hydro electric power plant automation
DESCRIPTION
basics of automation of hydro power plant...TRANSCRIPT
HYDRO POWER GENERATIONINDUSTRIAL TRAINING PRESENTATION ON
presented by
MD ABDUL RAHEMAN(10GAME1006)
Under the guidance of
M N SUNEETHA Executive Electrical Engineers
Asst. Professor Respective sections
Dept. of E and E Engineering K.P.C.L
UVCE , Bengaluru – 01 Bengaluru – 01
1. Overview of SCADA:
General components of SCADA
system:
• Sensors
• Remote Terminal Units
• Master units
• Communication Links
• Software
General Functions of SCADA:
• Data Acquisition
• Supervisory control
• Plotting
• Alarms
• Logging
• Load shedding
• Load restoration
• Automatic generation control
Need for SCADA:
•To reduce total cost.
•To reduce man power.
•To reduce future capital requirements.
•To improve level of service.
•To avoid environmental accidents.
•To comply with regulatory
requirements.
•To attain and maintain competitive
edge.
•To replace existing aging systems.
•To manage complex systems
2. SCADA Configuration :
Fig 2 System overview of VUGPH
•UCB (Unit Control Board)
•CCB (Common Control Board)
•CRB (Control Room Board)
•SCB (Switchyard Control Board)
•Central Control Room Equipment
•Video over IP System
•Uninterruptable Power supply
i. Unit Controlled Board(U.C.B):Cubicle design:
DEVICE FUNCTION
15” Touch panel Main device for control and supervision
of the unit
Lamp (Green) North bus selected
Lamp (Orange) South bus selected
Lamp (Red) Circuit breaker close indication
Lamp (Green) Circuit breaker open indication
Lamp (Green) Indication for Readiness of unit operation
Lamp(Orange) Indication for Alarm
Lamp (Red) Indication for Trip
Push Button Alarm/trip reset
Push Button Horn reset
Push Button Lamp reset
Key operated cam switch Control point selector switch with 3
positions:
Local
Maintenance
Remote
Double Voltmeter For manual synchronization
Double Frequency meter For manual synchronization
Active power meter For MW
Reactive power meter For MVAR
Push button Emergency Shutdown Unit
Key operated cam switch Voltage raise/lower selector switch
spring return type
Selector switch Speed raise/lower selector switch spring
return type
Selector switch Synchronizing selector switch with 2
positions:
Auto : Synchronization in Auto
mode
Manual : Synchronization in
Manual mode
( Manual Synchronization is also
possible from CRB if UCB is in Remote
mode.
Selector switch Bus bar Selector switch with 2 positions:
North bus select in manual mode of
synchronizing
South bus select in manual mode of
synchronizing
Selector switch FCB open/close selector switch spring
return type
Selector switch Generator CB open/close selector switch
spring return type
SYN3000 For automatic and manual
synchronization
Functions of the UCB:
The controller of the UCB executes following software modules:
Control and Sequencing modules:
•Control modes and place of control
•Sequence control (automatic start and stop of the unit)
•Automatic & Manual synchronization
•Control of auxiliaries
Safety module:
•Alarm System
•Emergency trip system for mechanic faults (“mechanical protection”)
Temperature supervision
Control and Sequencing modules:
A . Place of control :
• Remote : Controlled from HMI in control room
• Local : at unit’s own unit control board
B. Control Mode :
• Auto mode
• Auto step by step mode
• Manual mode
C. Sequencing (automatic starting and stopping of the unit)
covers complete automatic control under normal conditions
provides fully automatic step by step control of TG set
includes control of all auxiliary equipments of TG set
D. Automatic & Manual Synchronization:
Provision for automatic and manual synchronization
Synchroscope , double voltmeter, double frequency meter and
open/close for the breakers will be provided
E. Control of unit auxiliaries:
The control and monitoring of unit auxiliaries such as:
• CW pumps motorized valves of CW system
• governor OPU pumps excitation system
• generator brakes Main inlet valve
•Monitoring of pre-conditions of each auxiliary
•Facility to select main & standby devices
•Automatic over depending on the duration of the operation or detection of any
alarm/trip signals,
Safety module:
All signals which are giving evidence of an abnormal condition in the plant, will be
processed in the safety module
The safety module comprises of the following functions:
A. Alarm system:
All external and internally created signals (e.g. temperature exceeded)
which are used in the safety module are treated as alarm
Every alarm signal causes an acoustic alarm and is displayed on the
touch panel.
