funded by the european union comprehensive technical training · turbine gen. controls sub-system...

FUNDED BY THE

EUROPEAN UNION

High Pressure Cogeneration for Sugar Sector in Pakistan

Comprehensive Technical

Training

For Sugar Mills Staff on Operation & Maintenance of

Baggase Based HP Cogeneration System

Schedule: 10th July to 13th July, 2017

FUNDED BY THE

EUROPEAN UNION


Plant Control System

Purpose:

Plant Control System provides

necessary tools to enable the

operators to operate plant

safe reliable and efficiently.

FUNDED BY THE

EUROPEAN UNION


Purpose of Plant

Control System

1. Process monitoring, control and optimization

2. Plant and Unit performances analysis

3. Economical analysis of plant for optimization

4. Schedule optimization

5. Advanced control technologies

6. Equipment health management

7. Availability & Reliability

8. Ease of Trouble shouting & maintenance

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Automation

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General Structure

of Plant DCS

Basic Structure

HMIsPrinters Historian

Plant Data Highway

Unit Data Highway

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Plant Control System

Basic Plant Control

Plant Data Highway - Ethernet


Unit Data Highway - EGD


OSM

HARD WIREDSIGNALS

DUPLICATE WORK STATIONS

SEPARATEENGINEERING

Station

SEPARATESPARE PARTS

DCS

NT

Subsystems

PrinterPrinter

Printer

Turbine Control

HMI Operator Interface

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Plant Control

System continue

• UDH, PDH and Data Connectivity





COMMON UNIT DATAHIGHWAY

BOP Control

Turbine Control

Plant Historian

HMI Operator Interface

Plant Data Highway

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DCS integrated

Systems

• Asset Management System

• Online PPMS

Sensors /

Instrumentation

Turbine Gen.

Controls

Sub-System

Integration

Plant Controls

Integrated

Systems

Plant Controls

Control Modules

BOP, TSI & Water Treatment

Asset Management

Sys

Field Instruments and Transducers

Plant Performance

Monitoring

Online PMS

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Control System

features

• Real-time Process data collection

• Real-time process statistics

• Real-time process monitoring

• Schematics visualization & analysis

• Reports Generation

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Online PMS (Plant

Performance Monitoring

System).

1. Plant Performance

2. Unit Performance

3. Mass and Energy Balance

4. Boiler

5. Turbine

6. Feed water Heater

7. Condenser

8. Cooling Tower

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Online PMS Continue

1. Air Pre heater

2. Feed water Pump

3. Condensing Pump

4. Circulating Pump

5. Induced Draft Fans

6. Force Draft Fans

7. Primary Air Fans

8. Burners & Combustion

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Targets &

Achievements

1. Minimized operations cost

2. Overall efficiency increase

3. Fuel cost savings

4. Emission Reduction

5. Reliability an availability of the system

6. Schedule for Preventive maintenance

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A comprehensive Intelligent Power

Plan is aimed to improve the overall

Energy Efficiency in following aspects

1. Improved Generation Efficiency.

2. Saved Auxiliary Energy Consumption.

3. Better Heat Rate.

4. Reduced Emission.

AIM

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Basic Control

Functions

• ON-OFF Control

• Modulating Control

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ON-OFF Control

(Discrete Control)

This Control is divided into following categories:

• Motor-driven rotating equipments such as pumps, fans, compressors and conveyors

• Motor-operated shutoff valves and dampers

• Solenoid-operated equipment such as pneumatic shutoff valves

The control action of an ON-OFF Control system maybe initiated manually by a command from an operator or initiated automatically by the system-based on the intelligence received from the process

The control logic will withhold the ‘start’ command if the seal water temperature, exhauster, discharge air temperature or lube-oil pressure of exhauster is not adequate for safe operation for exhauster

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Modulating

Control (Loops)

There are basically two types of control

loops:

• Open Loop

• Closed Loop

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Modulating Control

(Analog Control Loops)

The basic elements of the Modulating loop are as follows:

• Set point

• Process Variable / Controlled Variable

• Controller

• Manipulated Variable

• Final Control Element

The water temperature is controlled variable. The controlled valve is the final control element. The control loop is said to be “closed” in that the controlled variable is measured value is used to verify the result of the controlled action.

