1

BRIEF HISTORY OF PLANT

Ever widening gap between the power demand and its availability in the state of Punjab was one of the basic reasons for envisaging the thermal plant at Lehra Mohabbat Distt. Bathinda. The other factors favoring the installation of this thermal were low initial cost and less generation period as compared to hydroelectric generating stations, its good railway connection for fast proximity to load center. Guru Gobind Singh thermal plant is Government undertaking (under P.S.E.B.) Initially it was going to set up at Bathinda under GNDTP but the air force personal restricted its set up at Bathinda hence plant site is shifted to Lehra Mohabbat about 22Km from Bathinda city. Later this plant was approved as a separate autonomous body with its name as Guru Hargobind Thermal Plant. The construction of the plant commenced in 1992 and its unit started working in December 1997. Its second unit commenced in August 1998. The main companies whose technology pawed the way of this plant are TATA Honeywell & BHEL in turbine and boiler control .The total set up cost of the plant is 1200 crores and the capacity of the plant is 2*210 =420 MW. The over all efficiency of the plant is 95%.

The power availability from the plant now meets 20-25% of the total power requirement in Punjab. It has gone a long way in ushering prosperity in the state by emerging a large number of agricultural pumping sets, more industrial connections, 100% rural electrification, increased employment potential reliability and improvement in continuity of supply and system and removal of power cuts to a great extent. It has also led fast development of environment in area around District Bathinda by providing employment to about 3000 persons. Two new units of 250MW each are going to be commissioned soon, sanctioning of which has already being done. The following considerations have to be examined in detail before selection of site for a plant: Availability of fuel such as coal. Ash disposal facilities. Space requirements. Nature of land. Most important availability of water. Availability of labour. Transport facilities. Public Society problems such as pollution. Development of backward area.

PROFILE OF THE PLANT

OWNER BOARD

Punjab State Electricity Board

NAME OF THE PLANT

Guru

Gobind

Singh

Thermal Plant

SITE LOCATION

Between

129

Km

and

132 Km, Milestone on Bathinda-Barnala Road

MAIN COMPANIES EVOLVED CONSTRUCTION STARTED COMMENCE MENT OF 1ST UNIT

TATA HONFY WELL and BHEL

IN 1992

IN DECEMBER 1997

COMMENCE MENT OF 2ND UNIT TOTAL SET UP COST TOTL CAPACITY OF THE PLANT TOTAL UNITS IN THE PLANT GNERATION COST OVERALL EFFICIENCY OF THE PLANT HEIGHT OF CHIMNEY
Flue

IN AUGUST, 1998

1200 Crores

420 MW

112 Paisa/kW

95%

220

Meters

Multi

SOURCE OF WATER

Bathinda Branch of Sirhind Canal

POWER DISTRIBUTION
Electric Power Generated here is send to various sectors through distribution center. This is the main product of the plant, which is our nations wide requirement. Electric Power drives all our factories, industries, Railways, Domestic equipment etc. Overall our life is dependent on the electric power now days. Distribution center distributes power from here to Barnala Sub Distribution Mansa, Bathinda, Delhi, Ludhiana and Duri as per requirements.

RAW MATERIAL AND THEIR SOURCES

Power generation is using coal, HFS etc. as burning fuels for the generation of steam from demineralised water. Coal coming from West Bangal & Bihar via Rail wagons of 3800 Kcal/kg & 35% ash contents as the minimum requirement with rate of rupees 680/-p.tone. &4000 Tons per Day in quantity. Water is taken from Sirhand canal by the tunnel link of underground 2600mm dia pipes, which is collected in water pond of 150 arcs area & capacity 100000 cubic meters.

BASICS OF A THERMAL PLANT

In a thermal plant, heat energy is converted into mechanical energy of turbine that is further converted into electrical energy with the help of generator. A schematic view of the simplest steam power plant is shown in fig. A that is on next page. The three main processes in the diagram are: -

Process AD: - Water is admitted to the boiler,

raised to boiling temperature and then superheated.

Process DF: - The super heated steam is fed to

the turbine where it does work on blades and rotates it.

Process FA: - Heat rejected to the condenser.

Circulating water carries a very large proportion (4060% of total heat). The basic cycle of a steam power

plant considered above is called the RANKINE CYCLE.

RANKINE

CYCLE

ON

TEMPERATURE

ENTROPY DIAGRAM
The Temperature Entropy (T-S) diagram is the most useful diagram for illustrating certain fundamental points about steam cycle. Ideal condition for steam cycle on a TS diagram is shown in the fig. That is on the page no.2 At point A the condense is at boiling temperature corresponding to the back (condenser) pressure. Heat (sensible) is added to this water to raise its temperature and pressure. At the point B, it reaches it saturation temperature. Evaporation begins at point B. Heat (latent because no rise in temperature between B & C, as evident from the diagram) addition continues. At C all the water evaporates and super-heating commences. This is shown by the curve CD and at D, the superheated temperature is achieved. Steam then expands as it enters the turbine and rotates it, as shown in the line DEF. At point E there is no super heat left in the steam and so from E to F there is increasing wetness. At F steam is passed out to the turbine to the condenser and condensation of steam takes place as represented by the line FA. At point A the steam has all been considered and condense is a boiling temperature ready to begin another cycle.

To summaries the above:

AB heat Addition) BC CD DF Evaporation of water in boiler (i.e. Latent heat addition) Superheating of steam (i.e. superheat Addition) Expansion of steam in turbine, point E Donates demarcation between superheated and wet steam. FA Condensation of steam in condenser. Heating of feed water (i.e. sensible

PROCESS OF POWER GENERATION: A generating unit of thermal plant consist of boiler unit, a turbine with accessories, a generator, a unit transformer and plant Overview diagram, which shows the process of generation of electricity, is on the next to next page. other equipment all arranged to operate as complementary part of a complete monolithic set. The

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ELECTRICITY EXPLANATION

GENERATION

PROCESS

The coal travels by the conveyer belts from the coal handling plant to the coalbunkers from where it is fed into pulverizing mills; which grind the coal into powder. The powder coal is carried from the mill by steam of air heated air in the air heater driven by primary air fan (PA) to boiler burners where it is blown into the furnace and burns like a gas a force draft fan provide addition controllable to the burners to assist combustion. The product of this combustion is dust and ash. (Ratio of 5to 1) the ash to the bottom of the boiler and is periodically sluiced to mash setting pits .The dust carried in the fuel gas to the precipitators where it is extracted by high voltage electrodes. The dust is then conveyed to settling lagoons or removed by the road for safe. The fuel gas passes by an induced draft fan (ID) to the chimney. The heat released by the burning coal is absorbed by long length of tubing which forms the boiler valves. Inside the tube extremely pure water that is known boiler feed water is converted by the heat into steam at high pressure and temperature. The steam is then superheated in further tubes and passes to the high pressure (H.P) turbine where it is discharged through the nozzle into the turbine blades. The energy of the steam striking the blades make the

11

turbine rotates after passing through the high-pressure turbine. The steam is returned to the boiler for reheating before passing through the intermediate pressure turbine (IPT) and to the low-pressure turbine (LP). Coupled to the turbine shaft is rotor of the generator, a large cylindrical electromagnet, so that when the turbine rotor rotates, other rotor rotates with it. The generator rotor is enclosed in the stator; which consist of large coils copper bar in which electricity is produced by the rotation of magnetic field created by the rotor. The electricity from the stator winding goes to a transformer; which increase its voltage so that it can be transmitted over the power lines into grid system. Mean while, the steam that is exhausted its useful energy in turning the turbine is turned back into water in the condenser so that it can be Used again in the boiler. Before entering in the boiler at the economizer the water is pumped by condense extract pumps heated in the low pressure (L.P.) heaters, deaerated in the deaerator increased in the pressure by boiler feed pumps and heated further in high pressure (HP) heaters. The water passes through the economizer to the steam drum then up through the furnace walltubing before returning to the steam drum for steam separation. The steam leaves the drum and heated further in the super heater on its way to the HP Turbine. The condenser

12

contains miles of tubings through which the cold water is constantly pumped. The diagram showing this whole process is shown on page no. 11& page no. 12