B. Mechanical Trip System:
The mechanical trip system handles all mechanical fault conditions of the
unit, which require an emergency shutdown
All electrical failures are detected and processed by the electrical protection
system
One hardwired contact from unit electrical protection relays indicating internal
failure of any relay will be interfaced with the respective UCB.
These signals will be integrated in the trip scheme to create ESD.
Each signal which has to initiate an emergency shutdown
And is handled independently by the control system through mechanic trip
system within the safety module
It causes an alarm as well as a shutdown of the unit
additionally a normal stop sequence of the sequencing software will also be
initiated
Any trip has to be reset manually of the “trip reset” button after all fault signals
have disappeared and the unit has come to stand still.
The reset can be carried out from the HMI in control room “REMOTE” mode or
from the UCB in “LOCAL” mode either through the touch panel or by the push
button provided on the UCB.
C. Temperature Monitoring:
All temperature values are supervised up to four limits. The limits are split into two main
groups: Upper and lower limits as follows –
Limit Type Definition
Too High Trip “Temperature too high”
High Alarm “Temperature high”
Low Alarm “Temperature high”
Too low Starting prevention “Temperature too low”
Table 9.2 Temperature Limit Table
The mechanical safety module always compares the actual temperature values
with set limits and initiates the requisite action such as alarm or trip
Each temperature signals can be monitored on the HMI in the control room or
the touch panel on the UCB in form of a bar graph.
Hardwired logics:
In addition to the trip signals the emergency shutdown logic will be
implemented in hardwire also
Emergency shutdown can be initiated through the push button provided on
the respective UCBs and Control Room Board in the control room.
The emergency shutdown will work in case of failure of the UCB controller.
Sequence of Event Recording:
The binary input modules of the controller are capable of acquiring the data
with a resolution of 1ms
transmit the same spontaneously to the control system
This data along with the time stamp can be viewed in the “Chronological
Event List (CEL)” on the HMI in the control room and on the touch panel in the
UCB. This feature is available on other control boards also.
Touch Panel- Local HMI:
The UCB is provided with 15” touch panel mounted on the control board
for the purpose of local operation.
ii. Common Controlled Board(C.C.B): Cubicle design:
Device Function
15” Touch Panel Main device for control and
supervision of the unit
Lamp (Orange) Indication for alarm
Lamp (red) Indication for trip
Key operated cam switch Control Point selector switch with 2
positions:
Local
Remote
Push button Alarm trip/reset
Push button Horn reset
Push button Lamp test
The CCB configuration is the same as that of UCB
This component control all relevant plant facilities which are responsible for
common auxiliaries e.g. Drainage, dewatering, Air compressor, low voltage
system/switchgear, DG set, Battery etc
Functions of the Common Controlled Board(C.C.B):
Control and sequencing module:
• Control modes and place of control : The AUTO Step by Step control Mode is not
available for CCB.
• Sequence control (automatic change-over scheme)
• Control of station auxiliaries
Safety Module:
• Alarm system
Hardwired logics:
Interlocking of breaker operation to avoid paralleling of power sources at the
415V bus bar or at SSB or UABs will also be provided in hardwired logic in
the respective control panels.
Touch Panel- Local HMI:
The UCB is provided with 15” touch panel mounted on the control board for the
purpose of local operation.
iii. Control Room Board(C.R.B):
The control room board contains all equipment necessary for metering, network
node for different interfaces, NTP timeserver
A. CRB Configuration:
The CRB consists of
•GPS-NTP Timeserver
•Pushbuttons, emergency pushbutton for all the units operation
• Auxiliary devices, such as miniature circuit breakers, relays, terminals etc. as
required
B. Unit synchronization:
Provision for automatic and manual synchronization
Synchroscope , double voltmeter, double frequency meter and open/close for
the breakers will be provided
synchro-check function will be part of SYN-3000 synchronizer.
The breaker open/close commands will be hardwired to the CBs in the
SWITCHYARD and status of the CBs will also be monitored through
hardwired signals from the SWITCHYARD.
