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PROJECT REPORT ON

PROGRAMMABLE LOGIC CONTROLLER


IN
FURNACE SAFEGUARD SUPERVISORY SYSTEM

RAMAGUNDAM SUPER THERMAL POWER STATION


NATIONAL THERMAL POWER CORPORATION LIMITED
RAMAGUNDAM

SUBMITTED BY
K.GAYATHRI (11B71A0444)
B.SRAVAN KUMAR (11B71A0421)
R.RAGHUBABU (11B71A0437)
R.SAIKIRAN (11B71A0430)

STUDENTS OF

Dept. of Electronics & Communication Engineering


SINDHURA COLLEGE OF ENGINEERING&TECHNOLOGY
(Affiliated to JNTU, Hyderabad)

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CERTIFICATE

This is to certify that the project entitled

PROGRAMMABLE LOGIC CONTROLLER


IN
FURNACE SAFEGUARD SUPERVISORY SYSTEM

At NTPC Ltd (RAMAGUNDAM)

SUBMITTED BY

K.GAYATHRI (11B71A0444)
B.SRAVAN KUMAR (11B71A0421)
R.RAGHUBABU (11B71A0437)
R.SAIKIRAN (11B71A0430)

STUDENTSOF
SINDHURA COLLEGE OF ENGINEERING&TECH
FOR THE PARTIAL FULLFILLMENT OF THE VOCATIONAL TRAINING
DEGREE OF BACHELOR OF TECHNOLOGY
IN

ELECTRONICS & COMMUNICATION ENGINEERING


AFFILIATED TO JNTU, HYDERABAD

EMBEDIES THE WORK DONE BY THEM UNDER MY SUPERVISION

PROJECT GUIDENCE PROJECT CO-ORDINATOR


Sri Y.AJENDER REDDY ShriK.SELVARAJU
DGM (C & I) A.G.M (C&I).

DATE:01-01-2015 TO 31-01-2015

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ACKNOWLEDGEMENT
The successful completion of any task would be incomplete without the mention of
the people who made it possible through their constant guidance and encouragement
crowns all the efforts with success.

We would like to extend sincere thanks toSri.K.SELVARAJUAGM (C&I) dept.


For giving this opportunity to do our institutional training atNTPC Ltd
(RAMAGUNDAM).

It is with deep sense of gratitude that I record thanks toShriY. AJENDER


REDDY DGM (C&I) dept. for the consistent support and exceptional resourcefulness
throughout our training period in (C&I) dept

We would like to express heartfelt thanks to Shri.B.SUSHANTH BABU,Principal of


SINDHURA COLLEGE OF ENGINEERING & TECHNOLOGY for his great
encouragement and motivation at all time on students.

We would like to express sincere thanks to Mr.PRAVEEN KUMAR SIR,Head


of the Department of ECE, SINDHURA COLLEGE OF ENGINEERING
&TECHNOLOGYfor his kind of co-operation and valuable suggestions in completion
of this project.

We would like to thank Sri. P.M.G.V. SRINIVAS, DGM -HR (EDC), Sri M.V.R
SHARMA, ASST. MANAGER(HR-EDC),for their valuable advises and guidance for
implant Training.

Finally we thank one and all who have given their assistance directly or indirectly.

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CONTENTS
Page. No.

ABSTRACT

I. FAMILIARISATION OF THERMAL POWER PLANT 1-7

II. FURNACE SAFEGUARD SUPERVISORY SYSTEM(FSSS) 8-20

Introduction
Functions of FSSS
Unit Start-up
Furnace Purge
Heavy Fuel Oil & Recirculation Valve Operation
Unit Shut-down

III. DESCRIPTION OF THE EXISTING RELAY BASED SYSTEM 21-27

IV. DRAWBACKS IN THE EXISTING RELAY BASED SYSTEM 28

V. UPGRADATION OF THE RELAY BASED LOGIC SYSTEM 29-38

Role of PLC
Communicating with Field Devices
Choosing a Programmable controllers

VI. CONVENTIONAL RELAY LOGIC IMPLEMENTATION (in FSSS) 39-43


Logic Diagrams
PA FAN
ID FAN

VII. CONVERSION OF RELAY LOGICS TO PLC LOGICS 44-61

Block Diagrams
o Purge Test
o Master Fuel Trip
o PA Fan
o ID Fan

VIII. SIMULATION OF PLCS 62-78

IX. CONCLUSION 79

X. BIBLIOGRAPHY 80

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ABSTRACT

In present day power plants ,control & Instrumentation plays a vital role, in
operating plant efficiently ,reliably and safely . The conventional control of auxiliary
equipment employs electromagnetic relay systems. With increase in size of the system, the
Complexity of the relay control system increases and reliability is at stake due to
mechanical failures and other wiring problems. So, there is need for conversion of
conventional relay logic system to programmable logic which offers high reliability and
flexibility. In our present project work, the relay logic of Boiler auxiliaries like PA
Fan,ID Fan, MFT, Purge of Furnace Safeguard Supervisory System are converted to PLC
logics.These logics are verified by using 32-bit simulator for ensuring the proper
functioning , which is accommodated by Programming Software.

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1) FAMILIARIZATION OF THERMAL POWER PLANT

INTRODUCTION

NTPC Limited is the largest thermal power generating company of India.


A public sector company, it was incorporated in the year 1975. To accelerate power
development in the country as a wholly owned company of government of India. At
present , government of India holds 89.5% of the total equity shares of the company and
the balance 10.5% in held by FIIs, domestic banks , public and others.
NTPC s share on 31march, 2005 in the total installed capacity of the country was 20.4%
and it contributed 27.1% of the total power generation of the country during 2004-
2005.Within a span of 30 years, NTPC has emerged as a truly national power company,
with power generating facilities in all the major regions of the country. Based on 1998
data, carried out by Data monitor UK, NTPC is the 6th largest in terms of thermal power
generation and the second most efficient in terms of capacity of utilization amongst the
thermal utilities in the world.

NTPC was among the first public sector enterprises to enter in to a Memorandum
of Understanding (MOU) with the government in 1987-1988. NTPC has been placed

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under the Excellent category (the best category) every year since the MOU system
became operative.
Recognizing its excellent performance and vast potential , government of the India
has identified NTPC as one of the jewels of public sector Navartnas - a potential global
gaint. Inspired by its glorious past and vibrant present, NTPC is well on its way to realize
its vision of being one of the worlds largest and best power utilities, powering Indias
growth.

The development of power in any country depends upon the available recourses in
that country . The hydel power totally depends upon the natural sites available and
hydrological cycle in that country. The development & fuel recourses .The sources of
power generation is not much desirable for the developing country as it is dependent on
high technology &they are highly capital based systems many times hydel power suffers
if draught comes even once during a decade & the complete progress of the nation stops
.The calamity of the rin draught on power industries has been experienced by many states
in this country .To overcome this difficulty ,it is absolutely necessary to develop thermal
plants in the country. Coal is the basic fuel for thermal power plants. Along with coal ,Air
,feed water forms the major requirement for a thermal power plant.

PLANT LOCATION AND LAYOUT:

NTPC Ramagundam is located at a latitude of 18-46E and longitude of 76-26N River


Godavari flows west to east. The site is accessible to NH7. The reservoir which serves as
the intake water source for power is located at the south. The ash disposal area and the
township are located to the west and north west respectively.
The NTPC at RSTPS generates 2600MW power through 3 units of 200 MW & 4
units of 500 MW used for domestic and industrial purpose in A.P & neighbor states.
The plant occupies 10,000 acres in a sparingly populated area at Jyothinagar of
Ramagundam, in KarimnagarDist of A.P. Ramagundam is selected for establishing a
thermal power plant as the site in having following facilities.
Availability of well flourished coal mines.
Continuous water supply.
Coal transport facilities

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Power is an important infrastructure in developing countries. Power development in
India received a big boost with the dawn of National Thermal Power Corporation Limited.
NTPC was incorporated in 7th November 1975. In the last 30 years, it has grown into
the largest power utility of India. Based on 1998 data, carried out by Data monitor UK,
NTPC is the 6th largest in terms of thermal power generation and the second most
efficient in terms of capacity utilization amongst the thermal utilities in the world.
NTPC Limited is the largest thermal power generating company of India. A public
sector company, it was incorporated in the year 1975 to accelerate power development in
the country as a wholly owned company of the Government of India.
NTPC has emerged as a truly national power company, with power generating
facilities in all the major regions of the country
NTPC, with an installed capacity of 220345 MW (from 20 different stations spread
throughout India) is generating 26.9% of Indias entire power requirement. So, it is
recognized as the Indias largest power utility with excellent core values. Customer
focuses organizational pride, mutual respect, initiative speed and total quality.
NTPC Vision
"A world class integrated power major, powering Indias growth, with increasing global
presence"

NTPC Mission
"Develop and provide reliable power, related products and services at competitive prices,
integrating multiple energy sources with innovative and eco friendly technologies and
contribute to society"

Core Values
Business Ethics, Customer focus, Organizational & Professional pride, Mutual Respect &
Trust, Innovation and Speed, Total Quality Excellence

Introduction to RSTPS:
Ramagundum is selected for establishing a thermal power plant as the site having the
following facilities.

1. Availability of well flourished coalmines

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2. Continuous water supply
3. Good transportation facilities.
Situated in a sparingly populated area at Jyothinagar of Ramagundam municipal area in
Karimnagardistrict of Andhra Pradesh, RSTPS is one of the largest thermal power
station in India and the largest thermal station in southern India.

SALIENT FEATURES:

Installed capacity: 2600MW

Unit size:3*200MW (stage -1)

3*500MW (stage-2)

1*500MW (stage-3)

Transmission system: 2400ckt kms-400KV


Sources of coal:South Guava coalfields of SCC.

Water source: Pochampad dam built on river


Godavari

Total reservoir capacity:5000 acres.

Beneficiary states : ANDHARA PRADESH

TAMIL NADU

KERELA

KARNATAKA

GOA

PONDICHERY

Total investment: Rs 2059.22 crores.

Coal consumption:8.6 Millions tones per annum.

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Water assumption: 250 cusecs

Coal transportation: Merry go round system (MGR) of


22.4km

Ash disposal: Ash pond kundanpally, village.

Total land:10,000 acres.

Chimney height: 255 mts (stage-1 and stage-2)


275 mts (stage_3)

Distribution of power : ANDHRA PRADESH(610MW)-29%

TAMILNADU (470 MW)-22%

KARNATAKA (345 MW)-16%

KERALA (250MW)-12%

GOA (100 MW)-5%

P0NDICHERY (50 MW)-2%

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Distribution Of Electricity:

Total Capacity of Ramagundam NTPC is 2600 MW of stage 1 , 2 & 3 ( i.e. 1,2,3,


& 4,5, 6 units ) distributing electricity to following states in MEGA WATT.