Plant overview
COAL PLANT
Conveyer belt

BOILER BUNKERS

PULVERISING MILLS

BOILER BURNER
FD Fan

COMBUSION
Dust Ash

CLEARED FUEL GAS PASS TO CHIMNEY VIA INDUCED DRAUGHT FAN

COAL BURN
Heat released

BOILS WATER WHICH GIVES STEAM

13

STEAM IS SUPERHEATED

PASSES TO H.P TURBINE

Continue On Next Page

CONTINUED FROM THE LAST PAGE:-

EXHAUSTED STEAM ENERGY Steam TURBINE BLADES CAUSES TURBINE TO ROTATE STEAM IS RETURNED TO BOILER FOR REHEATING

CONDENSER

USED AGAIN IN BOILER WATER IS PUMPED HEATED IN LP HEATERS DEAERATED IN DEAERATOR PRESSURE INCREASES BY BOILER FEED PUMPS

TIRBINE SHAFT IS COMPLED TO ROTOR OF GENERATOR

GENERATOR ROTOR IS ENCLOSED IN STATOR ELECTRICITY IS PRODUCED AT STATORWINDINGFROM WHICH IT GOES TO TRANSFORMER POWER IS STEPED UP BY TRANSFORMER
Power Lines

HEATED IN HP HEATERS ECONOMIZER

STEAM DRUM STEAM IS HEATED IN SUPERHEATER HP TURBINE

GRID SYSTEMS

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PLANT OVERVIEW

BLOCKS DISCRIPTION
SUPERHEATER (SH)
Super Heater (SH) is a plain tubular, non-drainable vertical in line spaced type, arranged for parallel flow. This super heater (SH) is located in the horizontal path after reheater. Next to Super Heater is Reheater System.

REHEATER SYSTEM (RH)

The reheater section is the single stage; spaced type, continuous loop, and plain tubular, non-drainable, vertical in line spaced type, arranged for parallel flow.

ECONOMISER SYSTEM (ECON)

The economizer system is a single block unit, is of continuous loop plain tubular, drainable horizontal, in line arrangement with water flow upwards and gases flow

15

downwards. The economizer tubes are suspended from economizer supports. intermediate header, using ladder type

DEAERATOR (DEA)
The deaerator (DEA) is provided to remove dissolved corrosive gases from feed water that goes to the boiler. It prevents internal corrosion of boiler tubes. The oxygen is reduced to untraceable limits by mechanical means in the condense living the deaerator.

BOILER FEED PUMP (BFP)

Boiler feed pump (BFP) is very important auxiliary of the powerhouse. It has to take supply of water from the deaerator, and supply it to boiler drum against the positive drum pressure.

MILLS
Bowl mills have been installed from pulverizing the raw coal. The coal of maximum size of 25 mm is received in raw coalbunkers from Coal Handling Plant. From the bunker, this coal is fed into the mill through Raw Coal

16

Feeder. Regulating the speed of the Feeder can control the feed of the coal mill.

CONDENSER (COND)
The condenser (COND) is a box type double pass with divided water box design that facilitates the operation of one half of the condenser while the other half is under maintenance. The steam space is of rectangular cross section to achieve optimum utilization of the enclosed volume for necessary air-cooling section at the center from where air and non-condensable gases are drawn out with the help of air evacuation pumps. The circulating water enters the water boxes from bottom and then travels through several tubes and leaves the condenser through upper water boxes in two distinct paths. Next to condenser is condensate extraction pump (CEP).

CONDESATE EXTRACTION PUMP (CEP)

There are two 100% capacity condensate extraction pumps (CEPs) provided in the system. Normally, one condensate extraction pump runs and other is kept as stand-by. These pumps are of vertical and centrifugal

17

canister

type

with

the

driving

motor.

Condensate

extraction pumps have five stages.

GLAND STEAM COOLER (GSC)

The gland steam cooler is used to condense the steam extracted from turbine glands and to maintain slight vacuum at the turbine glands to avoid steam leakage to atmosphere from turbine glands. It is a single pass heat exchanger with the main condensate entering from one end and leaving from the other end. Air steam mixture passes over the tubes in zigzag path due to number of baffles and thus steam is condensed there-by heating the condensate inside the tubes.

DRAIN COOLER (DRN CLR)

Drain cooler (DRN CLR) is provided to sub cool the drains coming from Low Pressure (LP) Heater to improve the cycle efficiency by heating up the condensate flowing through the tube system.

LP HEATERS (LP HTRS)

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The LP heaters (LP HTRS) are of the surface cooled type. They are designed for vertical mounting. These heaters are of tube system withdrawal type; these are of four-pass design. Condensate flows inside the tubes while steam flows Outside the tubes. The condensed steam is collected in the bottom of the shell that is drained out.

H.P. HEATER (HP HTRS)

High Pressure heater is supplied heating steam from extraction 5 taken from IP casing of turbine. The feed water enters first in this H.P heater and after getting heated goes to High Pressure (HP) heater 6. The feed water flows through the tubes from coldest zone to the hot most zones before it leaves the heater. The steam flows from hot most zones to coldest zone and the drain normally goes to deaerator. ROTARY AIR HEATER (RAH) The basic principal of operation of Rotatary Air Heater (RAH) is the same as the liung storm type except that the elements are stationary and the air hoods rotate with. In the gas pass at approximately 1 rev./min. The axis of

19

rotation may be vertical or horizontal but again and for similar reasons the vertical spindle is preferred. The drive is normally through an electric motor operating a pinion that meshes with the rack on the outer rim of the hood assembly. FORCED DRAFT FANS (FD FAN) To take air from atmosphere at ambient temp. To supply essentially all the combustion, air can either be seized to overcome all the boiler losses (pressurized system) or just put the air in the furnace (balanced draft units). INDUCED DRAFT FANS (ID FANS) Used only in balanced draft units to suck the gases out of the furnace and throw them into the stack. Handles fly ash laden gases at temperature of 125 to 250oC. ELECTROSTATIC PRECIPETATORS (ESP) The principles upon which Electrostatic Precipitators operates are that the dust-laden gases pass into a chamber where the individual particles of dust are given an electric charge by absorption of free ions from a high voltage DC ionizing field. There are four different steps in

20

the precipitation viz., ionization of gases and charging of dust particles, migration of the particle to the collector, deposition of charged particles on the collecting surface, dislodging of particles from the collecting surface.

VARIOUS

CYCLES

INVOLVED

IN

POWER GENERATION
PRIMARY AIR CYCLE: The primary air, generated by PA (primary air) fans, is used to carry the pulverized coal from the coal mils to the furnace. The Primary Air (PA) fans are two in number. A header called the PA fan duct of the air is made and two tapings are made from this header. One is passed through the AIR PRE-HEATER A and B, which, using the heat of the outgoing flue gases, heats the air, now called the hot primary air. This hot primary air is now divide into six parts A to F and then sent to the six coal mills by making a hot primary air header. The other tapping of air called the cold primary air is also made into a cold primary header and then divided into six parts A to F to be sent into six mills.

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Now lets consider the action of primary air on the mills by considering, say, mill A. Hot primary air A and cold primary air A pass through respective valves in their pipes before entering the coal mill. The valve is installed as the inlet flow temperature is to be maintained at >175C and the flow of the air flowing in the mill is to be at 54-tons/hr.the outlet temperature is to be maintained at >65C &< 10C. From the mill, four feed outlet are taken, carrying the coal to furnace. As these are six mills, so there are 24 feeds to furnace. The feed from each mill enters the furnace at 4 different corners but at the same elevation or height. The feed from other mills also enters the furnace at corners but at different elevations. All the feeds from the mill open equally. Now consider only one corner of the furnace. The feed from mill A enters the corner of the lowest elevation and those from mill F at highest elevation. The other feed is between them. In between feeds A & B, C& D, E & F, there are oil guns called feed AB, CD, and EF respectively. Below A and above F, There are auxiliary air inlets in the furnace. The primary air cycle is shown on the next to next page.

22

SECONDARY AIR CYCLE: The forced draft fans are used to generate the secondary air, which is used to help in the ignition and burning of the coal in the furnace. A common header is made of the two FD fans (A&B) and this passed through the two air preheaters, which heat the air using the heat from the flue gases, so that the cold air doesnt bring down the temperature of the furnace. The secondary air for combustion is preheated up to 317oC by means of regenerative air-heaters (Rotary Air Heaters). The air heater air out ducts are interconnected to provide a balanced air flow to the furnace and to make it possible to operate the unit at reduced load if one fan is out of service.

