Power Plant Automation-Internet

8/8/2019 Power Plant Automation-Internet

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WHAT IS AUTOMATION?


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WHY AUTOMATION ?


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ORIGIN OF AUTOMATION

D uring first industrialrevolution, theautomation impliesreplacement of Humanmuscles by machine.


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The Process control madethis conversion moresimpler by making thesemachine smarter andgave room to Second

industrial revolution.A s in simple example, wecan see the tank level canbe easily controlled by thecontroller and hence nomore human inteface isrequired.

ROLE OF PROCESS CONTROL IN AUTOMATION


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OPTIMIZING THE PROC ESS

This changes the perceptionfrom maximizing quantity of production to qualitycoupled with level of

comfort and safety.A utomation thus reducesthe human sensory andmental requirement, humanbrain is hence used increativity and optimizingthe process for a bettertomorrow.


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ENGIN EERING D EFINTION FOR AUTOMATION

A utomation impliessuccessful control,

which in turns requirescorrect combination of sensor, controller andfinal control element .

Sensor,

Controller

Final ControlElement


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It can be as simple as

maintainingtemperature of roomat 22 degree C elsiusor as complex asguiding spacecraft tomoon.


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INDUSTRIAL DEFINITION OFAUTOMATION

A utomation is the useof control system inconcert withinformationTechnology to controlindustrial machinery

and process, thusreducing humanintervention .


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W HER E AUTOMATION EXIST?CarsTraditional: appliances control(windows, seats, radio,..)motor control (exhaustregulations)C

ritical new applications:AB

S(anti-skip) and E P S (stability),brake-by-wire, steer-by-wire ( X-by-wire ) increased safety

RobotsExtension limited to 2-3 m(portal robots 10-20m)frequent reprogramming fornew tasks, toolingsimple embedded computer,

hierarchical control


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display unitvehicle control unit

DU

TCU

DU

TCU

VCU

radio link

LOCOMOTIVE

brakes signalingtraction control unitdiagnostics energy

VCU

Benefits: Reduce operation costs, faster diagnostics, betterenergy, management automatic train control.There are more than 30 computers in locomotives .


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AVIONIC SAVIONICS:flight control (safeflight envelope,autopilot,

engineer )flight managementflight recording(black boxes,turbine supervision)

diagnosticsfly-by-wire


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SUBSTATIONP rotection ( Lines,

transformers, generators) veryhigh speed response control(remote or local) to guaranteepower flow, safe operation(interlocking)measurement (local andremote), electricity bill, powerflow in grid

Pharmaceutical IndustryInventory

Recipe managementP ackagingSampling


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MANU FACTURING


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Extreme dependency on theavailability of the controlsystem

Connection toSupply chain management,

O rder fulfilmentCustomer relationship andCommercial accounting (S AP )

WAREHOUSE


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Oil & Gas, petrochemicals

Upstream": from the earth to the refinerydown-sea control

special requirement: high pressure,saltwater, inaccessibilityexplosive environment with gas.

Distributationspecial requirement: environmentalprotection

Downstream": from the oil toderived productsspecial requirement: extreme explosiveEnvironment


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CHEMICAL INDUSTRYL ogistics,local control of reactors

Characterized by batches of products, reuseof production reactors for differentproduct types (after cleaning).

CEMENT INDUSTRY

PULP AND PAPER INDUSTRY

METAL INDUSTRY


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P OWER TRANSMISSION


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Hydro- river

- dams- storage dams

Thermo- coal

- gas- atom- solar - waste

Alternative- wind- photo-voltaic

P OWER P LANT


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PO W ER PLANT SCEN ERIO IN INDIA


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At present 83*Thermal Power Plant.