STATE MW % AGE
ANDHRA PRADESH 610 MW 29 %
TAMIL NADU 470 MW 22 %
KARNATAKA 345 MW 16 %
KERALA 245 MW 12 %
GOA 100 MW 5%
PONDICHERY 50 MW 2%

Remaining 250 MW is used to any state, now it is used for A.P.


Total capacity of stage III (unit VII) is 500 MW distributing electricity to following
states in MW:

STATE MW % AGE
ANDHRA PRADESH 145.86 MW 29 %
TAMIL NADU 118.20 MW 23 %
KARNATAKA 86.76 MW 17 %
KERALA 1.61 MW 12 %
PONDICHERY 12.57 MW 2.5 %

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POWER PLANT FAMILIARIZATION

It is known for ages that when coal is burnt it releases heat energy.The same
phenomenon when chemically represented
C + O2 CO2 + HEAT ENERGY (395 KJOULES/MOLE)

In the boiler ,chemical energy is converted into thermal energy by heating water
and converting into steam .the steam produced in the boiler is expanded in turbine .In the
turbine ,the thermal energy of steam is converted into kinetic energy this motion of turbine
rotor is transmitted to generator in which much .Energy is converted into electrical energy
which is transmitted to various load centers through transmission lines .The energy
conversion diagram can be shown as below.

CH EMICALBOILERTHERMALTURBINEKINETIC ENERGY
GENERATOR
ELECTRICAL ENERGY
BOILER:
The heat energy produced in the boiler has two components
i) Energy contained in the flame .
ii) Energy contained in hot combustion products called flue gas.
The flame energy is used to convert water in to steam .At this stage it is called
saturated steam .In the boiler drum ,the steam is separated from water an for ther heated
at constant pressure .This makes the steam super heated .
Flue gas energy is used for :
i) Super heating of saturated steam.
ii) Reheatin of steam coming from HP turbine .
iii) Heating of combustion air in Air Preheaters .
The important components of boiler are
i) Mills
ii) Fans
iii) Air Preheaters

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Combustion can be represented in the boiler by the diagram.
The coal to be fired is fed to mills through feeders.The mills pulvarise the coal so
that it can be fully burnt.As coal is a heavy item ,air with high velocity is used to carry the
coal.This is called Primary Air.To remove the moisture in the coal primary air is heated
before it is sent to mills.It is done in primary air preheaters. The primary air is supplied by
primary air fans. The oxygen required for combustion is contained in atmospheric air. The
air required for combustion is called secondary air . This is supplied by FD (Forced Draft)
fans. The air from FD fans isheated to improve combustion efficiency. This is done in
secondary air pre heater .
The combustion products namely flue gas is drawn from the furnace to chimney
by ID fans(Induced Draft fan). The FD Fans &ID Fans together maintained furnace under
slight vaccum,so that flame and flue gas willnot come out .thios is to ensure safety.
The boiler consist of a large number of tubes extending the full height of the structure and
the heat produced raises the temperature of the wat3er circulating in them to create steam
,which passes to the steam drum at very high pressure .the steam is then heated further in
the super heater and fed through the outlet volve to the high_pressure cylinder of the
steam turbine .
Thesteam has been passed through the first cylinder(High Pressure) of the turbine,
it is returned to the reheater of the boiler and reheated before being passed through the
other cylinders (Intermediate and low pressure) of the turbine.

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ID
FAN

HEAT
SH STEAM

COAL MILLS

BUR
PRI. AIR
PAPHS NEARS
HRH

PA
FAN

SAPHS

FD
FAN SEC. AIR
CRH

STEAM AND CONDENSATE CYCLE :


In the power plant the medium used for conversion of one form of energy into
other is water or steam. To prevent scalining inside boiler tubes DM (Demineralised )
water is used. It being costly ,the water is recirculated after it expands in the turbine and
gives out its energy. For this purpose the steam after LP turbine is sent to condenser.
Where its heat is removed by circulating water (CW) . the water thus obtained is called
condensate. The condensate is pumped through condsate extraction pumps then it is
passed through low pressure heaters(LPH) and reaches deaerator . From turbine tapping
is given to heaters for heating the water. These are called extractions. This heating will
improve the efficiency. In the deaerator ,air from the condensate is removed by sprinkling
it and the deaerated condensate water is called Feed water.

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FEED WATER CYCLE :
The deaerated water from D/A is pumped by high pressure pumps called boiler
feed pump(BFP) . The pressurized feed water is passed through high pressure heater
(HPH). The feed water is heated in the HPHs by extractions from turbine .
The outlet from HPHs is passed through FW regulating station . This station controls the
FW Flow to the boiler . the feed water upon entering the boiler is passed through
Economizer .In this flue gas energy is used to heat the feed water further.Then it is sent
to boiler drum and FW cycle is shown below

STEAM

C.W.
CONDENSER
CEP

FEED WATER

STEAM CYCLE :
From drum feed water is sent through down comers and it is sent through riser
tubes located in firing zone.in the riser tubes the water is converted into steam. The steam
thus generated again reaches the Drum.
The density difference between water and steam will help the water circulation
from drum to drum again. The steam entering the drum from riser tubes is separated from
water in drum by cyclone separators. The steam is sent to super heaters from there. Super
heater outlet temp. is controlled by addition of spray water taken from FW line. The super
heated steam from boiler is sent to turbine this called Main steam. Its pressure is 170
kg/cm2 where as MS temp. is 535 deg.Cent . To increase the net output from the turbine
,the steam at the outlet of HP turbine is sent back to boiler for heating. This is called
Reheating.

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The CW receives the net output from LP turbine exhaust steam and this represent a
loss in the total cycle

Fig. 3 :

Extraction Steam Boiler Side

Economiser
BFP DRU

F/W CONTROL
Drain VALVE

FIG. 4

DRUM

RISER TUBES
HEAT

FURNACE

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FIG. 5

SH COILS LP

MS

H.P I.P. LP

CRH HRH
CW
RH CONDENSER

WATER

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ENVIRONMENTAL MANAGEMENT:

The steam coming out from the L.P. turbine is condensed in the condenser. There
are three reasons for condensing the outlet steam. Firstly, the work done in the turbine is
maximum if the pressure difference between the inlet steam and the outlet steam is
maximum. The steam input to the turbines is at a very high pressure (120 Kg/cm2) and the
outlet steam pressure is very low (nearly vacuum) due to the steam condensation in the
condenser. This is because the same amount of steam when converted to water requires
very less volume. Secondly, the feed water is dematerialized and has to be circulated back
to the boiler and not wasted because dematerializing is a very costly process. Thirdly, the
steam if not condensed would take very large space and the equipments succeeding the
turbine stages (H.P. heaters, L.P. heaters, feed water storage tank, etc.) would be of an
uneconomically large size.

The steam in the condenser is condensed with the help of circulating cold water in
the condenser. The cold water is circulated inside thin tubes in the condenser whereas the
steam passes from outside the tubes. The temperature difference is of about 15 to 20C.
Heat transfer takes place from the steam to the cold water and the condensed steam in
form of water is collected in the hot well.

Approximately, 10% of power generated by alternator is consumed by auxiliaries.


6.6 KV and 415 V buses feed these auxiliaries. The power is stepped down from 15.75 KV
(say) to 7 KV by the transformers known as Unit Auxiliary Transformers (UAT). The
auxiliary requirements at 415 volts are derived by Auxiliary ServiceTransformers.
When the generator is required to be started, auxiliary power is made available via
Station Auxiliary Bus.

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II. FURNACE SAFEGUARD SUPERVOISARY SYSTEM

1) INTRODUCTION

NTPC, Ramagundam super thermal power plant consists of three stages. Stage
I,3*200 MW,stageII, 3*500MW, stage III, 1*500 MW. In stage I boiler major auxiliaries
are two FD Fans, two IDFans, two Air pre heaters and turbine major auxiliaries are three
BFPs and two CEPs, stage II & III. Boiler main auxiliaries are two FD fans, two ID fans,
two PA fans and two air pre heaters. Turbine major auxillaries are three BFPs and two
CEPs.

A. Forced draught fan:

The FD fan sucks air from atmosphere , pressurizes it and sends it to furnace prior
sending it to furnace, the pressurized air is heated in secondary air pre-heater ( SAPH). The
source of heating in SAPH is the hot flue gas, which is leaving from the boiler. There are two
FD fans for each boiler. The pressurized hot air generally called secondary air acts as a
combustion medium in the furnace.

B.Induced Draught Fan :

ID fan extracts ashless flue gases from ESP system and sends it to the
chimney. Chimney sends out the gases to atmosphere at a greater height to prevent
pollution.

C.Primary air fan:

The primary air fans are used primarily to transport the pulverized coal to the
respective coal nozzles at each coal elevation in the furnace. Similar to the FD fan the
primary air fan also heats the air in the primary air fan pre heater ( PAPH) the source of
heating in the PAPH is also the waste flue gas. These are two PA fans to each boiler in
stage-II.
D.Boiler Feed Pumps:

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Steam is generated in boiler by heating the DM water. Boiler feed pumps ( three
per unit) are used to pump DM water from Dearator to Drum. Normally two BFPs will be
in service and the third will be standby. Third one takes start automatically once the
running pump trips.

E . Condensate Extraction Pumps:

Steam after doing work in turbine is condensed in condenser so that it becomes


water. This water is stored in hotwell. CEPs are used to pump this water from Hotwell to
Dearator from where it is pumped to Drum. Normally two CEPs will be in service and
the third will be standby. Third one takes start automatically once the running pump trips.

F.Air Pre-heater:

Each boiler is provided with two bisector regenerative air pre- heater which heat
the air using the heat of the exit flue gas.The heating elements ( baskets) are of specially
made metal plates and arranged compactly in three layers. The housing surrounding the
rotor is provided with duct connection both ends for air and gas. It adequately sealed by
radial, axial and circumferential sealing members which form passages for air and flue
gas. The rotor supported by thrust bearing at the top. Separate oil reservoir and level
indicator are provided for each bearing. As the rotor slowly rotates , the heating elements (
baskets) alternatively pass through the gas and air passages. Heat from hot flue gas
absorbed by the basket while passing through the gas passage and carried over to the air
passage, thus transferring the heat to the air. All the above boiler and turbine major
auxiliaries start, stop/trip and interlocks logics are implemented by relay based circuit
diagrams using electro magnetic relays and timers which involves complex physical
designing and poses operational & maintenance problems due to malfunction of
mechanical parts. The objective of this project work is to over come the above problems
by upgrading the existing relay based circuit diagram logics of boiler and turbine major
auxiliaries.

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2. FUNCTIONS OF FSSS SYSTEM

FSSS is designed to ensure the execution of a safe ,orderly operating sequence in


the start up and shut down of boiler and to prevent errors and omission in following such
a safe operating procedure .