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Distribution of secondary air to Wind Box compartments is controlled by the secondary air dampers. The steam coil air pre-heaters (SCAPH) one each at the outlet of FD Fans & before RAH has been provided to avoid the corrosion of RAH by increasing the temperature of secondary air entering the RAH when the boiler is initially lighted up. The secondary air path is shown in fig. That is on the next page.

Air I/l

PA FAN A&B

RAH A&B

MILLS A-F

PRIMARY AIR CYCLE

FURNACE

Air I/l

FD FAN A&B

SCAPH A&B

RAH A&B

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SECONDARY AIR CYCLE

AIR CYCLE

FLUE GAS CYCLE: Flue gases travel upward in the furnace and downward through the rear gas pass to the economizer and air heaters. In the economizer, the some heat of flue gases is utilized to heat the feed water before it goes to drum. Further in the air heaters, the residual heat of the flue gases is utilized to pre-heat the secondary and primary air. From the air heaters, the gases pass through the electrostatic precipitators (ESP) and induced draft fans to the stack. Interconnections of the gas ducts at inlet and outlet of electrostatic precipitators are provided.

25

FURNACE

RAH A&B

ESP

ID FAN A, B, C

FLUE GAS CYCLE

CHIMNEY OR STACK

26

WATER CYCLE: The steam after working in three casings of the turbine i.e. HP, IP & LP casings is condensed in the surface condenser installed just below the LP exhaust hood. The condensate is collected in the bottom portion called ho well from where it is pumped into the Deaerator by condensate extraction pump (CEP) through different heating stages through which condensate flows and get heated up gradually before finally reaching the Deaerator. The various heating stages are Gland Steam Cooler, Drain Cooler, and LP Heater (1, 2, 3) Deaerator. The approximate temperature rise of condensate after passing through above heating stages is from 40/45 at hot well to 166oC at the Deaerator (at full load). The condensate coming from LP heaters passes the tubes of vent condenser. The steam transfers its heat to condensate flowing within the tubes and gets condensed. The non-condensable gases along with some steam go out of the equipment. The drain (condensed steam) is returned to the deaerating header. The condensate after leaving the deaerating header enters the feed storage tank. From feed water tank, the boiler feed pumps takes suction of

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feed water thorough booster Pumps and discharge is fed to the boiler drum after passing through different heating stages viz. HP heaters (5, 6) and feed water regulation station (FW REG STN).

FM DM M/U COND. CEP A&B GSC DRN CLR LP HTRS FW REG STN FURNACE HP HTRS 5,6 BFP A, B, C DEA

steam

MAIN WATER CYCLE

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STEAM CYCLE
Steam is that part of the whole process cycle in which the fluent is steam i.e. part of the cycle containing steam. Steam is first of all generated in the boiler with the help of coal as a principal fuel. If it is not present in the adequate amount or not of high purity then heavy furnace oil (HFO) and light diesel oil (LDO) is used to produce heat in the furnace. The heat energy supplied in the furnace is absorbed by the water walls and gets heated up. This gives rise to the formation of steam bubbles in the water walls and the risers. The cold water in the drum there continuously displaces the moisture of steam bubbles and water by destabilizing a natured circulation. With the help of super heater (SH) the steam is super heated and passes to the HP Turbine. For high efficiency, the turbine is divided into three stages viz. HP Turbine, IP Turbine and LP Turbine. Now at the starting the temperature of the shaft of the turbine is less and at once increase in temperature may cause Sag in it therefore few cycles of heated steam passes through the HP BP so that the conductor in the turbine may achieve the equivalent temperature of the steam by this there will be no loss of

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heat due to temperature difference. Through HP BP it again passes through the furnace and there it reheats with the help of Repeater (RH) and then it passes to the IP Turbine at a temperature of about 551oC . From here it passes through the LP Turbine that rotates the coils of the generator and electricity has been produced. Like HP BP, LP BP is present as a direct passage of heat from IP Turbine to condenser where this steam is again changed into water.

MAIN STEAM CYCLE

HPT FURNACE HP ECON RH SH IPT BP

COND

LP

BP

LPT

GENER ATOR

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WORKING OF THERMAL POWER PLANT AT G.H.T.P.

Coal received from collieries in the rail wagons is mechanically unloaded by wagon tippler and carried by belt conveyor system to crusher house underground. In crusher house the coal is crushed up to 25mm. This coal is taken by belt conveyer to raw coal bunkers near coal mill. The coal is then milled to powder form having up to 0.5mm to1.0mm dia. There is a raw coal chain feeder that regulates quantity of coal from bunkers to coal mill where coal is pulverized as said above. That pulverized coal is then pushed to the boiler furnace by pressurized primary air from corner feeders. This furnace have water tube wall all around through which water circulates. Water is converted into steam by heat released by combustion of coal. The oils L.D.O.&H.F.O are used in combustion of coal forced by forced draught fan. That air is sent in the boiler furnace after heating in air heater by using the heat of flue gases. The greatly heated steam and water is sent to boiler drum, where the water is separated from steam and the dry steam is sent to the T.G.set, and the water is again sent to reheater and economizer.

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The steam having 130km/m2 to144km/m2 pressure and 5400 c temperature is sent to H.P turbine. Turbine is made from Germany which uses high pressure steam and rotates at 3000rpm.The steam used in H.P.Turbine is lost its heat up to 2400 c so to reheat i.e. to raise again the temperature and pressure of the steam. The steam is passed through the reheater and continuously sent to H.P&L.P turbine, made by B.H.E.L., rotated on the same shaft with 3000rpm. The steam from LP turbine is taken out in a vacuum condenser having (-) 0.9kg/cm2 vacuum. Here the steam is condensed by cold water pipes ciculation.The condensed steam in form of hot water is put into the hot wall. From where it is again feed into the boiler drum through the deaerator, LP heaters, HP heaters, BFP, Economiser etc. The condensating water, which is used to condense steam, takes heat from steam and it becomes hot. That hot water is taken to cooling tower where it is dropped from 10m heights to cool water by using natural air draught. This circulation is made by C.W.pumps And cooling is done up to 100 c. The products of combustion of furnace charge are flue gases and ash. About 20%of the ash falls in the bottom ash hopper of the boiler and is removed mechanically by mixing with water. The

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remaining ash carried by flue gases is separated in the Electrostatic Precipitator where the ash is electro statically evacuated And this dry ash is dumped in the ash disposal area. The cleaned flue gases are left to the atmosphere through 220m high chimney using I.D.Fan. The turbines are coupled to the same shaft upon which the generator is coupled. The Three phase generator produces 3-phase supply and which is pumped to the power grid system through generator transformer by stepping up the voltage which is further send for distribution. The raw water is taken from Sirhind Canal to ponds and after that some amount of water goes to the boiler through D.M. plant and the remaining water is clarified and used for the cooling purposes.

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SYSTEM DESCRIPTION
G.H.T.P.Thermal Power Plant consists of various systems. These are the following systems: Coal Handling System. Fuel oil system Ash handling system. D.M. Plant. Emergency Power supply system. Control & Instrumentation system. Data Acquisition system. Power supply distribution system

COAL HANDLING SYSTEM

G.H.T.P.Thermal Plant is coal-based power plant. The annual requirement of coal for 2 units based on specific fuel consumption of 0.60 kg/kwh is 1.381 million tones .The conveying and crushing system will have the same capacity as that of the unloading system 1000 TPH.The coal comes in the coal plant in large pieces. The coal is

35

fed to the primary crushers, which reduces the size of coal pieces from400mm to 150mm size. Then the coal is sent to the secondary crushers through forward conveyors be crushed from 150mm to 20mm as required at the mills. Then the coal is sent to mills through coalbunkers .In mills coal becomes in powder form, which is sent to the boiler with the help of priamary air fan. The coal is burnt in the boiler. Boiler includes the pipes carrying water through them. Heat produced from the combustion of the coal is used to convert water in pipes into steam. This steam generated is used to run the turbine. When turbine rotates the shaft of generated which is mechanically coupled to the shaft of the turbine get rotated and so 3 phases electric supply is produced.

FUEL OIL SYSTEM

Fuel oil is normally used for start up and for flame stabilization at low load. Initially in the boiler either L.D.O. or H.F.O. is combusted before the combustion of the crushed coal from the mill. Light Diesel Oil (L.D.O.) does not require preheating but Heavy Fuel Oil (H.F.O.) requires preheating because H.F.O. is very much viscous. L.D.O. or H.F.O. are used initially because this oil has less heat of combustion then coal. Heat liberated

36

from the combustion of these oils is used for starting combustion of coal as soon as coal starting combustion L.D.O. and H.F.O.is stopped and coal is supplied continuously from the fuel guns in to the boiler. The H.F.O. is preheated by using the heat of burnt gases, which is coming from boiler of the 2nd Unit through Chimney.