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Control Loops

• (A) Feed-Forward Control

• (B) Cascaded Control

• (C) Feed-Forward & Cascaded Control

Feed-back, feed-forward, and cascaded control techniques are the basic controlling functions used to build a control system that will maintain the plant parameters within designnormal operating conditions and keep the plant running safely and efficiently

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Modulating Control

Applications

Boiler Control System

Boiler-Follow Scheme: In thisscheme, the boiler controland turbine control aretwo separate controlsystems. The load demandsignal is sent directly tothe turbine controlsystems which positionsthe turbine valves inresponse to changes inload demands.

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Modulating Control

Applications

This scheme typically includes a Unit Development Program—it receives the load demand from load dispatcher and checks the demand signal from the load dispatcher & demand signal against allowable operating limits. The demand is subjected to maximum load that can be carried by boiler-turbine-generator (BTG) and minimum load desired.

Co-ordinated Control Scheme

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Modulating Control

Applications

1. This scheme provides a tight control on throttle pressure, but its response to load changes is very slow because the valves do not move until the firing rate has been adjusted to new demand level.

1. This scheme does not make use of any available stored energy from the boiler.

Turbine Follow Scheme

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Firing Rate Control

or Combustion Control

1. The firing rate control loop employs two closed loop controllers:

A. total fuel flow controller

B. total air flow controller

2. The firing rate demand serves as the fuel flow setpoint for fuel controller which uses the measured fuel flow as feedback signal to close the loop.

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Furnace Draft Control

It is a two-elementcontrol loop usinga furnace pressurecontroller plus afeed-forwardsignalrepresenting avariable, thatwhen changed –has an impact onfurnace draft suchas boiler air flowor the forced draftinlet control vaneposition.

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Superheat & Reheat Steam

Temperature Control

• Steam temperature control is carried out in all boilers to get a constant temperature within a range. Methods like de-superheating by water injection, flue gas flow diverting, burner tilting are few systems adopted. Main steam and reheat outlet temperature are controlled by these methods in boiler.

• All boilers used for both process and power generation plants have to maintain steam parameters within a particular range. The pressure and temperature of steam at superheater and reheateroutlets are to be maintained to achieve an optimum plant efficiency. In large capacity boilers, injection type de-superheating is more popular.

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Feed water

ControlMost boiler systems contain a de-

aerating tank which removes

dissolved gases from the feed

water (these gases can be

corrosive to the rest of the boiler

system). The de-aerating tank is

the source of feed water to the

pumps. Because feed water de-

aeration is achieved through

boiling, the water leaving the

tank may be very close to the

boiling point. It would be

undesirable for the water at the

pump suction to flash to steam,

so the de-aerating tank is located

at an elevation above the feed

water pumps. This elevation

should be chosen in order to

guarantee enough pressure at

the pump suction to prevent

flashing. The water pressure at

the pump suction is called net

positive suction head (NPSH).

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Super heater bypass

Control

• Feed water is supplied by the de-aerator, which also provides the necessary net positive suction head (NPSH) to the boiler feed pumps. The boiler feed pumps (BFP) must supply a constant flow necessary to replace water in the boilers that has been changed to steam. The boiler feed pumps (BFP) must also develop the required pressure to overcome head and drum pressure.

• The feed water system supplies proper feed water amount for the boiler at all the loads. The parameters of the feed water are temperature, pressure and quality. The feed water system consists of a feed water tank, feed water pump(s) and (if needed) high-pressure water pre-heaters.

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De-aerator Storage Tank &

Condenser Hot well Level

Control Loops

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Control System Hardware & Software.

Soft wares

1. Operating System.

2. Applications Software.

3. Third Party Software & Drivers.

4. Anti Virus.

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Control System

Hardware

1. Large Screen.

2. HMIs.

3. Computers.

4. Servers.

5. HSR and Media / dedicated Rack of HDD.

6. HUB and Switches.

7. Dot Matrix Printers.

8. Color Platters/Printers.

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Microprocessor based

Control Systems

Any instrumentation systems centered around a microprocessor are known as microprocessor based system. The logical and computing power of microprocessor has extended the capabilities of many basic instruments, improving accuracy and efficiency of use. The microprocessor is a versatile device for use in any instrumentation system.