C. NTP Time Server:
For time synchronization of the whole automation system
Via GPS receiver and the Ethernet station bus the time server
synchronizes every single component using the Network Time Protocol
(NTP)
The antenna will be mounted at a suitable location in the open within a
distance of 50m from the GPS server.
iv. 220kV Switchyard Control Board:
The 220kV Switchyard Control Board contains all equipment, necessary for interfacing
with bay controllers and supervision of the 220kV Circuit Breakers and Isolators
A. Configuration: •1AK1703 ACP rack equipped with
•Redundant power supply
•Redundant processor modules
•Redundant control system Ethernet interface to the power plant station bus system for
communication to the other functional areas using optical fiber
•Hardwired input/output modules (non-redundant)
•Interface to bay controllers
•Interface to protection relays
•Interface for engineering tool access
•Push buttons, selection switches, emergency push button for local operation
•Auxiliary devices, such as miniature circuit breakers, relays, terminals etc. as required.
•Fiber optic converter for interfacing with bay controllers
•Control point selection switch
B. Functions of SCB:
The Switchyard Control Board is configured to execute the following functions:
Interfacing with bay controllers:
The SCB interfaces with the bay controllers over IEC 60870-5-103 protocol over a fiber
optic link
The SCB will acquire the data concerning status of various devices such as CB’s and
isolators, electrical parameters of respective feeders, abnormal conditions from bay
controllers
display the same on the HMI in the control room
The operator commands given at the HMI in the control room are passed on to the
respective bay controllers through the SCB
Inter bay operation:
The SCB will carry out the following inter bay operations:
•Bus bar changeover – performing the switching sequence for change over of entire bus bar
section by coordinating different bay controllers. The bay specific interlocks are part of the bay
controllers.
•Inter tripping connections across different bay level
•Inter-bay data logic, such as summed up events signal or calculated values.
•Operation of bus bar PT isolators.
Acquisition of Switchyard related data:
The SCB will be interfaced with the common field devices of the switchyard such as
auxiliary power supply and common switchyard signals.
Synchronization of line CBs:
Automatic synchronization of the CBs by the respective bay controllers depending on the
command issued from HMI in the control room.
The synchronization of the CBs is also possible from individual bay controllers switching
it to local mode
The bay controllers perform the synchrocheck function before closing the CBs
Based on the selection of the bus, the SCB switches the selected bus PT connection to the
bay controllers
The breaker open/close commands will be hardwired to the CBs in the Switchyard.
status of CBs will also be monitored through hardwired signals from the switchyard.
Alarm System:
The alarms from the bay controllers will be acquired by the SCB
And displayed on the HMI in the control room and on the touch panel
Every alarm signal causes an acoustic alarm and is displayed on the touch panel as well
as control room HMI in the alarm list.
v. Butterfly Valve Control Board:
The butterfly valve control board controls the operation of the butterfly valve.
A. Butterfly valve RTUs:
For tele-control of two Butterfly Valves, a RTU for each Butterfly Valve is
provided
The scope includes the data transmission and the hardwired I/O interfacing to the
primary control systems (i.e. transmission of position indications and up/down
pulses).
B. Control Board:
Consisting of 1 cubicle for each Butterfly Valve, each equipped with:
1 RTU with respective inputs and outputs
1 set of auxiliary devices (MCB’s, relays, terminals etc) as required
C. Interfacing of both BFV with SCADA
Interfacing of both with SCADA to VUGPH will be done by optical fiber cable through
Ethernet switches.
vi. START-STOP SEQUENCE:
A start-stop sequence is an inbuilt feature of SCADA
The sequencing of starting and stopping of the generating unit under normal, emergency,
controlled operation etc. is programmed in the processor of SCADA system (UCB).
The starting and stopping is executed in steps on obtaining the feedbacks of the previous
step and fulfilling of the preconditions only the next step will be executed.
A. Standstill Conditions:
When the Hydel plant is not in operation, there are some conditions which should be
fulfilled
which might result in the saving of energy which was used for operation of those
components.