ASH HANDLING SYSTEM

When the coal is burnt in the boiler nearly 35% of the ash is liberated in the addition with another burnt gases. These ash and gases are coupled out by the reduce draft fan from the boiler E.S.P. is between the boiler and I.D.Fan. E.S.P. contains charge electrodes that attract the ash particles and the collect ash this ash is sent for disposal.

DEMINERALISED PLANT (D.M)

A Demineralised water treatment plant is provided for supplying make up water to the boiler. Water as it occurs is never pure as whatever may be the source always contain impurities .the major impurities of water are: Non-ionic & undissolved

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Ionic &dissolved Gaseous In the DM plant these impurities are removed chemically & Demineralised water is sent to the boiler.

EMERGENCY POWER SUPPLY SYSTEM

For the safe shut down of the plant under emergency conditions i.e. in the case of total power failure diesel generating sets are purposed to be installed for meeting the power requirements of the essential auxiliaries.

CONTROL&INSTRUMENTATION
The function of the control & instrumentation system is to add the operator in achieving the safe and efficient operation of the unit. The operator is to be provided with the adequate information considered essential for start up, normal operation, planned shut down and emergency shutdown of the unit. Centralized control of the boiler &turbine generator unit from a centrally located Unit Control Board (UCB) room is envisaged. It would be possible

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To start or to stop all electrically driven unit auxiliaries &power operated valves and dampers from UCB expect where recommended, otherwise, by the main equipment suppliers.

DATA ACQUISITION SYSTEM

In line with the modern practice of centralized monitoring and control of large capacity power plants Data acquisition system (DAS) shall be provided for monitoring and logging of different parameters of steam generator, turbine, important temperature points of H.T & L.T motors, generator & other auxiliaries of the unit. The system shall monitor, log, the various parameters at different time e.g. at the time of start up, shut down, normal run sudden load throw off positions. The electronic system of DAS shall be of high speed and equipment with alphanumeric and trend display CRT and alphanumeric logging printer.

POWER SUPPLY DISTRIBUTION SYSTEM

Power supply/control supply panels with adequate no. Of spare feeders shall be provided to meet the requirement of primary instruments, secondary instruments, controls

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panels, DAS, sequential control system protection and interlock system. Suitable arrangement for automatic changes over from normal supply to stand by supply and provision of uninterrupted power supply (UPS) to meet the essential load requirements shall also be provided.

TDC-3000
TDC 3000 organized by process plant instrumentation and control needs flexibility. Before going in detail of the TDC-3000 (DCS) we should familiar with the following objects.

AREA UNIT POINT CONCEPT: In TDC-3000 plant instrumentation is classified into areas and plant can be sub-divided into max. 10 areas. Collection of points on geographical or functional sets is identified as units, which in terms are assigned to respective plant area. In one area max. 36 units can exist.

Area boiler subdivided into 5 units.

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Feed water system (FW) Steam system (ST) Flue gas system (FG) Combustion air system (CA) Fuel system (FU) Each unit will have respective set of process data points.

AREA UNIT POINT DIAGRAM

POWER PLANT

BOILER

TURBUNE

FU TIC 100

FG FIC 100

CA FU AA

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TIC 100and FIC100: Points belonging to steam system unit of boiler area. Parameters of process points of the total plant (all areas) can be viewed on any of the universal station (with operating specific. and universal personality), but process parameter manipulation and alarm reporting are area

ALARMS AND MESSAGES: Alarm and messages will only reported for the points, which are belonging to the signed units. Whose area database is currently present in the universal station? Alarm acknowledgements console wide function.

MANIPULATION OF PROCESS PARAMETERS: -

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These are at the operator accessing level. Manipulation of parameters of the process points will be allowed only for the points, which are belonging to the assigned units, whose area database is currently present in universal station. Manipulation of parameters of the process points that are not belonging to the assigned unit to the area database currently present in the universal station, will be allowed only at the access level higher than that of operators access level.

ABOUT

THE

AREA

UNIT

POINT

ORGANISATION: 1.CONSOLE STATUS: - Unit display target is used to determine units configured and assigned to the area database present in the universal station. 2.SYSTEM MENU:-Organization survey menu target to determine the points attached to individual units of the area.

WHAT IS TDC3000: Total distributed control system (TDC) 3000 is a

Honeywell make DISTRIBUTED CONTROL SYSTEM.

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WHAT

IS

DISTRIBUTED

CONTROL

SYSTEM:
Functionally and physically separate automatic process controllers, process monitoring and data logging equipment, connected with each other to share relevant information for optimum plant control is called DISTRIBUTED CONTROL SYSTEM.

HOW DCS CAME IN TO EXISTANCE?

Customer in process industry resulted in advancements in control and instrumentation(C&I) technology. This advancement and their advantages and disadvantages are shown in fig.

44

Development of (C&I) technology from pneumatic to electronic equipment was itself a very big change. In electronic C&I equipment, various functional blocks were used to function under vinter dependent circuits and control logic. At this stage these functions were interconnected by signals through multiple cables.

45

Application of microprocessor and digital communication technique made it possible to distribute the C&I equipment distributed geographically and functionally, reducing multiple cable into single cable. This inter connection of processing function blocks of a system is termed as a network (N/W)

The signal level and states previously used through multiple cables are now digital information packets, multiplexed in time, around the N/w, sent and received by connected functional processors. Further advancement allowed the distribution of C&I system of various type of function n/w like: Process N/w Supervisory N/w Plant information N/w

46

Plant wide C&I automation dependent on these N/ws, emerging as a DCS. The important benefit of DCS, which is making it popular is the fact that even failure of processor or a N/w will not result in failure of other processors or N/ws of the system respectively.

WHAT

ARE

THE

FUNCTIONS

DISTRIBUTED AROUND A DCS?

Following diagram shows the function blocks in a DCS with their use:

47

WHAT IS THE MAIN BENEFITS OF DCS OVER CONVENTIONAL C&I EQUIPMENT?

Reduction in cabling in control room. Physically and functionally separate modules. More uniform operations and tighter controls. Excellent information management. Better integration of plant controls. Considerable reduction over maintenance efforts.

48

WHEN &FROM WHOM THE FIRST DCS WAS MADE AVAILABLE?

First DCS came in 1974 from HONEYWELL. It was named then TDC 2000 (total distributed control 2000). The communication link in TDC 2000 is called DATA HIWAY.

HOW

TDC

3000 AND

THEN

CAME IT

INTO IS

EXISTANCE? ORGANISED?

HOW

Further advancement resulted in release of TDC3000 in 1984. (LCN). This now release of DCS from HONEYWELL contained new Supervisory LOCAL CONTROL NETWORKK

49

EARLY TDC 3000 SYSTEM ACHITECTURE: -

HONEY WELL TDC 3000 is a data acquisition and control system that can be tailored to meet the user specific requirements. It can be small system with just a handful device, or it may be highly complex system with hundreds

50

of devices and several kinds of communication networks interconnecting these devices. The LCN connected to UNIVERSAL STATION (US) is used for man-machine interface and HISTOY MODULE (HM) is used for storage of process system related information. Process connected controllers like BASIC CONTROLLERS (CB) and ADVANCED MULTI FUNCTIONAL CONTROLLERS (AMC) are linked to LCN through the process N/w DH and an interface HIGHWAY GATEWAY (HG). Further development introduced a new process N/w UNIVEWRSAL CONTROL N/w (UCN) in 1989.The process N/w is connected to LCN through NETWORK INTERFACE MODULE (NIM). Capacity of NIM is higher than HG.

The new TDC 3000 system architecture after inclusion of UCN and process connected boxes is shown in fig below: -

51

APM and LM are the UCN connected automatic process controllers In various process plants TDC3000 is practically implemented with redundant communication medium (cables), gateway and process controllers.