Basically the system is designed to perform the following functions:

i) Prevent any fuel firing unless a satisfactory furnace purge sequence has first been
completed .

ii) Prevent start-up of individual fuel firing equipment unless certain permissive
have been satisfied .

iii) Make continued operation of fuel firing equipment subject to certain safety inter
locks remaining satisfied .

iv) Provide component status feed back to the operators.

v) Provide flame supervision when fuel firing equipment is in service and effect a fuel
trip up on adverse operating conditions

3.UNIT- STARTUP SEQUENCE:

The boiler can be placed in service intially or after a Master Fuel Trip in th e
following sequence through FSSS. Intially the heavy oil must be circulated and heated to
obtain the proper temperature and viscosity. After this is accomplished, the heavy oil trip
valve is closed and than the furnace purge cycle can be started . A successful furnace
purge cycle must be completed before any fuel firing can take place. After the furnace
purge cycle is completed, the heavy oil elevation (AB,CD,EF,GH) can be taken in service
An elevation is said to be In Service, when atleast three out of four heavy oil nozzle
valves are open and fuel oil flow is adequate at the individual oil nozzle valve.

After the heavy oil elevation is in service either of the adjacent oil elevation can
be taken into service because adequate Ignition Energy is now available to light-
off the core.

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The core elevation is said to beIn Service after the pulverizer is ON, the hot air
gate is open and the associated feeder is proven (i.e., feeder ON for more than 50sec ). A
fire ball signal is established when the associated fire ball flame scanners
ELEVATION FLAME indicator is illuminated on the FSSS console in control room .

FSSS LOGIC:

FSSS logics can be broadly divided into three sections.

i) Unit Logic

ii) Code Elevation Logic

iii) Oil Elevation Logic

These logics are dealt in detail below :

A.UNIT LOGIC :

Boiler purge logic which ensures a five minutes purge cycle is completed before
any fuel firing can take place various conditons to be meet to get PurgeReady and hence
for purgin are dealt in detail in annexure-1.

B)Master Fuel Trip Logic :

Which ensures a safe shut down of the boiler in case of any abnormal conditions
in boiler /furnace.In case of this abnormal conditions Master Fuel Trip Relay pickup and
ensures closer of main oil trip valve and all oil nozzle valves tuse cutting off total oil
supply ensures stoping of all pulverizersyatems and primary air fans cutting of total coal
supply to boiler.the various abnormal operating conditions under which Master Fuel Trip
act are dealt in Annexure-1.

c) Oil Trip Valve Operation Logic :

This logic ensures that oil trip valve can be opened after the purge cycle is
completed and no MFT condition is presnt in case the following conditions also satisfied .

All nozzle valves are closed

Heavy oil pressureand header temperature are satisfactory.

Similarly this logic ensures closer of oiltrip was in case of MFT.

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D) PA Fan logics :

This logic takes the count of total no. of pulverizers in service at any time, no. of
FD Fans and PA Fans in service. Monitors the HOT PA duct pressure,. Whether it is
going low /low-low. Depending on the

No.of PA/FD fans in service and also PA Header Pr . Status it gives primary air
permit to start pulverizers. In case of PA Header Pressure. going low-low or PA/FD fans
trips it ensures shut down of pulverizers from top elevation to bottom elevation in timed
sequence.

E) Scanner Air Fans Logic:

It monitors the scanner air duct to furnace DP and ensures starting of scanner air
fan A or in case it fails to start to ensures stand by of scanner air fan B . this logic gives
opened command to scanner fan outlet damper after starting fan. In case of both FD fans
not running ensures scanner air emergency

Damper is open.

F) Seal Air Fans Logic :

Monitors seal air header/cold air duct DP and ensures starting of seal air fan A or B
(in case A does not start ) provided atleast one PA fan is running gives open command to
seal air fan discharge damper once fan starts.

B.COAL ELEVATION LOGIC :

(i) PULVERIZER START LOGIC :

Each coal elevation has an associated coal mill .Each mill can be placed in service
mannually or automatically . Auto manual selection push button is available on FSSS
console for each unit. Intially PulverizerIgnitiant Permit signal must be established for
the mill to start . Other condition required to be established for starting the mill are given
in Annexure. Once the mill is ON associated HAG and feeder can be placed in service.

(ii) PULVERISATION SHUT DOWN LOGIC:

If any abnormal conditions are observed in arunning mill this shut down logic
gives trip command to the Pulverizer and associated coal feeder . The trip conditions are
explained in Annexure.

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(III) FEEDER START LOGIC :

Feeder start command also is given from FSSS Elevation logic only. This
command is continuously required to keep the feeder in service. Feeder speed of demand
minimum , pulverizerON,pulverizer outlet temperature is >130 degree Fahrenheit. and no.
MFT are the important conditions required to give the feeder start command from FSSS.

In case of pulverizer power high, bowl DP High or feeder OFF command, feeder
speed demand is driven to minimum.

Release feeder to auto signal is also coming from FSSS. None of the above
conditions are present and feeder is on for more than 50 sec ,release signal for auto is
available.

C.OIL ELEVATION LOGIC :

There are four heavy oil elevations AB,CD,EF & GH. For all these elevations
logics are same . Oil elevation can be placed in service auto /manual. For a particular
elevation for all the four corner together only one command is given (EX : one common
start command for elevation AB 1,2,3 & 4 guns) but start command goes to corners 1to 4
sequentially .First command goes to corner 1;after 15 sec start command goes to corner
3;again after lapse of 15sec start command goes to corner 2; again after lapse of 15sec
start command goes to corner 4. But a particular corner takes the start command only if
the following conditions are satisfied .

a)The particular corner oil gun engaged feedback available .

b)The steam scavenge valve closed for the particular corner .

c) The sequence of operation taking place for a particular oil gun once the command is
given is as follows .

i)The oil gun is advanced .

ii)Once gun advanced feed back is available the HEA Igniter is advanced .

iii)Once the Igniter advanced feed back is available sparkcommand is given to Igniter
transformer thus producing spark at the spark trip .

iv)The atomizing steam valve is opened for the particular corner .

24
v)Then HFO nozzle valve gets opend command .

vi) Then for this particular corners HFO flow satisfactoryfeed back comes from the
flow switch in the oil line

vii) The corner oil gun proves flame when the DISCR FLAME SCANNER senses
FLAME.

viii) When 25sec elapses after oil valve open, Igniter spark signal is removed and spark
rod is retraced.

ix) If the corner oil gun did not prove FLAME by this time OIL nozzle valve is
closed .particular corner steam- atomizing valve is also closed.

Implementation of FSSS :

FSSS in RSTPS 3 X 500 MW is programmable controller based .A programmable


controller is solid stage

Device designed to perform logic decision making for control applications in the
industrial environment .The controller system contains power supplies, a processor and
variable number of inputs &out put modules .the processor used in RESTS is Medicine
584 processor .it has one 8k memory capacity and I/O capacity of 128 inputs and 128 out
puts per channel.

End processor takes input commands (from console) and feed back status of
devices from local through input modules. Processor provides the out put signal to the
driven devices through out put module .the processor is programmed with all desired and
logic information. This program is stored in memory module in 584 processor .the
program can be entered in to the processor or existing programs can be modified with the
CRT programmer/pct. programmer/PC can also be used to monitor the program while the
processor is running.

In the system at RSTPS each pulverizer associate coal elevation logics are
provided in separate controllers .in addition the controllers for A,C,E,G elevation
AB,CD.EF,&GH programmers (respectively )are also stored .i.e,the process for a coal
elevation is for AB oil elevation and so on.

25
For unit logics (purge, start up&shutdown logics of unit) two separate controllers
are provided named as unit primary processor and Unit redundant processor is identical to
primary where as the filed status information and output command signal are processed by
an independent set of I/O modules. As explained each pulverizer each oil elevation each
peace of equipment in units sends the required inputs to its associated processor and takes
the command from the processor. Additionally each of the above equipment some
important input has its safety/shut down circuits operated redundantly through this second
processor also known as redundant processor for that equipment. This ensures that in the
case of any piece of equipment, even if the primary processor fails (any type of failure
such as power going off, hared ware failure, cable burning etc) there is a redundant path
available for monitoring the safe running /shut down of the equipment.

SAFE SCAN II-FLAME SENSING SYSTEM:

The safe scan flame sensing system is designed to detect flame from two different
sources using one scanner head .it will discriminate between and individual oil gun flame
and a back ground fire ball flame .it discriminate between the two flames by sensing the
characteristics (frequency and intensity level) of the visible light they emit .the system
consist of scanners located in guide pipes at each corner of the furnace and the electronic
chassis (card rack assembly) mounted in Control Equipment Room(CER).

The scanner assembly consists of a scanner head assembly, which contains a lens
for observing the flame and a fiber optic cable is contained with in a flexible hose and an
adjoining rigid pipe. the rigid pipe connects to the scanner hosing. The lens and fiber optic
cable is located on the Fire Sideof the wind box.

At the scanner housing assembly the flame signal impinges on a photo diode. the
photo diode converts the visible light (flame) signal to an equivalent electrical signal. this
electrical signal is conditioned by the amplifiers on the scanner housing assembly an
generate equivalent current signal. Which is transferred by a cable to the remotely located
card rack assembly .the cared rack assembly contains electronic circuitry, which separates
the current signal in to its frequency and intensity components

If the intensity component of the in coming signal falls out side the high and lie
acceptable limit set by the card electronics, the fault indication will come on the associated
channel. When intensity signal is within limits, above the drop out level set,

26
The channel intensity light comes on and the MA meter indicates the flame signal
intensity component.

When at least two of the four FLAME-FB light comes ON, the system 2/4 FLAME
light will come ON for the particular elevation. if less than two scanner channels senses
fire ball (FB) flame the system will indicate no flame.

A remote meter output is also available to indicate flame intensity in control room.

SCANNER COOLING ARRANGEMENT:

The external cooling air passes through the guide pipe, the flexible hole and the
annually between the scanner head and housing .the air is discharged into the furnace at
the top pf the scanner head there by removing any heat picked by the scanner from the hot
combustion air .the scanner head, there by removing any heat picked up by the scanner
frame the hot combustion air .the scanner should not be exposed to a continuous
temperature above 300 deg. F with out cooling air.

PULVARIZER AUTOMATIC START:

The pulverizer for the selected coal elevation can be placed in service
automatically after all of the conditions are satisfied.

1.The pulverizer ready signal remains satisfied.

2.The pulverizer automatic mode is selected by auto push button now auto starting of
pulverizer can be initiated by momentarily depressing pulverizer start push button. This
action causes following events to occur.

3.A 210-sec counting period is started.

4.An auto start support ignition signal for the associated coal elevation does not exist. This
signal will give command to place the associated oil elevation in service.