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*Source: Ministry of ower Website

Installed apacity in Mega Watt (MW) from 1950 to 2009(As on 31/05/2009)

MW 1700 4600 13000 28000 66000 112000 145588 149111

1950 1960 1970 1980 1990 2006 2008 2009


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20000

40000

60000

80000

100000

120000

M W

*Source: CEA Website

Actual Power Demand Vs Supply Position in India

Demand 81492 84574 87906 93255 100715 108866 109809

Supply 71547 75066 77652 81792 86818 90793 96685

2002- 2003- 2004- 2005- 2006- 2007- 2008-


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100000

200000

300000

400000

500000

600000

700000

M U

*Source: CEA Website

Actual Energy Requirement Vs Energy Supply Position in India

Demand 545983 559264 591373 631757 690587 739345 774324

Supply 497890 519398 548115 578819 624495 666007 689021

2002-03

2003-04

2004-05

2005-06

2006-07

2007-08

2008-09


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PO W ER CAPACITY DI STRIBUTION IN INDIA

53%

1%3%

25%

8%10%

Coal 53% Gas 10% Diesel1% Nuclear 3% Hydro 25% Rest 8%


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PO W ER SHAR EHOLDING IN INDIA


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CONC EPT O F M ERC HANT PO W ER

The U nion P ower M inistry isencouraging merchant power plantsacross the country as a means to createadditional generating capacity at afaster rate through private sectorparticipation.M erchant power is the term used bypower companies to describeelectricity sold in the open market.P ower plants usually sign long-termPPA s with state governments underwhich they agree to sell power to state-owned distribution utilities at a fixedrate for a specified period.


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OP EN ESSIN POLICY

To facilitate sale of power topower traders and third parties,the government has establishedan open access policy in powertransmission.Introduced in the Electricity A ct,2003, open access basically refersto the right to transmit powerover a system belonging to a thirdparty.W ith such concerted efforts in allareas, M erchant power isconsidered a favourable optionfor private sector .


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AG ENCI ES IN VOL VED IN D EVELOPM ENT O F PO W ER PLANT

Independent P ower P roducer ( IPP )Engineering, P rocurement & Construction(EPC ) Company

Consulting Engineering CompanyO EM s, Equipment manufacturers,Control and Instrumentation CompaniesG overnment departments and ministriesRegulatory Authority etc.


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S.No Sector Hydro Thermal Nuclear Wind/Rest Total

1 P rivate 1,230.00 11,800.50 0.0 10,994.70 24,025.20

2 State 27,055.70 46,672.30 0.0 2,247.70 75,975.70

3 Central 8,592.00 36,399.00 4,120.00 0.0 49,110.30

4 Total 36,877.70 93,725.30 4,120.00 13,242.40 149,111.20

Power Scenario in IndiaInstalled Capacity in MW as on 31-05-09Total Installed Capacity is 1 ,49, 111.2 MW


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TARG ET O F PO W ER G EN ERATION

A s per Central Electricity A uthority s ( CEA )projection for the 11 th P lan (2007-2012),Capacity addition required - 78,578 M W58 ,571 MW of Thermal (approx. 1 0,

786 MW per annum)16 ,627 MW of Hydro3,3 8 0 MW of Nuclear

A s per CEA / P lanning Commissionprojection for 12 th P lan (2012-2017),

Capacity addition planned - 82,200 M W comprising of:40, 2 00 MW Thermal30,000MW Hydro,12 ,000 MW of Nuclear power plants .


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W HY COAL BA SED PO W ER PLANT

IN INDIA ?


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COAL PRODUCTION AND CON SUMPTION

India ranked third in theworld with 7 percent coalreserves of the total

world reservesSeventy percent of thetotal coal produced isconsumed for powergeneration. Steel &cement are other majorconsumers.


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HO W PO W ER PLANT W ORK S?


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POWER P L ANT L AYOUT


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Coal Storage

ConveyorsAnd Scale

Coal Crusher

DraftFans

RawCoalSilo

Coal Feeder Bottom AshConveyor

Influent Water Treatment

FeedWater Heater

Feed Water P umps

Furnace

Boiler

Ash Removal Air QualitySystem(Scrubber, P recipitator)l

Stack

BagHouse

Fly AshConveyor

Generation

HotWellP ump

Feed Water Tank

ToWastewater Treatment,To Effluent

Transformer

ToDistribution

Substation 1

Substation 2FromNeighboringUtility

ToDistribution

P ulverizer

Fuel Handling Furnace/Boiler Transmission

Water/Wastewater Water/Wastewater


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ROLE OF ENGINEER IN POWER PLANT

The operation andmaintenance of powerplant is done byengineers of various

disciplines likeM echanical, Electrical,C &I, C ivil etc.B ut the role of C &I Engineer is even moredemanding, a C &I Engineer have to be veryproficient.