WHAT

IS

TDC

3000

PROCESS

OPERATION:

52

This means, monitoring and operating the process plant using universal station of TDC3000 system, this includes: Calling various displays. Monitoring status, values, trends, modes and event on displays. Manipulating parameters. Responding to various alarms and messages. Taking various hard copies on printers. Storing important process related information. Sensors and actuators of various kinds from the process plant are connected to process controllers through N/ws; process information (values, status, modes, alarms etc.) is made available on the US displays. From US it is possible to manipulate direct actuator drive, values and mode change of different parameter in automatic control function, also various commands to controllers and other N/ws connected function blocks can be sent from the US. Monitoring and operation of TDC3000 system itself is also done at US. Along with process operation, system operation aspects are also practiced in TDC3000 process operation session

53

UNIVERSAL STATION
Universal Station is the man machine interface of TDC3000 system. In our subsequent session we will be learning and practicing above-mentioned activities from US. US is a single window to the process as well as TDC3000 system allow the operator both monitored and manipulate the process the system. System configuration is also done from Universal Station. Before operating TDC 3000 universal station we should be familiar with the following concepts: Universal station equipment. Universal station personality. The Access level type of universal station for operating security.

54

DIFFERENT PERIPHERAL CONNECTED TO THE UNIVERSAL STATION (U.S).

Color video display monitor with touch screen facility. Operators keyboard. Electronic card rack. Engineer keyboard (optional). Cartridge/floppy drive (optional). Printer (optional). Trend pen recorder (optional). Video copier (optional). Track ball (optional). DIAGRAM OF US IS SHOWN BELOW: -

55

1.COLOUR VIDEO SCREEN DISPLAY MONITOR WITH TOUCH FACILITY: Consist of 48cm. (19-inch) high resolution colors CRT and associated electronics. Each CRT has brightness and contrast thumb wheels and a degaussing push button on the bezel. The color video display monitor shows system displays and process displays. The touch screen option on the color video display monitor is implemented using infrared sensor and transmitters that are located in the bezel of the CRT screen.

2.OPERATING KEYBOARD: Contain 147 touch keys that initiate actions. In this 85 are user configurable function keys & 61 are standard operated function keys. Red and yellow color lamps (LEDs) are included on certain keys to indicate important process and TDC3000 alarm systems. User Configurable keys are 85 buttons on left side of operator keyboard, that the user can define or configure to perform certain functions, such as call up

56

of certain critical frequently displays. Cross screen displays or to activate particular action sequence. Standard Output function keys.61 keys on the right side of the operator keyboard. These are further divided into five groups: Standard Process displays call &display control keys. Standard system displays call &system function keys. Standard process alarm management keys. Standard operator control keys. Standard numeric keys.

AC

POWER

ON/OFF

AND

ELECTRONICS

MODULE
It is the part of the US, helps in AC &DC On/Off control, main electronic processors, memory, and Local control network (LCN) interfaces and other interfaces to connected peripherals and optional devices. Also, the DC power supply, fan module and necessary interconnecting cable assemblies for the US are also housed in the same unit.

4.ENGINEER KEY BOARD: These are of two types: -

57

One is fixed in front of operator keyboard.

2nd one is plugged into appropriate model of US.

5.CARTRIDGE AND FLOPPY DISK DRIVE: Used for random data storage. Both type of disk drives are compact, easy to use, data storage and retrieval devices that accept removable magnetic media. Disk drive: - 5.25-inch floppy diskette called floppy disk drive. A floppy disk is a flexible; double sided, double density, enclosed in a sealed jacket and has storage capacity of 1.2-MB. Cartridge disk drive accepts cartridge disk. The cartridge disk is compact and high capacity disk rigidlyencased in plastic casing. A cartridge drive has storage capacity of 20/40/150 MB.

6.DOT MATRIX PRINTER: Take B/w hard copy of various processes & it can print Logs Reports, Trends and Journals. Whatever is on the VDM screen, including Graphics? A record of alarms.

58

7.TREND PEN RERCORDER: Record continuous trend of process values on the recorder paper. Up to 8 trends pen can be driven by US. The trend pen recorders can be mounted on the universal station within full view of the operation.

8.VIDEO COPIER: Video copier is an optional colour copier, which can be attached with a US to take on the VDM screen. hard copy of current display

9.TRACK BALL: Cursor pointing and target selection device Front mounted by the operator keyboard panel.

59

UNIVERSAL STATION PERSONALITY

To service man machine interface needs, following two software functions termed, as personalities are available for Universal station (U.S). OPERATOR PERSNALITY is used for process operation from US. ENGINEER PERSONALITY is used for TDC 3000 system configuration for process control engineering and system maintenance. With the operating personality present in US, the operator can: Monitor and manipulate process parameter including startup and shut down of plant units. View and manage the process and system alarm and message. Display histories. Display and print process trend and averages. Display and print reports, logs, and journals. and print continuous and discontinuous

60

Copy data to/from floppy diskettes or cartridge. Monitor and change status of system equipment in the control room and near the process. Load operating programs and data busses from a history module, floppy diskettes, or cartridges. Functions of Operator & Engineer

personalities in single software packed are also available which is termed as UNIVERSAL PERSONALITY (U.P).

SYSTEM FUNCTION:
Monitoring

AND

PROCESS

OPERATION

and

controlling

continuous

and

discontinuous process operation. Annunciating and handling alarms. Display and printing trends and logs, journals and reports. Monitoring diagnostics. and controlling system status and

PROCESS ENGINEERING FUNCTIONS: Network configuration.

61

Building process database. Building custom graphics. Designing reports. Preparing control language (CL) programs.

SYSTEM MAINTENANCE FUNCTIONS: Diagnosing system problems. Displaying and printing information required during troubleshooting.

62

LOADING OF UNIVERSAL STATION: Loading is the task of putting any one of the above mentioned personality programs (OP/EP/UP) in the memory of US. After the loading a personality, the US can serve as the man machine interface with appropriate functions. Loading of US is required on the following circumstances: On initial start up of US. Power resumption after power failure Change of personality program is in the US After resetting the malfunctioning US. The US is loaded with operator personality in following steps: Step 1: A. check US powered ON B. Adjust the contrast and brightness controls on VDU panel to the prompt. C. Check the prompt on the left top of the powered

63

ON universal station screen. D. If the prompt is present then go to step 2 Else press RESET button on OKB and wait for Prompt on US. Step 2: A. Press LOAD key on OKB B. Check on the US screen If N, 1,2,3,4,X? displayed then go to step 3 Else contact the trainer. Step 3: A. Type N and press ENTER key on OKB. B. Check on the US screen; If OPR, ENG, X? displayed then go to step 4 Else contact the trainer. Step 4: A. Type o and press ENTER key on OKB. B. Check on the US screen. If load in progress displayed then go to step 5 Else contact the trainer. Step 5: wait till CONSOLE STATUS display appears on the Screen. After the console status display appears on the US screen, US takes little more time to settle down with the personality programs.

64

UNIVERSAL SECURITY: -

STATION

OPERATIONAL

Following operational security is implemented in universal station: Checking each data entry for the right type. Universal station checks each data entry from keyboard for the right type required for the operation. Restricted access to TDC3000 functions and database like operating parameters, configuration data and programs. Following three access levels designed for the restricted access to TDC3000 database are shown below in figure: -

65

THREE ACCESS LEVELS ARE GIVEN BELOW: Operator level Supervisor level Engineer level Operator level: -permits the user to effectively monitor and manipulate process parameters during normal operation, but doesnt permit changes to sensitive process parameters. Supervisor level: -permits user to alter sensitive process parameter and permit all the functions allowed at the operating level. Engineer level: - permit user to access the entire data base to perform process and system configuration functions and programs along with all the functions allowed at the operate and supervisor level.

66

Level of access is determined by the keyboard, key-switch position, access level position is marked on the key- switch panel. Following key types enables key-switch positions: Supervisors key Engineers key

SUPERVISORS KEY
It enables the access key switch to supervisor level.

ENGINEERS KEY
It enables the access key switch to engineer level. This key can enable the key switch to supervisor level also. Without a key, the key switch remains enabled for the operator level access. The access key can be removed from the key switch only by bringing the key switch position back to the operator level. One more special level of operational security can be configured called view only.

67

VIEW ONLY
This level of access allows call up of various displays on US screen for viewing, but does not permit any data entry.

TDC OPERATOR CONSOLES

The group of universal stations is called an operator console. Universal stations are combined to: Provide the required area and unit specific

perception of the process plant to the operator. Collect methodical responses from the operator for the process plant area and unit specific operations.

Printers, floppy /cartridge drives and trend pen recorders attached to respective us can be shared within an operator console.