5.The auto start memory signal is established. When the associated Heavy oil elevation
in service signal is established, the coal mill ignition permit signal will get established.
After the associated oil elevation start time(75 sec) is expired and the IGNITION
PERMIT remains established .the following event occur:

27
6.The auto start pulverizer and open hot air gate signal is established .The auto start
pulverizer will make the pulverizer in service in the same manner as described in manual
start section .the associated hot air gate open signal will get armed.

7.when the pulverizer is proven on the following events occur:

a) The hot gate will get opened.

b) A 60-sec feeder counting period is started.

8.when the 60-sec counting period expires an auto start feeder signal is established for
5-sec and causes the following events to occur:

a) The 180-sec counting period is reset which establishes the ignition permit required
signal. This counting period is stated when the auto start feeder signal is removed or the
feeder is on.

b) b) If the hot air gates opened, the feeder is placed in service in the same the manner as
previously described in the manual start. When the 210-sec counter expires the
following events occur :

a) The auto start pulverizer and open hot air gate signal is removed.

b) The 60-sec feeder counting period is rest.

c) If the pulverizer remains on but the feeder is off, an unsuccessful auto pulverizer start
memory signal is established.

d) This causes the following event to occur :

e) The unsuccessful pulverizer start alarm comes on.

f) The pulverizer start permit, NO UNSUCCESSFUL START light goes off.

g) When the feeder is off for 3 minutes and auto stop pulverizer signal is established
which shut down the associated pulverizer automatically.

UNIT START-UP:
The unit can be placed in a service initially or after a boiler trip signal establishes
A master fuel trip. The heavy fuel oil must be recirculated and heated to get the proper
temperature and viscosity. After this is achieved, he HFO trip valve must be closed and the
furnace purge cycle can be started.

28
After the furnace purge cycle is successfully completed, HFO trip valve must be
opened before any of the fuel oil elevation can be placed in service heavy oil elevation is
in service when at least three out of four oil nozzle valves are fully open and fuel flow is
adequate at the association oil nozzle valve. After the oil elevation is in service, adjacent
coal elevation can be placed in service.
The coal elevation is in service after the pulverizer is on, the hot air gate is
opened and associated feeder is proven fire ball signal is established when the associated
fire ball flame scanners elevation flame indicator is illuminated.
The following section describes in detail the manner in which the unit is placed in service.
4. FURNACE PURGE:
Before starting any fuel firing (initially or after a boiler trip), a satisfactory furnace
purge cycle must be successfully completed.
To start a furnace purge cycle, the following purge permissive must be satisfied:
1 Heavy oil trip valve is closed.
2.All heavy nozzle valves are proven closed in all elevations (AB,CD,EF,GH).
3. All PULVERIZERS (A to H) are off.
4.All feeders (A to H) are off.
5.All flame scanners (four discriminating and seven fire ball scanners) indicate no
flame.
6.Establish air flows between 30% more than of full load airflow and less than 50% of full
load airflow.
7.All hot air gates to be closed.
8. Drum level should be satisfactory.
9 All auxiliary air dampers (nos) should be modulating.
10.ALL pa fans are off.
11.No boiler trip causes present.
Once all the above conditions are satisfied THE PURGE READY PUSH TO
PURGE indications will appear on the control disc. Now the operator can start the purge
cycle by depressing PUSH TO PURGE button. Once it is pressed, a 5-minute purge
cycle starts and after the purge cycle, PURGE COMPLETE indication comes on,
establishing purge complete signal.
If any of the purge permissive disappear before the 5-minute purge time is expired,
the purge ready and push to purge lights will go off and the 5-minute counting period
will reset.

29
If this occurs, the purge requirement must be-re established and another furnace
purge cycle is to be started.
The PURGE COMPLETE SIGNAL removing the MASTER FUEL TRIP
memory signal and establishes a no master fuel trip signal.
The following events now occur:
a) Both of the (red) BOILER TRIP lights go off.
b) The PURGING and PUSH TO PURGE lights go off.
c) The CAUSE OF TRIP memories is reset.
d) The heavy oil trip valve can now be opened after other conditions are satisfied .It is
noted the HFO trip valve can also be opened at any time if all HFO nozzle valves are
closed and heavy oil re-circulation valve is opened.
e) Oil burners can be taken in to service and further, milling systems can be taken after
satisfying all other conditions.
f) Auxiliary air damper can be closed.
h) Loss of fuel trip arming signal can be established after other conditions are satisfied.

5. HEAVY FUEL OIL AND RECIRCULATION VALVE OPERATION:


Before the unit is placed in service the heavy fuel oil must be heated to the proper
temperature .To obtain this, HFO trip and HFO recirculation valves are to be kept opened
and oil is to be re-circulated. After satisfactory temperature is achieved heavy oil trip valve
must be closed to get purge permissive. When purge complete signal is established, the
HFO trip valve can be reopened, with out opening recirculation valve, after meeting the
following conditions:
1. All HFO nozzle valves are closed.
2. HFO oil supply press is satisfactorily.
3. HFO-header temperature is satisfactory.
After this HFO trip valve is fully open and if any heavy oil nozzle valve is not
closed, the heavy fuel oil trip valve will be automatically closed if the HFO header
temperature is low-low.
The HFO trip valve will be closed automatically if any of the conditions occurs:
1. After any heavy oil valve is not closed ,any of the following conditions will
automatically close HFO trip valve:
The following conditions exist for more than two seconds:
A) HFO header temperature low-low.

30
B) HFO header pressure low.
C) Atomizing steam pressure lows.
D) The MFT memory signal is established.
2. The unit critical power is not available for more than two sec.
After the HFO trip valve is fully opened any of the oil elevations can be placed in
service after other conditions are satisfied.

6. UNIT SHUTDOWN:
If the unit, which is in operation, is to be shut down the following sequence s are to be
followed:

1. Boiler load is to be reduced.


2. Each pulverizer, which is in operation, is the shutdown.
3. If the pulverizer us the manual mode of operation :
a) Place the heavy oil elevation in service.
b) Reduce the feeder speed demand to minimum
c) Close the hot air gate.
d) Stop the feeder.
e) Stop the pulverizer.
4. If the pulverizer is in auto mode of operation, the pulverizer stop buttons to be
depressed to initiate the shut down .The following action will be initiated automatically.
a) The associated oil elevation is placed in service.
b) The feeder speed command is reduced to minimum.
c) Hot air is closed.
d) Feeder is stopped.
e) Pulverizer is stopped.
The oil elevators can only be shut down manually by depressing associated oil elevation
stop push button.

31
PULVERIZER AUTO SHUTDOWN:
When pulverizer is in auto mode operation, the pulverizer can be shut down in the
manner described below:
Momentarily depress the associated stop push button this will cause the following events
to occur simultaneously:
a) An auto store signal is established.
b) An auto start command is established for the associated oil elevation.

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III. DESCRIPTION OF THE EXISTING RELAY BASED SYSTEM

INTRODUCTION TO PERMISSIVES, INTERLOCKS AND PROTECTIONS OF


AN

EQUIPMENT:

A major equipment or minor equipment of a process industry basically will have one
motor and a pump/fan coupled to it for transfer of a liquid or air or any other media. The
motor may be low tension(LT, 440V, 3 phase) or High Tension(HT, 6.6KV or 11Kv).As
for as electric motor is concerned, the local Motor Control Centre will take care about
single phase, under/over voltage problems and earth fault detection etc. The pump/fan side
also several parameters like bearings, cooling systems, vibrations etc are to be
continuously monitored for best performance and immediate action in case of failure.

PERMISSIVE:

A permissive is a permit like system which checks that the particular parameter
whatever specified in the logic is healthy or not. Otherwise, it will not allow the system to
start. It is a initial condition. After start of the equipment, the status of the permissive can
change and on that account, it will not cause any trip.

INTERLOCK:

Interlock is logic after starting of one particular equipment, the other equipment
will get permit or for stopping of the equipment as per logic. Once the logic is proved the
interlock will operate.

PROTECTION/TRIP:

Trip is a protection for safe operation of the equipment. It may be motor or


pump/fan. When the said parameter crosses the limit and logic for trip is enabled, the PLC
will extend the trip to the equipment. Depending upon the requirement, on delay timers,
off-delay timers can be incorporated to generate alarm as well as to take corrective action
immediately.

33
A. A POWER PLANT WILL HAVE

A boiler and its auxiliaries like Induced Draft air fan for creating suction in the boiler,
a Forced Draft fan to supply the sufficient quantity of air to take the combustion, a
Primary Air Fan for supplying air for carrying pulverized coal to furnace.
A turbine for converting the mechanical energy to kinetic energy and its auxiliaries like
Boiler
feed pumps, Condensate Extraction Pumps, High Pressure heat exchangers and Low
Pressure Heat exchangers, etc. Since, the boilers and its auxiliaries are supplied in 1980s,
the PLCs are not introduced in NTPC first plants like Ramagundam. The relay logic
presently available with all auxiliaries of boiler and turbine. Whereas boiler protections
are of most critical nature, it is provided with MODICON 584 PLC by designer,
Combustion Engineering USA.The present relay logic system which is available is
explained hereunder.

C. INTRODUCTION ABOUT ELECTRO-MAGNETIC RELAYS AND ITS


FUNCTION:

RELAYS
A relay is an Electro-mechanical device that uses the magnetism caused by the
power flow in one circuit, to force an action in another circuit.

How a relay works?

CONTACT

CIRCUIT B

CIRCUIT A

COIL

1.The power flow in Circuit A builds a magnetic field around the coil.
2.The magnetic field pulls-in the metal contact in circuit B, and power is allowed to
flow.The principle of relay action is important to process and machine control. It allows
one circuit (or device) to be turned ON by using the power flow of another circuit (or
device). In this way processes and machines can be linked together to promote smooth
product flow.

34
ADVANTAGES OF THE RELAYS:
The coil power supply voltage may be one voltage level like 240VAC and the
contact power flow may be of other voltage like 220VDC or 48VDC for giving running
contact or starting an equipment or for generating an alarm or control room operator. The
scheme is shown in the following figure.

MAGNETIC PULLING DIRECTION

NOMALLY CLOSED CIRCUIT D WITH 240V AC


CONTACT

NORMALLY OPEN CIRCUIT C WITH 220V DC

NORMALLY OPEN CIRCUIT B WITH 48V AC

CIRCUIT A 240VAC COIL

The contact can be more than one. Normal relays will come with 2 NO contacts +
2 NC contacts. We can also have 4NO + 4NC contact configuration or any other as per
process requirement like 3 NO + 1 NC or 5 NC + 3 NO.
The contact change over from NO to NC or NC to NO is also possible by simple
change over/reversing the contacts. For each parameter to be monitored, one relay can be
used and its auxiliary contacts can be used for various purposes as indicated above.All
these relays can be placed in a small or big panel where proper wiring can be done and
various supplies can be extended. Generally, these relay panel cabinet is called Auxiliary
Relay Panel.