•Cooling water pumps OFF
•Generator brakes OFF & Brake jack released
•220KV CB OPEN
•Excitation OFF
•MIV CLOSED
•BPV CLOSED
•MIV OPU OFF
•Turbine OPU OFF
•UGB Oil vapour exhaust OFF
•LGB Oil vapour exhaust OFF
•All 6 Needles CLOSED
•Transformer Oil Pump OFF
The standstill conditions are as follows:
These Conditions don't have any sequence
Any of the above conditions failing to respond, will lead to an alarm to the operators and
he can take appropriate actions.
B. Pre-conditions:
•ESD & QSD relays RESET
•Generator brakes OFF & Brake Jack release
•220kV Earth switch open
•220kV CB open
•Excitation OFF
•MIV closed
•BPV Closed
•Selector switch GEN/COND in generator position
•HPOS OFF
•CB(52G) Trip coin HEALTHY
•All 6 Deflectors CLOSED
•OPEN status of the MIV
•CW Pumps selection on HMI
•Following should be in remote mode:
HPOS motor
UGB vapour exhaust motor
LGB vapour exhaust motor
Transformer oil pumps
Pre-conditions for Turbine operation- No load operation:
•Turbine operation mode completed
•Excitation ready
•Transformer cooling oil pump ON
•Transformer Oil Flow OK
•Transformer Alarms/trips not active
•Transformer Cooling water flow OK
•220kV CB OPEN
Pre-conditions for No Load Operation-Line operation:
•No load operation mode completed
•North bus or South bus isolator CLOSE
•220kV CB not tripped/no alarms •220kV CB OPEN
C. Start Sequence:
Each step has to be completed mandatorily for the next step to be executed.
Each step is followed with a feedback
Different sensors are being installed at different parts for the required system to collect
the data and sent to the SCADA servers
If any of the above mention feedback is unavailable, the next start step will not be
activated and sequence will be shifted to Stop sequence automatically in an AUTO
operation.
For every step there are some pre conditions as well as the feedbacks
Without the preconditions getting fulfilled, it is not possible to start any step
For every step there is time supervision
If time taken is more than it is considered as fault and the Stop sequence is initiated.
START SEQUENCE
Command Pre-conditions Feedback
Start Step: 1
Turbine Oil Pump Unit On
Pre-condition for Standstill-
Turbine operation
Turbine Oil Pump Unit
Main/Standby feedback
Start Step: 2
MIV Oil Pump Unit ON
Step 1 completed MIV Oil pump Main/Standby
ON feedback
Start Step: 3
CW Pump ON
Step 1-2 completed CW Pump A/B/C ON feedback
Start Step: 4
Transformer Cooling Oil
pumps ON
Step 1-2-3 completed 1. Transformer pumps A/B
ON feedback
2. Cooling Oil flow fail
Start Step: 5
HPOS Motor ON
Step 1-2-3-4 completed
Start Step: 6
1. Start LGB Oil Vapour
Exhaust motor
2. Start Oil Vapour
Exhaust Motor
Step1-2-3-4-5 completed
Start Step: 7
1. Start Step Valve
2. BPV OPEN
All the steps 1-6 should be
finished with all the feedbacks
required.