68

An operator console can contain maximum ten US with or without respective optional equipment. USs belonging to one console needs not to be located at the same place. Alarm acknowledgement is console wide.

OPERATORS KEY BOARD

The operators keyboard with its key organization is shown below:

69

It consists of user configurable function keys& standard operator function keys.

DESCRIPTION OF STANDARD OPERATOR FUNCTION KEYS.

It is subdivided into five types of keys: Standard system displays call & system function keys. Standard process display call &display control keys. Standard process alarm management keys. Standard process operator control keys. Standard numeric key.

70

STANDARD SYSTEM DISPLAYS CALL & SYSTEM FUNCTION KEYS.

SYST STATS: System status key calls up the system

status display on US. The red lamp of the key blinks when

71

there is an unacknowledged system alarm and remains steady ON when all console alarms are acknowledged but not removed.

CONS STATS: Console status key calls up the console

status display on US. The red lamp of the key blinks when there is an unacknowledged console alarm and remains steady ON when all the console alarms are acknowledged but not removed.

RECRD: Trend pen recorder key activates trend pen

recording of selected point on the trend pen recorder. The red lamp of the key becomes ON while recording is in progress. Pressing the key again terminates the recording and lamp switches OFF.

FAST: Fast update key causes the update rate for

process related display information to increase to 2second interval instead of the standard update rate of once in 4 seconds. Red lamp of the key becomes ON when fast update is selected. Pressing the key again terminates the fast update and the lamp switches OFF.

CANCL PRINT: cancel print key is used to abort any

currently printing output on any printer in the console. When pressed, the prompt asks the operator to enter the

72

console related printer number. Cancel print does not function across stations with different personalities.

PRINT DISP: print display key is used to print the

current screen display on the assigned printer.

PRINT TREND: print trend key activates trend printing

for the selected point. Trend for all points in an operating group can be printed on the dot matrix printer.

SYST MENU: system menu display calls up the system

menu display.

LOAD: load key is used to initiate the Universal Station

for personality loading. It works only when the US is not having any personality loaded in its memory and is in POWER ON condition.

73

STANDARD PROCESS DISPLAYS CALL & DISPLAY CONTROL KEYS

These are the sixteen keys located at the left column of the standard function keys. The diagram is shown below:

74

GROUP: Group display key calls up the required group

display on the Universal station screen. A group number is required to be entered after pressing of the key.

DETAIL: detailed display key calls up the detail display

of required point on the universal station screen. A point ID is required to be entered after pressing this key.

UNIT TREND: unit trend key calls the unit trend display.
A unit ID is required to be entered after pressing this key.

TREND: trend key calls up the trend of the selected

points on the group display currently shown on the Universal station.

BATCH: function of this key is deferred.

75

GOTO: go to key used to select a point on the group

display. A point number (1to8) is required to be entered after pressing this key.

SCHEM: Schematic key calls up a schematic display on

the universal screen. A schematic name is required to be entered after pressing this key.

HELP: Help key calls up the pre configured display for

showing required help associated with current display on the universal station.

DISP SET: not implemented. HOUR AVG: hourly averages key calls up the hourly
average of process values of the points from the group display, currently showing on the universal station screen.

PRIOR DISP: prior display key calls up the display that

showing immediately before the current display on the universal station screen.

ASSOC DISP: associated display key calls up the

configured display associated with the current display on the universal station screen.

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DISP BACK: display back key calls up next lower

numbered display within the same type of display currently showing on the universal station screen.

DISP FWD: display forward key calls up next higher

numbered display within the same type of display currently showing on the universal station screen.

PAGE BACK: page back key calls up the next lower

numbered page of a multi page display currently showing on the universal station screen.

PAGE FWD: page forward key calls up the next higher

numbered page of a multi page display currently showing on the universal station screen.

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PROCESS ALARM MANAGEMENT KEYS:

There are the middle eight keys in lower rows of the standard function keys. These keys are used for alarm management. Diagram showing these keys is shown below:

78

ACK: alarm acknowledges key is used to acknowledge

the process and system alarms for the console. Details of use of this key will be covered in alarm management.

SIL: silence key is used to silence audible alarms in the

console. Pressing this key dose not ACKNOWLEDGE the alarms.

MSG SUMM: message summary key calls up the

message summary display on the universal station screen. The red lamp of the key blinks on the presence of messages that require but operator acknowledgement. operator Steadily ON lamp indicates the presences of a message acknowledged requires confirmation/cancellation.

ALM SUMM: alarm summary key calls up the area

alarm summary display on the universal station screen.

79

The red and yellow lamps of the key represent different alarm priorities. On the occurrence of the process alarm the respective priority lamp blinks for the operator attention & requires operator acknowledgement.

ALM ANNC: alarm annunciator key calls up the alarm

annunciator display on the universal station screen.

MSG CONFM: message confirmation key is used to

confirm a message currently displayed on the message summary display.

MSG CLEAR: message clear key is used to clear

messages that have been acknowledged and confirmed on the message summary display.

UNIT ALM SUMM: unit alarm summary key calls up

the unit alarm summary display. A unit ID is required to be entered after pressing this key.

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STANDARD PROCESS OPERATOR CONTROL KEYS

These are the right side fifteen keys of the standard operator function keys. These keys are used to change the process parameter currently selected on the universal station display.

81

MAN: manual mode key used to change the operating

mode of the selected point to manual mode of operation.

AUTO: auto mode key used to change the operating

mode of the selected point to automatic mode of operation.

NORM: normal mode key used to change the operating

mode of the selected point to normally configured mode for operation.

SP: set point key used to initiate set point value changes
of a point. A value is required to be entered either by numeric keys or by raise/lower keys after pressing this key.

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OUT: output key is used to initiate analog or digital

output value changes of respective points. A value is required to be entered either by numeric keys or by raise/lower keys after pressing this key.

SLOW RAISE: slow raise or digital state (ON) change

key.

SLOW LOWER: slow lower or digital state (OFF) change

key.

FAST RAISE/FAST LOWER KEY: fast raise /lower

keys are used to fast increment/decrement the selected value of the point. When the key is pressed fast increment /decrement in value results every 2/3 of a second by 2,3,5,10%of the full scale depending on the system configuration.

CLR ENTRY: clear entry key clears an entry made

before the ENTER key is pressed.

SELECT: select key is used to select an item at the

current cursor position.

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TAB KEYS: tab keys are used to position the cursor on

the universal station screen. On pressing these keys cursor can be moved horizontally left/right or vertically up/down. If the key is held down the cursor movement is continuous.

STANDARD NUMERIC KEYS

These are the 13 keys centrally located on the standard operator function keys & are used to enter numeric values. The numeric keys are shown below:

84

The ENTER key is pressed to complete the data (numeric as well as well alphabetic keying) entry.

TOTAL PLANT SOLUTION

The total plant solution TPS system consists of a local control network& at least one process network. There are three possible process networks, the Data hiway, the Universal Control Network (UCN)& the programmable logic controller (PLC) subsystem. Each of the process networks has an interface (called a gateway) that allows it to communicate with the Local Control Network, which is where TPS work station are located. The gateway for universal control network interface is called the network interface module

85

(NIM)&

the

gateway

for

the

Programmable

Logic

Controller subsystem is called the PLCG. The process network (Data Hiway, Universal Control Network, Or Programmable process data Logic from/to Controller process Subsystem) transmit

connected devices such as controllers & data aquisation devices (such as temperature, flow & level) through their gateway to local control network. This makes it possible to see what is happening at the process without leaving the workstation, on the local control network. TPS workstation can be Universal Station Or Global Universal Station (GUS). Combination of these devices is also possible.

TOTAL PLANT SOLUTION SYSTEM OVERVIEW

86

THE MAJOR COMPONENTS OF TPS SYSTEM ARE: UNIVERSAL CONTROL NETWORK (UCN)
The communication channel for the advanced process manager is called universal control network (UCN) .The UCN is the platform for processors I/O connections to the TDC 3000.