35
D. EXISTING 500 MW BOILER MAJOR AUXILLARIES RELAY

BASED CIRCUIT DIAGRAM OF ID FAN ARE GIVEN BELOW.

+220 vdc -220 vdc


C1
Scoop Min C3
ID A Start
Lub.oil pr. Command
adeq
Local Push
Button Inlet vane
Stack Path Start Impulse
minimum
Available
Brg temp
not high
C2
ID B not Any FD -
220 vdc running
Disch. Running
Dmpr.closed

Oil Temp
& lvl ok

C1&C2 LOCAL START PROVISION

C1&C3 - REMOTE (UCB)START PROVISION

36
ID FAN PERMISSIVES
The following permissives are to be satisfied to start the ID Fan:

1) Scoop tube minimum: ID Fan motor runs at constant speed. Scoop tube couples the
pump to the motor hydraulically and loads accordingly. During starting of motor, if the scoop
tube is kept maximum it will over load the motor and the starting current will be very high. To
avoid the damage to the motor due to over current the scoop tube is kept at minimum during
start up

2) Lube oil pressure adequate: The lubricating oil provided for the ID Fan does two
functions lubricating and cooling of bearings. Due to the heavy mass and speed of rotation of
the shaft, the heat evolved because of the friction between shaft and bearing will be very high.
Lube oil is used to remove this heat. To minimize the heat due to friction, lube oil is supplied
at certain pressure, so that the rotor shaft hardly touches the bearings and hence very little heat
generated. This parameter so vital that a protection (lube oil pressure very low) is provided on
this to the pumps

3) Inlet vane minimum: To avoid over load of ID Fan vane should be kept minimum.

4) Bearing temperature not high: Bearing are cooled by lubricating oil when the fan is taken
in to service, the Bearings experience temperature rise despite being cooled by lube oil,
because of loading. When the temperature rises too much, it may damage the bearings. Prior
to starting the machine, the Bearing temperature is maintained to keep it within limits, so that
even after loading (star up) Bearing temperature does not rise beyond dangerous levels. This
parameters is so critical that a protection Bearing temperature too high is given on this
limit is < 75c.

37
5) Discharge dampers closed: The discharge damper must be kept in closed condition after
the fan starts, discharge damper is opened after a time interval. If the damper fails to open
with in the specified time, the supply to the fan is interrupted and fan trip acts.

6) Oil temperature & level normal : ID Fan oil cooler oil temperature should be less than
65c for inlet and 80c for out let and oil tank level be normal.

7) ID B Not running / any FD running: Any one of the FD Fan must be running or other ID
not running.

8) Stack path available : The dampers coming in the path of ID Fan inlet vane to be kept
open. That is from ESP inlet/outlet and ID inlet.

38
CONDITIONS FOR TRIP CIRCUIT DIAGRAM.
T1

+220 vdc

post purge
furnace fan/motor
pressure brg. temp lube oil damper
hi/low hi-hi pressure fail to hyd coupling hyd
lo-lo 0pen brg. temp coup-
hi-hi ling
oil
temp
hi-hi

-220 vdc
T2

T1 & T2 TO BREAKER TRIP CIRCUIT.

39
CONDITIONS FOR TRIP CAUSES:

1) Post purge furnace pressure hi- low : This trip will act only after purging is completed
with 5minutes furnace pressure goes high low. Alarm setting +100and 100 Trip
+250mmwc and 250mmwc.

2) Fan/ motor bearing temperature high-high: The temperature of the bearings should be
with in the permissible limits. The temperature sensors will sense the temperature and the
associated relay picks up when the temperature is with in the permissible limit. Once the
value is crossed, the relay will drop and an alarm will be generated to alert the desk
engineer at 75c and trip at 100c.

3) Lube oil pressure low-low : Any type of bearing , lube oil is required for proper
lubrication and cooling of the bearing material. In case sufficient lube oil flow is not
adequate temperature will rise due to rubbing between metal to metal. Ultimately damages
the rotor. To avoid such kind of rubbing protection is required. (0.5 kg /sq cm).

4) Damper fail to open: The damper opens on starting of the fan, if any reason if the damper
does not open with in 3 minutes fan will trip.

5) Hydraulic coupling bearing temperature hi-hi: The speed control of the ID Fan is done
through hydraulic coupling the oil temperature and bearing temperature of the hydraulic
coupling should be less than the selective set points when it goes high -high this will trip
the Fan. Alarm set point is 80 c trip is 90 c.

6) Hydraulic coupling oil temperature hi- hi: Hydraulic coupling temperatures is


maintained at 65 c of alarm and trip 75 c for inlet , and outlet 80 c of alarm and 100 c
trip.

40
IV. DRAWBACKS IN THE EXISTING RELAY BASED SYSTEM

DISADVANTANGES OF RELAYS: Relays have been used for decades. Programmable


logic controllers (PLCs) were introduced in 1970 as a way to replacing large, expensive
panels of relays due to the following problems.

a. The wiring problem: The panels will be given various types of input voltages like,
240AC,220VDC, 48VDC etc.When, the time passes away, all these cables will become
brittle/damaged and supplies will get grounded, leakage voltages will develop and cause
spurious tripping/alarm generation. Tracing of cables is a big problem and continuity of the
core is some time lost and create problem. Looseness of cable terminations will lead to
tripping/not extending the required contact.

b. Power requirements: Requirement of various power supplies various relays is a big


problem. A circuit breaker in Electrical MCC uses, 220VDC as a standard and same will be
extended to Auxiliary Relay panel for giving equipment running contact generation. A alarm
logic requires 48V DC and an interlocking supply may be 240V AC. Mixing of these voltages
due to any reason, may lead to damage of the equipment. Each relay will have one supply
voltage and size. All are to be accommodated in the panel.

c. Repair and replacement time: The time to trace the circuit for any fault will take more
time. The coils get heated up due to continuous supply and bulged and will not release at the
appropriate time, even though the supply got cut off. Relay may be found in dropped/picked
up condition, but the contact change over might not have been taken place due to carbon/dust
accumulation on the contact.

41
Replacement of coil needs supply isolation. Sometimes, the isolation is not possible
due to continuous running of the equipment. The problems associated with contacts are much-
much more and it is very difficult to find the fault.

d. Logic problems: The panels are filled with various type relays and wiring work will be
done as per the circuit requirement. Whenever there is a modification in the circuit, the wiring
is to be changed after isolation of supplies and checking. Each and every modification will
take long time as per the circuit time and physical location of the relays and inserting the new
relays if required. Redressing of the cables to be done. Proper termination to be done.

42
V. UPGRADATION OF THE RELAY BASED LOGIC SYSTEM

All the above problems in the process industry engineers to search for a way to replace
relays, without losing the benefits of the operating principle. In 1970s the programmable
logic controllers have been found and these PLCs started replacing the relay panels and
hardware logic with software logics.

ROLE OF PLCS:

PLCs are closely related to computers by virtue of their computational abilities and
logic solving speed. PLCs receive inputs, solve logic, and set the appropriate outputs based
on those inputs and logic. Lets use the simple control sequence, in figure below, to illustrate
the process.

IN PUT LOGIC OUT PUT

OR
M
T
R
SWITCH NO NO POWER FLOW MOTOR OFF

I would like to control the operation of a motor by turning a switch ON or OFF. The
switch will be our input device and the motor will be our output device.
It will be safer to begin with the output device (the motor) in an inactive state. The ON/OFF
state of our input (the switch) is read and recorded. The application program (logic) is now
running. We close the switch. At some point in the application the state of the input is
examined to determine if there is power flow. Based on the logic that we provided in the
program, the motor must be turned ON if there is power flow. The output point is activated in
response to our logic program and power is allowed to flow to the motor.

43
In this simple program I have seen several important operating principles of PLCs:
STEP 1: To provide a safe start up from a known condition, the outputs always default to
OFF before the PLC does anything.
STEP 2: All of the inputs are sensed, and their ON/OFF state is recorded (latched) by the plc
logic.
STEP 3: The logic decides how to set outputs based on:
A: The input condition, and
B: What we said to do when that input condition exists.
STEP 4: The logic controls power flow to the output device. The logic circuit does not supply
the power to the output device, it only switches the power flow to it. Regardless of its size,
cost, or complexity every plc has certain major function blocks. The function blocks, shown
in following figure are the:
Power Supply
Central Processing Unit .
Memory, and
Input and Output modules.

POWER
CPU MEMORY
SUPPLY

I/O
MODULE S

44
POWER SUPPLY:
The function of a power supply is to allow error free electrical operation of the PLC.
The power supply provides the PLC with adequate current and the proper voltages. In general,
PLCs require several dc voltage levels. Some voltages operate the CPU section, other
voltages provides the switching and latching action of the I/O modules. The typical DC
voltages supplied by the power supply are: +/- 12V DC, +/- 5V DC, +4.3V DC
The power supply can be housed inside the PLC mainframe, or it can be external. External
power supplies are connected to the CPU by specially designed cables and connectors.
Auxiliary power supplies are used for expanding a PLCs I/O capabilities.

CPU:

The CPU is the brain of the programmable logic controller. Its function is to provide
your application with all of the logic solving and computational capabilities that we need.
In addition, the CPU directs and schedules all of the PLCs internal activities. We have
already had a look at the order in which the PLC solves user logic. As you recall, there is a
strict set of rules for solving an applications logic:
STEP 1: All of the outputs default to OFF.
STEP 2: Latch all of the inputs.
STEP 3: Solve the problem logic.
STEP 4: Set the outputs based on that logic, and
STEP 5: Repeat steps 2,3,4 and 5.
The CPU uses these results to direct all of the PLCs internal scheduling. The rules are
contained in a program called the operating system. The OS is a very complex program that
resides in the PLCs main memory. It is transparent to the user. That means that as it never
works you never see it performing its functions, or interact with it. The OS directs all of the
PLCs logic solving, communications, scheduling, and other decision making processes. The
CPU is connected to the all of the other functional blocks. It can send and respond to
information from memory and I/O modules. These are bi-directional communications.
Information is sent and received as electrical pulses. These pulses travel in between CPU,
memory, and I/O modules on a group of wires called bus. In parallel communication several
electrical pulses travel side-by-side, arrive and are interoperated all at one time.

45
In serial communication, the pulses travel each other as they travel along a single wire.

The importance of CPU cannot be overstated. Without it, the PLCs would be impossible.