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Network

Topologies

Hybrid Topology Tree Topology

Star Topology Ring Topology

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RS232C Interface

RS232C interface is widely used standard for direct point-to-point data transmission between two digital equipments.

It is the recommended standard of Electronics Industry Association.

This interface specifies interconnection & signal exchange.

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Programmable

Logic Controller

Basically PLC consists of:

1. Input Module

2. Processor

3. Output Module

Other accessory systems are power supply & interconnecting wires.

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Layout of PLC

Schematic Diagram

Ladder Diagram

Relay Ladder Logic Diagram is used for PLC Programming. The ladder diagram is derived from the schematic wiring diagram (elementary wiring diagram).

The two types of PLC programming devices are:

Hand-held programming devices

Stand-alone programming devices

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DCS Basic

Configuration

DCS has been categorized into:

• Control Module –performs control & PID(proportional & integral & derivative), binary logic and arithmetic functions.

• Data-processing Module –manipulates data, performing functions as data table, graphic display, variable trending, report generation, and long-term data storage and retrieval.

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Distributed Control

System

1. Large Screen Display.

2. Operator Interface HMIs.

3. Alarm Display.

4. SOE & Event Logging.

5. GPS Time Synch System.

6. Historian.

7. Engineering Station & Printer.

8. Weather Monitoring System.

9. Online Performance Monitoring System.

10. Asset Management System.

11. Alarm, Event and Report Printers.

12. Web-Server.

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EUROPEAN UNION


Distributed Control System Continue

13. UPS

14. Cyber Security.

15. Remote Monitoring Server.

16. SCADA & AGC connectivity with DCS.

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EUROPEAN UNION


Trending

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Plant Graphics

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Controllers & their Status

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DCS Specs

1. Redundancy of Controllers.

2. Redundancy in critical field devices (Controls)

3. Number of I/O Points (Digital & Analog).

4. Signal Processing Speed.

5. Connectivity features.

6. Security Provisions.

7. Third Party integrations.

8. User friendly.

9. Built in Libraries for Programming.

10.Time Synch & Redundancy.

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DCS Management

Essential Tasks of System Manager (I&C Engr.)

1. System Backup.

2. System Crash Recovery Preparation.

3. System Diagnostics & troubleshooting software on dedicated laptop.

4. Reference Commissioning Data preservation.

5. Daily Messages & Events Review of System.

6. DCS Software & hardware related messages.

7. Archiving.

8. System health checks.

9. Power Source including the UPS (batteries & inverter).

10. Standard UPS time & Safe shutdown.

11. Memory card Battery Backups & replacement.

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DCS Management Continue

1. System Password Protection.

2. Limited Access to users.

3. Effect of USB/External HDD.

4. Running Virus Scanners.

5. Adding the Programs & Precautions.

6. System Limitations.

1. Memory Review.

2. HDD space review.

3. Program Cycle Execution Time.

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EUROPEAN UNION


Present Control

Systems Different OEMs are making Control Systems out of which following are the best known, these are different in many features but very commonly used systems are.

1. GE.

2. Siemens.

3. Emerson.

4. Yokogawa.

5. Honeywell

6. ABB.

7. Alstom.

8. Invensys.

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EUROPEAN UNION


Major controls of Boilerfor power plant

FUNDED BY THE

EUROPEAN UNION

High Pressure Cogeneration for Sugar Sector in Pakistan47

PID’s bagasse

fuel feeding system

E

E

E

E

Plate slide Plate slide

E

VSD

VSD

Fixed speed

VSD

Fixed speed

Signal load control4- 20 mA-

E

E

PI

PS

Spreader air fans

MCCAutomatic

start standby

Sight glassSight glass

Sight glassSight glass

peepholes

2 inch connections

3inch

inch

inchinch

Rotary air damper

Rotary air damper

Spreader fans

3 more

Bagasse feeding and spreading system

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EUROPEAN UNION


PID of Air system

FGAP2grate

FGAP2 overf

FGAP1grate

GFAP1overf

Right side wall

left side wall

Overfiring nozzles

2 * 5 dumping grates

5 air dampersPut air on and it will closeNormally open by spring

Raw water 1 inch

overflow

Push button for operation at each grate

E

VSD

E

VSD

StapOFA

Stapgrat

e

FT

FT

TT

TT

TT

TT

PT

E

VSD

o/c

o/c

E

VSDo/c

o/c

Load controlAir fuel ratio

E

Damper fan close directly automatic when fan stops.