87

It is high speed, high accuracy & high security process control network. It is peer to peer communication capability allow for easy sharing of process data making it convenient to implement sophisticated control schemes. The UCN features a 5-mega bit per second Carrier Band Communication System with a token bus network. It is designed to be compatible with IEEE and ISO standard. UCN communications are consistent with the growth and direct of evolving international standards, appropriate honey well extension for secure process applications. The UCN uses redundant coaxial cables and can support up to 32 redundant devices. The UCN support peer-to-peer communication for sharing data between devices on this network & allowing greater coordination of control strategies. This feature enables sharing information among advanced process manager, process manager, and logic manager on the network (UCN process connecting device) and local control network modules such as history module, application module and plant network module, thus offering tremendous power and flexibility in implementing advance coordinated control strategies. The UCN is connected to single or multiple LCNs using network interface module (NIM). Up to 20 UCN

88

and data Hiway can be connected to the same LCN. At LCN all of the process data from this process network is available for the standard TDC3000 operate, control history and management functions. For example, both UCN & data Hiway based information can be combined into the sane group and custom the graphic displays. Or accessed for history or more advanced control functions as needed. FUNCTIONAL DESDCRIPTION: The universal control network provide a power communications platform for efficient secure real time process communication .as a leader in a process control, HONEYWELL has extensive, expensive with real time process network

LOCAL CONTROL NETWORK (LCN)

The TPS system consists of many different hardware modules. These modules are dependent on one another and require efficient and reliable communication paths between them. LCN is basically used for man machine interface.

LCN DESCRIPTION

89

Each of these nodes has a separate address and is configured to this address through the use of these jumper plugs (pinning) at the time of installation. Each of the Hardware Module (nodes) attached to the LCN have some common functionality, consisting of an LCN interface mechanism, a processor and memory. This common functionality is often referred to as the kernel. An LCN node takes from when distinct hardware is added to its Kernel or common logic. A specific purpose board such as diskette controller, video generator, special hardware board, etc. bring a personality with it to the LCN hardware module. In addition, the node is loaded with a unique software package, The written specially of for that application. combination common

hardware, special hardware and specially designed software combine to form the nodes specialized personality. The LCN network consists of two redundant coax cables that run continuously from node to node (in a bus topology). Each cable is connected to each nodes LCN interface circuits with a T-connector. One cable is marked CABLE A and the other is marked CABLE B.

90

Both redundant cables are connected to each node. Each node has specific connection for both A and B cable and they must not be crossed. Terminators are used on the ends of both cable A and B. The over all length of each LCN cable segment should be kept nearly equal to its redundant companion with a maximum length of 300 meters and maximum load of 40 physical connections for each LCN cable. Fiber optics can be used to exceed some limitations.

LCN COMMUNICATION PROTOCOL

The LCN communication Protocol is broadcast type of local area network. Modules talk(broadcast) on both the A and B cables simultaneously, but they listen(receive) on only one cable. All LCN modules hear all transmission but, depending on message destination and type, only some modules process certain messages.

A token passing algorithm is used so that up to 64 modules can share access to the LCN. The communication master node defines (to other nodes) which cable should be used for listening. The communication master node is the Universal Station (US) with the lowest LCN address; it

91

periodically issues an instruction to switch cables. This ensures that both cables remain functional. If any node experiences difficulty in receiving data on a specific cable, it switches cables and informs the communication master. The communication master then informs all the other nodes to switch to the good cable and dispatches a message to the system maintenance control center (SMCC) requesting maintenance on the suspect cable. This allows operation to continue while the faulty cable is being repaired.

TOKEN PASSING
Following figures illustrate a sample LCN arrangement where token passing has been established between several nodes. The number inside the ring in the figure represents the node address of the modules on an LCN. Remember, the ring is imaginary; the physical nodes are really in a string with the actual node addresses arranged in random order.

LCN OVERVIEW

92

TOKEN PASSING SYSTEM

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AVANCED PROCESS MANAGER (APM)

It is an advanced data acquisition and control device used for regulatory, logic and sequence control operation required for continuous or batch applications. It consists of

94

a redundant advanced process manager module (APMM) and maximum 40 input out put processors (IOP). The advanced process manager (APM) is Honeywell premier TDC 3000 data acquisition and control device for industrial control applications. Like the process manager (PM), the advanced process manager new technology platform offers a range of capabilities that best meet today and tomorrows process requirements. The ASPM offer highly flexible I/O functions for both data monitoring and control. Power control functions, including regularity, logic and sequencing control for provided for continuous, batch or hybrid applications. An optical toolbox of functions that can be configured and programmed meets the needs of data acquisition and advance control requirements in a highly secure and performance intensive manner. Of course, Amps capabilities include peer-to-peer communication and compatibility with industry standard protocols. As seen in the figure the advanced process manager is a fully integrated member of the TDC 3000 family.

ACCORDINGLY APM IS CAPABLE OF: Performing data acquisition and control functions, including regularity, logic and sequential control functions, as well as per to peer communications

95

with other universal control network-reside4nt devices. Providing bi-directional communication to modbus and ALLEN BRADLEY COMPATIBLE subsystems through a serial interface. Fully communicating with operators and engineers at universal station and universal workstations. Procedures and displays are identical or similar to those used with other TDC3000 controllers. Plant personnel may already be familiar with them. Supporting higher-level control strategies available on the Local Control Network through the application module and host computer.

ADVANCED FEATURES: As described above, the Advanced Process Manager (APM) has the same functionality that of the process manager (PM) plus: Digital input sequence of events (DISOE) processing. Device control points. Array point for CL programs. Foreign device (serial) interface capability. Larger memory (over four times larger than the PM).

96

String variables. Time variable.

FUNCTIONAL DESCRIPTION: The advanced process manager is designed to provide flexible and powerful process scanning and control capabilities .To do this, it uses advanced multiprocessor architecture with separate microprocessor dedicated to perform specific tasks. The APM consist of the advanced process manager module (APMM) and the I/O subsystem. The advanced process manger module consists of an advanced communication processor and modem, advanced I/O link interface processor and advanced control processor, a redundant APMM can be optionally provided. The advanced communication processor is optimized to provide high performance network communications. Handling such functions as network data access and peer-to-peer communication, it also supports high accuracy time samps.

97

NETWORK INTERFACE MODULE (NIM)

The network interface module (NIM) provides the link between the LOCAL CONTROL NETWORK and the UNIVERSAL CONTROL NETWORK. Accordingly it makes the transition from the transmission technique and protocol of the local control network to the transmission technique and protocol of the universal control network. The NIM provides the LCN module access to data from UCN resident device. It support program and database loads to the advanced process manager and forward alarms and message from the network device to the LCN. The NIM is also available in the redundant configuration to provide automatic continued operation in the event of primary failure. LCN time and UCN time are synchronized by the NIM. The NIM broadcast LCN time over the UCN. The APM uses it for all alarms (or events) time stampings.

LOGIC MANAGER (LM)

98

The logic manager (LM) is a process-connected device that resides on the TDC 3000 Universal Control Network as a peer to the process manager. The LM consists of a standard Honeywell Logic Controller (LC) that contains a two-slot option module known as Logic Manager Module (LMM) and is mounted in one or more standard TDC3000 cabinets. The main features of Logic manager are: 1. Direct peer-to-peer communication with other UCN devices. 2. Communication with operator, engineer and maintenance technicians at the universal station. 3. Support of higher-level control strategies through communication with AM. 4. Database saving and restoration from the HM.

The logic manager (LM) is implemented for the application requiring fast logic program execution, extensive digital or interlock logic and ease of ladder programming.

99

LOGIC MANAGER OVERVIEW: -

100

As shown in the figure the Honeywell 620 Logic Controller uses two basic types of racks. These are: Processor Rack I/O Rack Logic Manger (LM) consists of a Honeywell 620-35 PLC processor rack with Logic Manager Module (LMM), Parallel and Serial I/O racks and an MS-DOS Loader Terminal. The LMM serves as an interface between the 620-35 processor racks and the UCN. It converts the PLC data into UCN format and vice versa. The MS-DOS loader terminal is an IBM compatible PC, which serves as a man machine interface and is used for graphic display and ladder programming. The communication between the PC and processor take place using an interface board and a serial cabinet shipped with 620-35 PLC. The LM processor subsystem consists of a standard Honeywell 620-35 processors rack plus a two slot optional module known as Logic Manger Module (LMM), used for UCN connectivity. The subsystem hardware includes the chassis, back plane, and front plates. The processor module is vertically positioned in

101

the racks with the component side towards left. Back plane connector is offset to prevent inserting a module upside down. The rack fits into an 8 NEMA 12 enclosure or 19 instrumentation rack with 14 slots to insert modules. The LM processor rack has 14 slots from A to N where different optional or standard modules could be inserted. THE DIFFERENT LM PROCESSOR RACKS ARE: Processor Module (PM)-slot H System control Module (SCM)-slot G Register Module (RM)-slot F Memory Module slot E Input/output Control Module (IOCM)-slot I Power Supply Module (PSM)-slot J&K Parallel link Drive Module (PLDM)-slot N Serial Link Module (SLM)-slot L & M Logic Manger Module (LMM)-slot A &B Redundancy Control Module (RCM)-slot C Addition 8Kword Memory Module

102

REDUNDANCY SYSTEM
The LM redundant control system consists of two identical configured processors, each containing a redundancy control module (RCM). One processor is LEAD processor and the other is the BACKUP processor. The system permit sharing of data between the two redundant processor by transferring I/O status cable, register table and system status table. In the event of failure the control of I/O is transferred from the LEAD processor to the back up processor.