MEMORY:
The memory provides the internal storage for all the information that the PLC needs
to operate,and solve the program logic. The PLCs memory is contained is small electronic
packages called integrated circuits (ICs). The ICs store all the information in a specified
locations, defined by OS, called addresses.
The memory connected the CPU by a bi-directional bus. The OS resides in Read Only
Memory(ROM). ROM is used to store information that will never be changed. ROM memory
an be interrogated and asked to copy its information on to a bus- and thats all. It is not
possible to write new information into ROM, or alter ROM information any way.
Another types of ROM that are available like Programmable ROM (PROM),Erasable
PROMs. the important point to remember is that Read Only Memory is used to store
information that the user logic and PLC will never change.
Another type of memory is Random Access Memory (RAM). Like ROM, RAM is contained
in ICs. unlike ROM you can read from and write to a ram address. This gives your
application the ability to change values while the PLC is running. RAM memory lets you to
alter the old information and insert the new information.

46
Input/output:
Input and output modules connect the CPU to the field devices. They provide the only
information path between our process or machine and the CPU . I/O modules are self
contained, plug in units. I/O modules plug into racks or housings. These racks, or housings,
can be located very close to PLC or thousands of feet away. An I/O module may have up to
32 individual circuits. Each circuit is called a point of I/O.
This small system would have a total of 24 I/O points. Again the function of the I/O is
to provide information to CPU about the condition of in put field devices, and take action
output field devices as directed by CPU. In addition, the I/O modules protect the CPU from
the environment by isolating it electrically. Input modules receive information about the
ON/OFF condition of field devices. The information is buffered (electrically isolated) and
sent to the CPU. These input field devices may be switches (limit, toggle, proximity, etc.)
thumbwheels, or a variety of other sensors (temp, position, etc.) powered by the output
module. The output module only provides the switching action .the appropriate power for the
user must supply the field device.
In addition to the four main function blocks, a complete system needs a programming
terminal/panel and input and output field devices.

PROGRAMMING
TERMINAL

POWER CPU MEMORY


SUPPLY

INPUT I/O OUT PUT


DEVICES MODULES DEVICES
DEVDEVIC
ES

47
The programming terminal let you enter and retrieve information from the PLC. Some
programming terminals built into the face of the PLCs. These auxiliary panels are called
RAP panels.
(Register Access Panel ).Most PLCs are programmed through an external programmer.
These external programmers can be hand held or table top mounted.
THEORY OF OPERATION:
The operating system determines how and when each of the function blocks of the PLC will
perform.
1. INPUT MODULES:
They are wired between the input field devices and the CPU. They buffer the signals from
the field devices to isolate the CPU from the factorys electrical environment
2.CPU:
It directs the logic solving internal scheduling and other decision making processes for the
PLC.
3.MEMORY:
It is the physical location of the OS and all other information that the PLC needs to operate
and run the user program .
4.OUTPUT MODULES:
They are wired between the output field devices and the CPU. They buffer the CPU
signals from the out put field devices to isolate the CPU from the factorys electrical
environment.
NETWORKS, RAILS, RUNGS & SCAN:
The elements have to be arranged in a logical sequence by the application programmer
.The programmer assigns each element a certain location in relation to all other elements in
an application these locations are fixed positions with in a network.
NETWORK:
A network is a group of elements that are usually related to each other in some way.
They may all be motor starting circuits, or all adders, are a complete loop of some operation.
All the logic in one network is solved before the next network is begun. The scan cycle will
read the inputs first, and then solve all the elements in the network1 followed by elements in
network2, and then network3.

48
The networks contain logic elements. The number of elements that a network can hold
is determined by the type of PLC and the type of logic elements. The logic elements are
arranged with in the networks on a skeleton of rails and rungs.

NETWORK 1 NETWORK 2 NETWORK 3

RAILS AND RUNGS:

Each network has two vertical rails, a power rail(left) and a ground rail(right).Power
passes through normally closed contact(N.C) when its associated field device are called is
inactive. Voltage from the power rail passes through N.C contacts and turns the coil ON. The
rung provides the path for Power flow from the voltage source to ground.
SCAN:
Regardless of how many networks logic elements, the program has, the CPU solves
the logic in a certain order-top to bottom and left to right; one network at a time.
On the first pass the PLC solves the logic represented by contact1(NO)then contact2 (NC) and
then contact 3 (NO) second solves the horizontal shots on rungs A&B and solves.

49
COMMUNICATING WITH FIELD DEVICES:
PLCS communicate with field devices, programming panels and other PLCs by
using electrical pulses. The pulses are small changes in DC voltages. The 0V level is an OFF
signal and is represented by the number 0.The 5V level is an ON signal and is represented by
the number 1.To properly decode the transmission of pulses the PLC must time them. A serial
transmission has timing points as shown T0-T7.
In figure, the same eight pulses are sent side by side. This is a parallel transmission.
The bus receives all the pulses at the same time(T0) so parallel is much faster than the serial
transmission.

BITS, BYTES, NIBBLES AND WORDS:

A bit is a single electrical pulse. It can be ON(1) or OFF(0) in serial or parallel. Eight
bits are called a byte. That is, eight distinct ON and OFF states with in the appropriate
timings.
The byte can be divided in half, each half is called a nibble A byte can also called as a
word. In some systems the word is used to signify 16,24,32 or even more bits. Bytes are held
in ICs called registers. Registers stores the bit patterns of PLCs memory. The register has
many storage locations, called an address. The byte stored in 16 bit registers are referred to as
higher order byte and lower order byte 0.

I/O REFERENCE NUMBERS:

The PC identifies discrete input and outputs points and register values with no.
Prefixes. A discrete point of I/O is a single ON or OFF signal that communicates with a field
device. Discrete output points are identified by a prefix of 0 .For example no. 00001 identifies
a discrete output point for some PC and the 0001 identifies the discrete output point for the
PC. The length of the number depends on the type of the PC. Discrete input points are
identified by a prefix of 1. For example, the no. 10001 identifies a discrete input point for
some PC and the no. 1001 identifies a discrete input point for the other PC. The length of the
number depends on the type of the PC.

50
Input registers are identified by prefix 3. For example, the no. 30001 identifies a
discrete input point for some PC and the no. 3001 identifies a input register for other PC. The
length of the no. Depends on the type of the PC. Output (or holding) registers are identified by
the prefix 4 .for example the no. 40001 identifies a discrete input point for some PC and the
no. 4001 identifies an output register for the other PC. The length of the number depends on
the type of the PC.

0XXXX or 0XXX- discrete output points.


1XXXX or 1XXX- discrete input points.
3XXXX or 3XXX- input registers.
4XXXX or 4XXX- output(holding )registers.

Input/Output MODULES:
I/O modules are the physical link between the input and output field devices and the
CPU. In addition, I/O modules provides the electrical isolation for the PLC. They are held in
mounting units called racks, or housings. These are the four group of the I/O:
1. Discrete,
2. BCD register,
3. Analog ,and
4. Special function.
DISCRETE I/O:
Discrete I/O modules are available with up to 16 inputs and output points. The discrete
input modules are referenced with a number1 as its prefix. The discrete output modules are
referenced with the number 0 as the prefix. Discrete modules respond only to OFF or ON
conditions. For example, an input module wired to switch 10002 would be able to
communicate only a closed switch (ON) condition, or an open switch (OFF) condition of
CPU.

51
CHOOSING A PROGRAMMABLE CONTROLLER:

Selection of I/O modules and field devices should be followed by the selection of the best
PLC for our application. The size of the PLC is defined by its number of I/O points.
a) Mini up to 64 I/O points.
b) Small up to 128 I/O points.
c) Medium 128 to 512 I/O points.
d) Large more than 512 points.

There are eight steps to making a reliable decision about the best PLC for our application.
Describe the process
Describe the PLC functions
Determine I/O and field device needs.
Determine the memory requirements
Describe system layout.
Describe the system environment
Determine the system support needs
Determine people support needs.
DESCRIBE THE PROCESS:
PROCESS GOALS:
Improved productivity
Improved flexibility
Improved safety
Improved information management
CONTROL APPROACH:
Stand alone
Distributed or centralized.

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SYSTEM INTERFACES:
Peripherals (printer, bar code reader, etc.)
Information (computer, data logger etc.)
Human (keypad, CRT, touch-screen, etc.)
SYSTEM REQUIREMENTS:
Longest scanning time the process can afford.
CONSIDERATIONS:
Not all system update every I/O scan.
Remote I/O may increase update time.
Communications and information transfer may add time to system throughput.
Throughput is limited by slowest system element.
Cost of down time vs cost of spares
AVAILABILITY

Identify maximum allowable and schedule downtime.


Identify cost of downtime.
Identify critical components that could cause process failure.
Identify replaceable in-process elements.
PROTECTION:
Spare components.
Hot stand by hardware and program.
Redundant controllers with bump less transfer.

53
VI. CONVENTIONAL RELAY LOGIC
IMPLEMENTATION IN FSSS

PRIMARY AIR FAN:


The following permissive are to be satisfied, to start the primary fan.
1) Blade pitch minimum: The blades are adjusted, initially such that the load on the fan
is minimum at the time of starting. This can be achieved by setting the blade pitch
minimum at the time of starting. However, during operation the blade pitch
minimum can be adjusted according to the requirement.
2) Lube oil pressure adequate: The pressure of the lubricating oil for the bearing is to
be maintained at the desired level. The pressure of the oil is sensed and is given to
the relay coil. So, the relay picks up and signal is sent to the corresponding contact
closes when the pressure is adequate.
3) Bearing temperature not high: The temperature of the bearings should be with in
the permissible limits. The temperature sensors will sense the temperature and the
associated relay picks up when the temperature is with in the permissible range.
4) Discharge damper closed: The discharge damper must be kept in closed and after
the fan starts running after a time interval the discharge damper is opened and. if
discharge damper fails to open with in the specified time the supply to the fan is to be
tripped.
5) Lube oil level in tank adequate: The pressure of the oil in the oil tank is monitored
continuously. If the pressure is adequate the relay corresponding to the input will
pickup and the input is made available to the controller.
6) Any FD running: Any one of the forced draught fan must be in running condition.
7) Start permit from FSSS: The furnace safeguard supervisory system will check all
the conditions that are to be satisfied to start the PA fan. It issues the start permit if
all the required conditions are satisfied.

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CONDITIONS FOR THE TRIP SIGNAL: -

1) Bearing temperature high: If the temperature of the bearings exceeds the permissible
limits then the trip signal occurs and the fan will be disconnected from the supply.

2) Discharge damper fails to open: If the discharge damper valve fails to open within
5seconds after the occurrence of PA fan start command the PA fan should be tripped
off.

3) MFT: If the master fuel trip is activated the fuel supply to the boiler is stopped. So
the primary air fan should be tripped in order to prevent the airflow in to the boiler.

