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Suresh SharmaBHEL -PEM-C&I, NOIDA
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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
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SAFE OPERATION OF PLANT
LOWEST COST OF GENERATION
LONGEST EQUIPMENT LIFE
MINIMUM ENVIROMENTAL FFECTS
MAXIMUM EFFICIENCY
ENERGY CONSERVATION
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IT IS APPLIED TO OPERATE VARIOUS COMPONENTS /
DEVICES (FINAL CONTROL ELEMENTS) OF PLANT WITHIN
SAFE OPERATING ZONE IN ORDER TO GET THE DESIRED
PARAMETER .
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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.
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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 .
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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
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• 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
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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 .
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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
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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.
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RELAY BASED SYSTEM .
SOLID STATE .
PRO-CONTROL .
Max DNA .
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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
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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
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CENTRAL CONTROL ROOM
ELECTRONIC EQUIPMENT ROOM
UPS / BATTERY ROOM
SWAS ROOM
COMPUTER ROOM
HMI ROOM
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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 .
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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 .
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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 .
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o MANPOWER AVAILBILITY FROM CONTRACTOR SIDE OF
COMMISSIONING SKILLS .
o AVAILABILITY OF TESTING INSTRUMENTS LIKEMULTIMETERS, CURRENT SOURCE ETC .
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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 .
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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 .
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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 .
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PANEL CHECKS :
o PROGRAM LOADING IN THE PROCESSOR .
o PROCESSOR REDUNDANCY CHECKS .
o COMMUNICATION REDUNDANCY CHECKS .
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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 .
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SG CONTROLS
TG CONTROLS
STATION C&I CONTROLS
OTHERS
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SG CONTROLS
o FSSS- OIL ELEVATIONS, MILLS AND FEEDERS, FLAME
SCANNERS
o SADC
o APRDS
o HPBYPASS
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TG CONTROLS
o TURBINE PROTECTION
o GOVERNING
o ATRS
o
TSI
o OTHERS
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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 .
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OTHERS
o VIBRATION PANELS
o MASTER CLOCK
o HART MANAGEMENT SYSTEM
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DURING TRIAL
o AVAILABILITY OF PARAMETERS .
o TUNING OF AUTO LOOPS .
o GUIDANCE AND SUPPORT TO OPERATORS .
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