REDUNDANCY CONTROL MODULE

It is a primary component of a LM redundancy control system. It is responsible for: Transferring I/O status table, Data register table and system status table information from the LEAD to BACKUP processor. Monitoring the status of other RCM and its own host processor.

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Switching the control from LEAD to BACKUP processor in the event of hardware failure of LEAD processor or the user request.

SERIAL LINK SELECTOR

This is general purpose switching device, which may be used, for connecting MS-DOS loader terminal to the two processors.

REDUNDANT SIOM
In LM redundant system this module is used instead of normal SIOM. It has two ports to which the serial I/O cables coming from the two processors are connected. It also has the RUN/FREEZE toggle switch. When the switch is in: RUN position normal communication between SLM and serial I/O track is permitted FREEZE position all real I/O is freezing and communication between SLM and serial I/O rack is halted.

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OVERVIEW OF REDUNDANCY SYSTEM

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OPERATION SYSTEM

OF

REDUNDANCY

CONTROL

Consider a LM redundancy processor system with two processor viz. A and B. suppose initially processor A is in lead status and processor B is in the backup status. In the two processor same ladder program is stored and before every program scan processor A updates the I/O status and register data in the processor B. thus even though both the processor share the same program and data but actual controlling is done by processor A. a backup processor can be requested to take over the control of the system either automatically (when lead processor fails) or manually (by pressing the lead request switch). When the RCM of the back up processor (in above case it is processor B) grants the lead request it take following action: It informs the RCM of processor A that it is taking over the control of the system.

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It commands PBS to transfer all PBS to transfer all parallel I/O operation to it instead of processor A. It commands SLS to transfer all serial I/O operation to it instead of processor A. Turns on the LEAD status LED on the front plate. The RCM of the processor A, in turn relinquishes the control of serial and parallel I/O racks and turns off the LEAD status LED. Now the processor B act as a lead processor and processor A act as a backup processor in the PLC system. Normally the manually lead request is done while updating the control program. Thus there is no disturbance in the process operation while a program upgrading is being done. After the fault is recovered or when a new program is down loaded the user can again put processor A in lead position using above method. A step by step method of online program down loading making use of redundancy is as follows: Consider above LM redundant processor system with two processor viz. A and B with initially, say processor A in lead status and processor in backup status and we want to download a new program in the system. Ensure that both the processors are online. That is they are either in RUN or RUN/PROG mode.

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Press led request switch on the RCM of processor B and wait till the LEAD status indicator becomes on. Now processor B executes the control program and the program A is backup status. Put processor A in PROGRAM mode using the mode key switch on its PLDM. Connect the MS-DOS loader terminal to processor A and download the modified ladder program to it. Put processor A in RUN or RUN/PROG mode using the mode switch key on its PLDM. Press led request switch on the RCM of the processor A and wait till the lead status indicator becomes on. Now the new control program start execution and the processor B goes in backup state. If the new program is not working properly then repeat steps 2 to 6. Put processor B in PROGRAM mode so that the new program gets downloaded in the processor B from A via data cable. Wait till PORT ACTV indicator on the both RCMs is on and after that put processor B back in RUN or RUN/ROG mode.

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INDUSTRIAL TRAINING REPORT

Doing at

GURU HARGOBIND THERMAL PLANT LEHRA MOHABATT DISTT. BATHINDA

In

The Partial Fulfillment For The Requirement Of Award of DEGREE

In Electronics&communication

SUBMITTED TO:

H.O.D. ELECTRONICS&COMMUNICATION S.U.S.C.E.T.TANGORI MOHALI

SUBMITTED BY:

INDER VERSHA E.C.E-FINAL YEAR

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ROLL NO. 9901744

ACKNOWLEDGEMENT Industrial training is the effort to provide linkage between the student and Industry in order to develop the awareness of industrial approach for saving the problem based on broad understanding of tools, modes of operation of Industrial Organization. With the deep sense of gratitude, I express my sincere thanks to PSEB, Patiala, who permitted me to take up training at the Organization. I wish to extend my thanks to Er. M.S.Thind (S.E./C&I), Er.A.K.Chugh (Add. S.E.), Er.K.K.Jain (Add.S.E)&Er. Chhabra (Add.S.E) for their considerable help to join the training in different sections of C&I department. I humbly express my cordial thanks to Mr. Parveen Jain (A.E), Mr. AjitPal Singh (A.E), Mr. Dhiraj Bansal (A.E) and Mr. S.k.Sharma (A.E) for their extra pain to see me through my problems. They have been always a source of encouragement and inspiration for me. Under their efficient guidance, I had no problem in acquiring and getting various jobs done. I am always thankful to staff of industry for their kind cooperation and help, which made me training a success. I feel that information gathered by me during this training will surely help me a lot in coming future.

ABSTRACT

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My industrial training of six months of seventh semester of B.Tech. Electronics&communication As planned by Punjab technical university is organized in the Thermal Power Generation Plant at Lehra Mohabbat Distt. Bathinda. My training of six months is divided in three departments of control&instrumentation each of two months. This report contains overall plant circuit &department wise description. INDERVE RSHA I

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CONTENTS

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INTRODUCTION WORKING OF THERMAL PLANT

SYSTEM DESCRIPTION TDC 3000 UNIVERSAL STATION TOTAL PLANT SOLUTION REDUNDANCY SYSTEM

INTRODUCTION BRIEF HISTORY OF PLANT

PROFILE OF PLANT POWER DISTRIBUTION RAW METERIAL &THEIR SOURCES BASICS OF THERMAL PLANT

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RANKINE CYCLE ON TEMPRATURE ENTROPY DIAGRAM PROCESS OF POWER GENERATION PLANT OVERVIEW BLOCKS DISCRIPTION VARIOUS CYCLES INVOLVED IN POWER GENERATION

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SYSTEM DISCRIPTION

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COAL HANDLINGSYSTEM FUEL OIL SYSTEM ASH HANDLING SYSTEM D.M.PLANT EMERGENCY POWER SUPPLY SYSTEM CONTROL&INSTRUMENTATION SYSTEM DATA ACQUISATION SYSTEM POWER SUPPLY DISTRIBUTION SYSTEM

TDC 3000 SYSTEM

AREA UNIT POINT CONCEPT DISTRIBUTED CONTROL SYSTEM FUNTIONS DISTRIBUTED AROUND DCS BENEFITS OF DCS TDC ARCHITECTURE

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TDC 3000 PROCESS OPERATIONS

UNIVERSAL STATION

DIFFERENT PERIPHERIAL CONNECTED TO U.S. UNIVERSAL STATION PERSONALITY LOADING OF U.S U.S OPERATIONAL SECURITY TDC OPERATOR CONSOLES

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OPERATORS KEYBOARD DESCRIPTION OF STANDARD OPERATION FUNTION KEYS

TOTAL PLANT SOLUTION

1. OVERVIEW OF TPS 2. MAJOR COMPONENTS OF TPS LOCAL CONTROL NETWORK (LCN) DESCRIPTION LCN COMMUNICATION PROTOCOL TOKEN PASSING

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OVERVIEW OF LCN ADVANCE PROCESS MANAGER (APM) CAPABILITIES OF APM ADVANCE FEATURES FUNCTIONAL DESCRIPTION NETWORK INTERFACE MODULE (NIM) LOGIC MANAGER (LM) OVERVIEW OF LM DIFFERENT LM PROCESSOR RACKS

REDUNDANCY SYSTEM

REDUNDANCY CONTROL MODULE SERIAL LINK SELECTOR REDUNDANT SIOM OVERVIEW OF REDUNDANCY SYSTEM

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OPERATION OF REDUNDANCY CONTROL SYSTEM