INDUCED DRAUGHT FAN: -


PERMISSIVES:-
1) Permissive o.k.: The following conditions must be satisfied to start the ID fan:
a) Scoop level: The scoop level should be minimum at the instant of starting.
b) Inlet vane: The inlet vane should be in the minimum position. This is to prevent
the motor from drawing high starting currents.
c) Bearing temperature: The bearing temperature should not be high.
d) Lube oil pressure: The pressure of the lubricating oil should be maintained at the
desired level.
e) ID fan permit: The start permit from the FSSS will be issued to ID fan after
conforming that, all the requisite conditions are fulfilled.
f) Any FD running: Any one of the FD fans should be in running condition.
g) ID-A start command: ID fdn start command should be made available.
h) Stack path available: All the dampers in the path of the air that is ESP dampers
inlet and outlet, ID fan inlet and outlet dampers etc. should be kept open.
i) Air damper: The outlet vane of the Id fan should be closed initially and soon after
the fan is started the damper should open. Both inlet and outlet valves should be
kept closed at the time of start.
If that above conditions are satisfied the "permissivesO.K." indication will
Glow.

55
CONDITONS FOR TRIP COMMAND:

In the event of any one of the following conditions the trip command will be activated.
1) FD-b running: The FD fan-b should be in running condition otherwise trip occurs.
2) Bearing temperature: Bearing temperature should be within the permissible
limits, otherwise trip signal will be activated.
3) Dampers: If the dampers fail to open after the motor starts running then the ID fan
trip signal is activated.
4) Furnace pressure: After the completion of the purge cycle, the pressure inside the
furnace should not be very high or very low.
If any of the above conditions occur, the trip command signal is issued and -ID
fan supply is disconnected.
After the ID fan starts running the per missives can be varied so in order to
maintain the motor in running condition

56
VII. CONVERSION OF RELAY LOGICS TO PLC LOGICS

FURNACEPURGE:
Before starting any fuel firing (initially or after a boiler trip), a satisfactory furnace
purge cycle must be successfully completed.

To start a furnace purge cycle, the following purge permissives must be satisfied:
1. Heavy oil trip valve is closed.
2. All heavy oil -nozzle valves are proven closed in all elevations (AB, CD, EF, GH).
3. All pulverizes (A to H) are off.
4. All feeders (.A to H) are off.
5. All flame scanners (four discriminating and seven "fire ball" scanners) indicate no
flame".
6. Establish airflow between 30% more than of full load air flow and less than 50% of full
load air flow.
7. All hot air gates to be closed.
8. Drum level should be satisfactory.
9. All auxiliary air dampers (9 no's) should be modulating.
10. All PA fans are off.
11. No boiler trip causes present.
Once all the above conditions are satisfied, "PURGEREADY AND PUSH TO
PURGE" indications will appear on the control disc. Now the operator can start the purge
cycle by depressing "PUSH TO PURGE" button. Once it is pressed, a 5-minute purge cycle
starts and after the purge cycle, "PURGE COMPLETE indication comes on, establishing
'purge complete' signal.
If any of the purge permissives disappear before the 5-minute purge time is expired,
the "purge ready" and "push to purge" lights will go off and the 5-minute counting period will
reset.

57
If this occurs, the purge requirement must be re-established and another furnace purge
cycle is to be started.
The "PURGE COMPLETE signal removing the "MASTER FUEL TRIP"memory
signal and establishes a "no master fuel trip" signal.
The following events will now occur:
a) Both of the (red) BOILER TRIP lights go off.
b) The PURGING and PUSH TO PURGE lights go off.
c) The CAUSE OF TRIP memories are reset.
d) The heavy oil trip valve can now be opened after other conditions are satisfied. It is noted
that the HFO trip valve can also be opened at any time if all HFO nozzle valves are closed and
heavy oil re-circulation valve is opened.
e) Oil bumers can be taken into service and further, milling systems can be taken after
satisfying all other conditions.
f) Auxiliary air dampers can be closed.
g) 'Loss of fuel trip alarming' signal can be established after other conditions are satisfied.

58
59
c) MASTER FUEL TRIP (M.F.T):
The master fuel trip command will be given if any one of these conditions are occur.
1) Loss of reheat: Loss of reheat can occur if neither turbine nor HP/,LP bypass is
providing path for the steam. If this condition persists for more than 5-sees the boiler has
to be tripped.
2) Inadequate water circulation: If CC pumps are not available for recirculation of
water from drum to drum, sufficient heat transfer through water walls will not takes place
to avoid Starvation the boiler is to be tripped.
3) Low a flow: The low airflow can occur if the following conditions are met: Airflow is
less than 30% and boiler load is greater than 30% and there is master fuel trip. If MFT is
not activated, the low airflow indication is not achieved even though the airflow is less
than 30%. If this condition persists there is danger of explosion..
4)
LOSS FD/ID /APH: when air entry and flue gas exit paths are not ensured, fuel can not be
admitted. Hence boiler is to he tripped.
5) Drum level high: high drum level may allow the water to be carried over to
turbine where it can damage the blades if the problem persists for 10 seconds the boiler is
to be tripped.
6) Drum level low: low drum level leads to starvation of water walls.
7)
Furnace pressure 2/3 high how trip: In both cases boiler is to be protected against fuel entry
in to a disturbed furnace.
8) All feeders off: When all the fuel feeding equipment is lost boiler should be tripped to
allow purging to be done, it is to prevent any accumulated fuel inside the furnace.
9) Unitflame fail: when flame is not there it is dangerous to admit fuel because it will
lead to explosion.
10) All BFPs tripped.
11) Loss of control current supply power: If electrical supply is not available, their
hardware can't work. Running boiler in that condition is unsafe.
12) Emergency trip: This is to protect turbine against entry of inadmissible quality steam.
The MFT will be reset if there no trip command and purge is completed.

60
61
Oil feeders O.K.:
This signal will he activated if any of the following conditions occur:
1) Any one of the feeders is in operation.
2) Any one of the oil valves is open.

Reset signal for MFT:


The MFT will be set if the following conditions are satisfied,
1) Oil feeders o.k.
2) MFT signal will be reset if there is no signal from MFT Redundant Processor.

62
PRIMARY AIR FAN:

The following per missives are to be satisfied, to start the primary fan.
1) Blade pitch minimum: The blades are adjusted, initially such that the load on the fan
is minimum at the time of starting. This can,be achieved by setting the blade pitch
minimum at the time of starting. However, during operation the blade pitch
minimum can be adjusted according to the requirement.

2) Lube oil pressure adequate: The pressure of the lubricating oil for the bearing is to
be maintained at the desired level. The pressure of the oil is sensed and is given to
the relay coil. So, the relay picks up and signal is sent to the corresponding contact
closes when the pressure is adequate.

3) Bearing temperature not high: The temperature of the bearings should be with in
the permissible limits. The temperature sensors will sense the temperature and the
associated relay picks up when the temperature is with in the permissible range.

4) Discharge damper closed: The discharge damper must be kept in closed and after
the fan starts running after a time interval the discharge damper is opened and if
discharge damper fails to open with in the specified time the supply to the fan is to be
tripped.

5) Lube oil level in tank adequate: The pressure of the oil in the oil tank is monitored
continuously. If the pressure is adequate the relay corresponding to the input will
pickup and the input is made available to the controller.

63
6) Any F.D running: Any one of the forced draught fan must be in running condition.

7) Start permit from FSSS: The furnace safeguard supervisory system will check all
the conditions that are to be satisfied to start the PA fan. It issues the start permit if
all the required conditions are satisfied.

CONDITIONS FOR THE TRIP SIGNAL:

1) Bearing temperature high: If the temperature of the bearings exceeds the permissible
limits then the trip signal occurs and the fan will be disconnected from the supply.

2) Discharge damper fails to open: If the discharge damper valve falls to open within
5seconds after the occurrence of PA fan start command the PA fan should be tripped
off.

3) MFT: If the master fuel trip is activated the fuel supply to the boiler is stopped. So
the primary air fan should be tripped in order to prevent the airflow in to the boiler.

64
65
INDUCED DRAUGI FAN: -

PERMISSIVES:-
1) Permissive o.k.: The following conditions must be satisfied to start the ID fan :
Scoop level: The scoop level should be minimum at the instant of starting,
Inlet vane: The inlet vane should be in the minimum position. This is prevent
motor from drawing high starting currents.
Bearing temperature: The bearing temperature should not be high.
Lube oil pressure: The pressure of the lubricating oil should be maintained at the
desired level.
ID fan permit: The start permit from the FSSS will be issued to ID fan after
conforming that, all the requisite conditions are fulfilled.
Any FD running: Any one of the FD fans should be in running condition.
ID-A start command: ID fan start command should be made available.
Stack path available: All the dampers in the path of the air that is ESP dampers
inlet and outlet, ID fan inlet and outlet dampers etc. should be kept open.
Air damper: The outlet vane of the Id fan should be closed initially and soon after
the fan is started the damper should open. Both inlet and outlet valves should be
kept closed at the time of start.
If the above conditions are satisfied the permissivesO.K. indication will glow.

CONDITONS FOR TRIP COMMAND: -


In the event of any one of the following conditions the trip command will be activated.
FD-b running: The FD fan-b should be in running condition otherwise trip occurs.
Bearing temperature-. Bearing temperature should be within the permissible limits,
otherwise trip signal will be activated.
Dampers: If the dampers fail to open after the motor starts running then the ID fan trip
signal is activated.
Furnace pressure: After the completion of the purge cycle, the pressure inside the
furnace should not be very high or very low.

66
If any of the above conditions occur, the trip command signal is issued and ID fan supply
is disconnected. .
After the ID fan starts running the permissives can be varied so in order to maintain the
motor in running condition.

67
68
ANNEXURE

MASTER FUEL TRIP:


MASTER FUEL TRIP (MFT) is initiated in any of the following conditions :

Both FD fans are OFF


Both ID fans re OFF .
Inadequate water wall circulation for more than 5 seconds.
Loss of Reheat Protection for greater than 10 seconds.
Both BFPs tripped.
Drum-level high for more than 10 seconds (2/3 logic)
Drum level low for more than 10 seconds (2/3 logic)
Furnace pressure high (2/3 logic)
Furnace pressure low (2/3 logic)
Loss of all fuel.
All feeders are OFF and loss of A.C. Supply at elevation in service.
Unit flame failure.
Loss of unit critical power for more than 2 seconds
Both Secondary APH are OFF
Emergency trip (Manual)
Loss of 220 V D.C. Supply for more than 2 seconds.
Air flow less than 30% and boiler load greater than 30%

69
Boiler Trip (MFT) will reset after purge completion.
PURGE READY
Purge Ready signal at control room is available when all the following conditions are
satisfied.
All HFO nozzle valves are closed.
All pulverizers are OFF
All feeders are OFF .
No MFT condition present.
All scanners sense no flame (Fire ball and Discriminating scanne.,,
All Auxiliary dampers modulating.
Both PA fans OFF.
All HAGs closed.
Air flow more than 30% and less than 50%
HFO trip valve is closed.
Wind box to furnace DP is adequate.

