM CONTRACTOR SIDE OF

COMMISSIONING SKILLS .

o AVAILABILITY OF TESTING INSTRUMENTS LIKEMULTIMETERS, CURRENT SOURCE ETC .



FIELD CHECKING

o CONTROL VALVE CALIBARION AND POSITION FEEDBACK

ADJUSTMENT .

o MOTORISED VALVE OPERATION, LIMIT/TORQUE SWITCH

ADJUSTMENT .

o INSTRUMENT MOUNTING AS PER HOOK UP DIAGRAM .



PRE POWER UP CHECKS :

o CHECKING OF PANELS WITH RESPECT TO BILL OF

MATERIALS .

o CHECKING OF PANEL FOR LOOSNESS IN CONNECTION .

o ELECTRONIC AND ELECTRICAL EARTHING .

o PANEL MEGGARING .

o PANEL CLEANLINESS .



POWER-UP CHECKS :

o VOLTAGE LEVEL AT INPUT OF PANEL .

o POLARITY CORRECTNESS IN CASE OF DC SUPPLY .

o FUSE HEALTHINESS .

o POWER SUPPLY AT VARIOUS LEVELS .

o POWER SUPPLY REDUNDANCY CHECKS .



PANEL CHECKS :

o PROGRAM LOADING IN THE PROCESSOR .

o PROCESSOR REDUNDANCY CHECKS .

o COMMUNICATION REDUNDANCY CHECKS .



DRY CHECKS :

o CONTROL VALVE OPERATION FROM CONTROL ROOM .

o MOTORISED VALVE OPERATION FROM CONTROL ROOM .

o SIMULATION OF INPUTS FROM FIELDS .

o LOGIC CHECKS BY FORCING INPUT SIGNALS .



SG CONTROLS

TG CONTROLS

STATION C&I CONTROLS

OTHERS



SG CONTROLS

o FSSS- OIL ELEVATIONS, MILLS AND FEEDERS, FLAME

SCANNERS

o SADC

o APRDS

o HPBYPASS



TG CONTROLS

o TURBINE PROTECTION

o GOVERNING

o ATRS

o

TSI

o OTHERS



STATION C&I

o BINARY LOGICS ( ID, FD, PA ,BFP, CEP AND MISC LOGICS) .

o ANALOG CONTROLS ( AIR FLOW, DRUM LEVEL, FURNCE

PRESSURE AND OTHER CONTROLS) .

o

CORDINATED MASTER CONTROL AND RUN BACKS .



OTHERS

o VIBRATION PANELS

o MASTER CLOCK

o HART MANAGEMENT SYSTEM



DURING TRIAL

o AVAILABILITY OF PARAMETERS .

o TUNING OF AUTO LOOPS .

o GUIDANCE AND SUPPORT TO OPERATORS .



Documents

Control & Instrumentation Commissioning - an Overview