PT

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EUROPEAN UNION


49

PID’s Flue gas

system

Dumping grate

PT

TP

TP

TP

TP

TP

TP= testpoint of 1 inch

Fly ash arrestor

PI

TT

Pressure control

PS

PS

H L

E

FGAP2grate

FGAP2 overf

FGAP1grate

GFAP1overf

sup2

sup1B

sup1A

evap

2 *

eco

E 2 * E 2 *

XT

O2

E

VSD

E

VSD

o/c

o/c

pT

TP

TP

TP

TP

TP

TP

TP

TP

TT

drain

Damper fan close directly automatic when fan stops.

Trip boiler

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EUROPEAN UNION

High Pressure Cogeneration for Sugar Sector in Pakistan50

Sup 1 BDeaerator

LT

LIC

PT

PI

LS

LG

LIC

To sample cooler ¼ inch

Dosing hydrazine½ inch

Dosing ammonia½ inch

Design pressure deaeratorat 2 barg, saturated and 100% vacuum

2 inch drain

Condensate And demi water return

??inch

From LP header? inch

Into demi water tank1 inch

? inch

1/2 inch

Steam air preheater

1 inch drain

To pressure/temperature reducing station

?? inch

BFW pumps

Capacity?

To BFW pumps

L

HTo cond pumps

E

? inch

PI

PI

?? inch? inch

Second pump

2nd

2nd

To boiler

2nd

PT

Start 2nd

pump

L

PID feed water

system

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EUROPEAN UNION


condensate

Condensate vesselDiam 1000 and 1500 mm highOn 4 m level

2 inch balancing line

?? tph LP steam from outlet steam turbine at 1,2 barg

To condensate clean tank

LT

LG

12 inch

? inch? inch

? inch

? inch

? inch

3 inch

System Steam air preheater

8 inch

? inch globe

Condensate vessel

Installed near vessel

Water level control valve

TIC

At 8 m level

Design 3 barg 150 C

PID steam air

preheater system

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PID Water system

boiler

2 inch

2 inch

LS

LG

LL

LT

1 in

ch

1 in

ch

2 inch

2 inch

LS

LG

LL

LT

1 in

ch

1 in

ch

Steam drum

eco

1 in

chTri phosphate dosing

??inch

FT

1 inch

From BFW pumps

FIC

LIC

1 in

ch 1 in

ch

To de-superheater

Parabolic valve for manual control

1 i

nch

1,5 inch

1,5 inch

1,5 inch

1,5 inch

Sample cooler

Trip boiler ( stop feeder and air supply)After stop air fans then stop ID fan

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PID Steam system

boiler

Steam drum

sup1

sup2

Sample cooler

1 in

ch

4 * 4 inch

?? inch

TT

TT

Steam to sootblowers

PI

TI

1 inch

1 inch

1 inch

FT

TI

?? inch

FT

TT

TI

PT

PS

Trip boiler

LIC

Feed forward signal on steam flow

To 3 comp water control

Feed forward for fuel control

Load control

silencer

PID Water system

boiler

Continued..

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PID Soot blowing

system

Fly ash arrestor

FGAP2grate

FGAP2 overf

FGAP1grate

GFAP1overf

sup2

sup1B

sup1A

eco

2 *

E

E

E

E

E

eco

E

E

E

E

E

E

2 *

2 *

2 *

3 *

evap

evap

E

2 *

3 *

3 *

3 *

3 *3 *

3 *

3 *

2 inch

PT

PI

From de-superheating line at inlet superheater2

1,5 inch

1,5 inch

1,5 inch

Blow down vessel

TT

TT

2 inch

Design pressure 25 bargDesign temp. 400 C

Design pressure 124 bargDesign temp. 450 C

Pressure control

Automatic sequence control

Signal to start/stop sootblowers

Signals from sootblowers

temperature control

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EUROPEAN UNION


Thank You for Your Kind Attention

funded by the european union comprehensive technical training · turbine gen. controls sub-system...

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