LIST OF PROTECTIONS OF STAGE -11


BOILER AUXILARY EQUIPMENT
A. FD FAN:
PERMISSIVES:
Blade pitch minimum
Discharge damper closed
Lube oil pressure adequate
Control oil pressure adequate
Oil tank level normal
Bearing temperature not high
Both ID Fan running & other FD Fan not running OR
One ID Fan running & other FD fan not running.

70
TRIPS:
Fan bearing temperature very high
Post purge furnace pressure, very high/very low
Outlet damper fail to open in set time(3 min)
No ID fan running or one ID fan and one FD fan already in service.
B. PA FAN:
PERMISSIVES
Blade pitch minimum
Lube oil pressure adequate
Control oil pressure adequate
Bearing temp. not high
Discharge damper closed.
Lube oil tank level adequate
No MFT .& Cold air damper closed
Atleast one FD fan is running and
PAPH A[b in service & respective air inlet/outlet dampers are open

TRIPS:
Fan bearing temperature very high
MFT
Outlet damper fails to open.
C. ID FAN:
PERMISSIVES:
Scoop position minimum
Inlet vane minimum
Bearing temperature not high
Oil temp and oil level in hydraulic coupling OK.
Lube oil pressure adequate
Both inlet and outlet dampers closed.
Other ID fan not running or Any FD fan running.

71
TRIPS:
Bearing temperature very high
Lube oil pressure very low
Post purge furnace pressure Hi/Low
Discharge damper / suction damper fail to open
Hydraulic coupling bearing temp. very high
Hydraulic coupling oil temperature very high.

D. SGWC PUMPS:
PREMISSIVES :
Discharge valve 1 open
Discharge valve 2 open
Motor cavity temp. not high
Casing -suction manifold DT not high
Motor cooling water flow adequate.

TRIPS:
Discharge valve 1 not fully open
Discharge valve 2 not fully open
Motor cavity temp. high (60 deg. C)

72
VIII. SIMULATION OF PLC'S

CONCEPT 32 BIT SIMULATORS:

Introduction:
The Concept-PLCSIM32 program simulates Quantum PLC unit and its signal states.
Area of Use:
The simulator is presently only available for IEC languages (FBD, SFC, LD, IL and
ST).
How to start Programming:
The title bar shows the name of the application (PLC Sim32) and the address of your
PC-interface card. The first text box in the simulator window shows the status of the
simulated PLC. This field is read-only. The displayed status is determined by Concept, as
with a real PLC. The status may be shown a s the following:
DIM (Dim Awareness) the simulator is in an undefined state
STOPPED The simulator (the simulated PLC) is stopped.
RUNNING The simulator (the simulated PLC) is running.
The type of PLC to be simulated can be selected from the first list box. The following
registers are available:
State RAM: Provides an overview of the signal memory.
1/OModules: Shows the configuration currently loaded or the signal memory of a selected
group of components.
Connections: Displays connections between the simulator and programming device(s).
Overview:
A controller is simulated with the PLCSIM32 simulator using 4 main steps-.
Step Action
I Program creation and controller configuration.
2 Activating the simulator.
3 Construction of the connection between Concept and simulator.
4 Downloading the program.

73
,
Program creation and controller configuration
The following steps describe how to create Programs and configure the controller.

Step Action
1) Create your program and your controller configuration in Concept.
2) Save your project with File Save.

Activating the simulator


The following steps describe how to activate the simulator:

Step Action
1 Run PLCSIM32 simulator in the Concept Program group.
2 Select the controller type appropriate to your project in the simulator.

Construction of the connection:


The following steps describe how to construct the connection between concept and the
simulator.

Step Action
1 Using Online (V Connect... open the Connect to PLC dialog in Concept.
2 Select the IEC Simulator (32-Bit) entry in the protocol Type list box.
3. In the Access range, activate the change configuration option button.
4. confirm with OK. Response :A connection has been made between the
programming unit and simulator. A note then appears, saying that the configurations
of the programming unit and the simulator are different.

74
Downloading the program'
The following steps describe how to download the program
Step Action
1 Using online Download open the Download Controller dialog.
2. Confirm with download Response : your program and your
configuration are loaded into the simulator. You will be asked if you
wish to start the controller.
3 Confirm with yes Response : You may now test the behavior of your
IEC user program.

75
State RAM:
Introduction:
This register shows the status of the signal memory. Each individual Reference area is
assigned two lines. (Register, State RAM)
a) Left mouse button: Selected register
b) Left mouse button, Modify value
c) Left mouse button, Modify value
d) Right mouse button: Selected format
e) Right mouse button: Selected format and range of values

Column 1 (register addresses):


The first column contains the first of the 16 register addresses for Ix or Ox references.
Clicking with the left or right mouse button on the register address opens the Input Bool /
output Bool dialog, allowing you to alter the register addresses. The current register
addresses for references 3x and 4x are displayed. Clicking with the left mouse button on the
register address opens the input Register / Holding Register dialog, allowing you to alter the
register addresses. Clicking with the left mouse button on the register address opens the input
Register / Holding Register dialog box, allowing you to alter the register addresses.

Column 2 (signal memory):


The bits for the ix and 2x references are indicated by a checkbox in the second column.
A red checkbox indicates a value of "O" in the signal memory. A green checkbox indicates a
"I". For Ix references, clicking with the left button of the mouse toggles the value in memory.
For Ox references, clicking with the left mouse button opens the Coil Set Dialog box,
allowing you to alter the current values in memory. As Ox references are normally set by the
program logic, it is necessary to use this method to ensure that the required memory location
is set. it is not possible to do this simply by toggling, as toggle and write instructions can
logically occur at the same time. The value set in the dialog box is valid until it is overwritten
by the program logic. For 3x references the 3rd column contains a slider with which the
signal memory values can be altered. Move the slider with the left mouse button to specify a
signal memory value. For 4x references the display in column two shows the current value of
the register.
Column 3 (signal memory):
The 3rd column contains the signal memory value for the current register address (see
column 1). For Ox and I x references, the 16 bit value shown in the second column is
interpreted as a word. Clicking on the signal memory value with the left mouse button opens
the Change Value dialog box, allowing you to alter the values in the SRAM values. For, Ox
and 4x references, these values are only valid until overwritten by the program logic.
Clicking with the right mouse button opens a menu for defining the display and entry formats.

Function (FUNC):
A program organization unit which, when executed, will yield exactly one data element.
A function has no internal state information. Multiple calls to the same function with the
same input parameter values will always yield the same output values. Details about the
graphical form of function calls can be found in the definition "Function Block (instance)".
Contrary to function block calls, function calls have only one single unnamed output because
its name is the name of the function itself. In FBD, each invocation/call is identified by a
unique number above the graphical block; this number is automatically created and cannot be
changed.
Project:
General term for the highest level of a software tree structure which defines the overall project
name of a PLC application. After the definition of the project name, the system configuration
and the control program can be saved with this name. All data which is created while creating
the configuration and the program are belonging to project for this special automation task.
General term for the complete set of programming and configuration information in the
project data base which represents the source code that -describes the automation of a system.

77
Section:
A section, for instance, can be used to describe the mode of operation of a technological unit
such as a motor.
A program or DFB consists of one or several sections. Sections can be programmed with the
IEC programming languages FBD and SFC.
Within a section, only one of the listed programming languages can be used.
In Concept, each section has its own document window. However, to have a better overview
it is recommended to subdivide a large section into several smaller ones. The scroll bar is
used to move around within a section.
State RAM:
State RAM (state memory) I is the memory location for all variables addressed in the user
program through references (direct representation). For example, input bits, output holding
bits, input registers, and output/holding registers are located in State RAM.

Status bits:
There is one status bit for each node with global input, specific input or output of peer cop
data. If a defined group of data was successfully transferred within the set timeouts, the
corresponding status bit will be set to - 1. If not, this bit is set to 0, and all data belonging to
this group (to 0) will be deleted.
Traffic Cop:
The Traffic Cop is an 1/0 map, which is . generated from the user 1/0 map. The Traffic Cop
is scheduled in the PLC and contains e.g. status information in addition to the user 1/0 map.
Library:
A collection of software objects intended for reuse when programming new projects, or even
to build new libraries. Examples are the library of Elementary function block types. EFB
libraries can be subdivided into groups.
Variables:
Variables are used for data exchange within sections, between several sections, and between
the program and the PLC.

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Variables consist at least of a variable name and a data type.

If a variable is assigned a direct address (reference), it is called a located variable. If a variable


is not assigned a direct address, it is called an unlocated variable. If the variable is assigned a
Derived data type, it is called a multi-element variable.
In addition, there are constants and literals.
Unallocated variable :
The Variable is maintained and stored by the system. The assigned address in the PLC is not
published because the variable is addressed by its symbolic name.
Base 2 literals:
Base 2 literals are used to specify integer values in the binary system. The base is identified
by the prefix 2#. The value cannot have a sign (+/-). Individual underscore symbols (_)
between the numbers have no significance.
Example:
2#1111_1111 or 2#11111111 (255 decimal)
2#1110_0000 or 2# 11100000 (224 decimal)
Base 8 literals :
Base 8 literals are used to specify integer values in the octal system. The base is identified
using the prefix 8#. The values cannot have a sign (+/-). Individual underscore symbols (_)
between the numbers have no significance.
Example:
8#3_77 or 8#377 (decimal 255)
8#34_0 or 8#340 (decimal 224)
Base 16 literals :
Base 16 literals are used to specify integer values in the hexadecimal system. The base is
identified using the prefix 16#. The values cannot have a sign (+/-).Individual underscore
symbols (_) between the numbers have no significance.
Example :
16#F_F or 16#FF (decimal 255)
16#E_0 or 16#E0 (decimal 224)

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Conclusion

In Present day power plants, safety of working personnels Protection of the


equipment, reliable control & operation are given the prime importance. This has prompted
the necessity for looking forward to advanced control equipment. In furnace safeguard
supervisory system the operation and control carried out by conventional relay logic systems,
which involves complex physical designing and poses operational and maintenance problems
due to malfunction mechanical parts. So, in above context there is need for switching on to
programmable logic. The conversion of relay logic to PLC logic, the verification of logics
functioning with original system with the help of simulator, is presented along with general
operation of thermal power plant. description of FSSS and some programming concepts.

Hence, we finally conclude that PLC prove to be very good choice for the control and
operation of, "Furnace Safeguard Supervisory System".

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BIBLIOGRAPHY

Introduction to Programmable Logic Controllers


Reference Manual By Gould Electronics
Auxiliary relay panel drawings of ID FAN
Reference Siemens drawings
About Furnace Safeguard & Supervisory System
Reference Manual By NTPC
Boiler Safeguard Protections
Reference Manuals By B H E L
About relay panel diagram
Reference manual volume ARP-1 by NTPC

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