Start Step: 8
Service seal Valve OPEN
Bypass valve OPEN Service seal valve OPEN
Start Step: 9
MIV OPEN
1. BPV OPEN
2. Service Seal Valve OPEN
3. No Service seal pressure
4. Pressure equalised
MIV OPEN
Start Step: 10
BPV CLOSE
1. MIV OPEN
2. Service Seal OPEN
BYPASS CLOSE
Start Step: 11
TG ON
1. MIV OPEN
2. Bypass CLOSE
3. TCOP ON
4. Transformer cooling oil
flow OK
1. Needles OPEN
2. Deflector OPEN
3. Rated speed
TURBINE OPERATION COMPLETED
Start Step: 12
Excitation ON
1. Turbine Operation
completed
2. Pre-conditions for Turbine
operation
3. No load operation
1. Check Generator voltage
should be equal to 11kV
2. No alarms from excitation.
NO LOAD OPERATION COMPLETED
Start Step: 13
Auto changeover UAP
Supply Preferential
1. No Load operation
completed
2. Pre-conditions for No
Load operation- Line
operation
3. UAP Preferential
supply healthy
4. UAP Preferential
5.Breaker control in
AUTO mode
1. UAP supply source
Preferential
2. UAP Supply healthy
3. UAP Non Preferential
Breaker OFF
4. Two CW Pumps
running
5. CW inlet pressure OK
6. CW flow OK
Start Step: 14
Auto synchronizer ON
1. 89N or 89S CLOSE
2. 89G CLOSE
3. CB OPEN
4. Earth Switch OPEN
220kV CLOSE
Start Step: 15
Power Control Mode
ON
GCB CLOSE 1. 220 kV GCB CLOSE
2. Machine synchronised
3. Active Power set point
is given to TG
4. Machine running at
Base load of 10 MW
D. Shutdown Sequence:
For every step to work it is necessary that all the feedbacks are proper. If any step is not
completed then the emergency shutdown of the system is carried out.
SHUT DOWN SEQUENCE
Command Pre-conditions Feedback
Stop Step: 1
1. Special Stop Command to TG given
2. Decrease the Load to 0 MW
220 kV CB CLOSE MW decreased to 0 MW.
Stop Step: 2
Decrease MVAR to minimum
220 kV GCB CLOSE MVAR reduced to 0
MVAR
Stop Step: 3
220 kV GCB OPEN
220 kV GCB OPEN 220 kV GCB OPEN
Stop Step: 4
Changeover of preferential supply to non-
preferential supply
1. 220 kV CB OPEN
2. UAP Non
Preferential
supply healthy
3. UAP Non
Preferential
Breaker healthy
4. AUTO Mode
1. Supply changed to
CAP
2. UAP preferential
breaker OPENS.
Stop Step: 5
Excitation OFF
220 kV CB OPEN Excitation OFF
Stop Step: 6
TG OFF
220 kV CB OPEN Excitation OFF
Stop Step: 7
MIV CLOSE
Needles and deflectors
CLOSE
MIV CLOSE
Stop Step: 8
SSV CLOSE
1. Needles and
deflectors CLOSE
2. SSV OPEN
SSV CLOSE
Stop Step: 9
HPOS Motor ON
Speed less than 240
RPM
HPOS motor ON
Stop Step: 10
Pneumatic Brakes OFF
Speed at 75 RPM Brakes applied feedback
from limit switches,
Stop Step: 11
MIV OPU OFF
Speed at 0 RPM Brakes applied feedback
from limit switches
Stop Step: 12
Start Stop Valve OFF
MIV OPU OFF MIV OPU Main & Standby
Pumps OFF
Stop Step: 13
Turbine OPU Pumps OFF
Stop Step 1-12
completed
Turbine OPU Pumps OFF
Stop Step: 14
Pneumatic Brakes OFF
Stop Step 1-13
Completed
Brakes Released feedback
from limit switches
Stop Step: 15
Auxiliaries OFF
Speed 0 RPM 1. CW pumps OFF
2. LGB Oil Vapour
Exhaust Motor
OFF
3. UGB Oil Vapour
Exhaust Motor
OFF
4. Transformer Oil
Pump OFF
5. GOV&MIV
OPU OFF
E. Sequence for Quick Shut Down (QSD):
In this first reduce the load to base load (5MW) by closing the needles and deflectors
and then trip the unit
If the feedback for MW=5 is not received within 20seconds, then system
doesn’t wait anymore, but issues ESD command.
Sl No. Conditions
1 Temperature of generator hot air is very
high
2 Temperature of generator cold air is very
high
3 Main pilot line filter is 75% clogged
4 Oil pressure is too high or too low in oil
pressure tank
5 Oil level is too low in oil pressure tank
Following are the conditions for QSD:
Table 9.10 Conditions for QSD
Fig 9.3 Sequence for QSD
F. Sequence for Emergency Shut Down:
S. No. CONDITION
1 Temperature of Stator winding is very high
2 Temperature of any generator core is very high
3 Temperature of any generator tooth is very high
4 Unit protection system fault occurs
5 Unit protection DC supply failure
6 Oil level of upper bearing very high
7 Fault in UCB processor
8 Generator Backup Earth fault protection
9 Cooling water pump trips
10 Vibrations in the guide bearing are too high
Table 9.9 Conditions for ESD
Fig 9.2 Sequence for ESD
vii. Relay Protection
Fig Protection scheme for generator