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ROL E O F C &I ENGIN EER IN PO W ER PLANT

Responsible for allmeasurements made in theplant.The accuracy of themeasurement determines

the efficiency of theprocess, the efficiency of each process in turndetermines the totalefficiency of the plant.The C &I engineer has anintimate knowledge of theprocess, without which it isneither possible toinstrument the process norcontrol it .


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COMPL EXITY IN PO W ER PLANT

A P

owerP

lant is a complexthing and its construction isfrantic, long drawn outinvolves many people,

difficult conditions like dirt,noise, extreme temperature,complex cabling, thousandsof instruments ,systems

makes the task of C &I engineer challenging anddemanding .


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LARG E AND VARI ED M EA SUR EM ENT

In P ower P lant, C&Iengineer is responsible formeasurement as close to 4

degree C entigrade nearthe condensor to 1200degree centigrade insidethe boiler. N ot only this the

pressure measurementrange varies from vaccumto very high pressure .


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SELECTI VITY O F M EA SURING IN STRUM ENT S

The proper selection of which instrumentto be used when, i.e. we cant measure theflow simply by conventional flowmeter ata M ain steam line at 550 degree Celsius.T

he instrument mounted for this purposeof measurement requires not only shouldbe accurate but also reliable and efficient.For instance, Thermocouple can not beused in rugged places so RTD is used.

The goal of C&I engineer is to make surethat all the measurements, calibration,maintenance, control are donesatisfactorily well for proper functioning of power plan


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M EA SUR EM ENT DON E IN PO W ER PLANT

Process measurements :Pressure, Temperature,Flow and Level.

Analytical measurements(SWAS) : pH, Conductivity,Silica, Hydrazine andDissolved Oxygen.


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Condition monitoringmeasurements for

rotating equipment :Vibration, speed, bearingtemperatures,eccentricity, axial shift,displacement.

Emission monitoring(CEMS): CO, SOx, NOx

Environmentalmeasurements : Windvelocity, Ambienttemperature, Humidity,Rainfall etc .


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M EA SUR EM ENT PARAM ETER

Indication of the parameter -can be either LOCAL orREMOTE

LOCALmeans indication of theparameter at the field by adial type gauge, liquid levelgauge or flow glass.

REMOTEmeans that theprimary signal is converted toan electrical analog signal andtransmitted to the controlroom for indication / control .


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W HY M EA SUR EM ENT AR E


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W HY M EA SUR EM ENT AR ECONTROLL ED ?

The C&I engineer is responsiblefor control philosophy of eachsystem of the power plant.

For instance, The Temperaturemeasurement at the outlet of M Sline is in the range of 550 degreeCelsius, during maintenance ortrip, Bypass and control valve

plays an important role, the goalof C&I engineer is to make surethat excess steam is properly sentto the Condensor or deaerator forthe right purpose .


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WHAT IS CONTROL SYSTEM?


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CONTROL SYSTEM

A control system is a device or setof devices to manage, command,direct or regulate the behavior of other devices or systems.

There are two common classes of control systems, with manyvariations and combinations: logicor sequential control andfeedback or linear controls . There

is also fuzzy logic, which attemptsto combine some of the designsimplicity of logic with the utilityof linear control .


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CONTROL SYSTEM LEAD S TO


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CONTROL SYSTEM LEAD S TO INNO VATION

The control systemhas made the humanrelieved from thetedious calculationswhich sometimeleads to error, thus

allowing maximumchances of creativityand innovation .


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M ost control systemare complicatedenough to demandthat a controllerperform some sort of

mathematicalcalculation before acontrol action isinitiated thus concept

from calculus andalgebra is required.


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W hy DC S?High ReliabilityImproved Response TimeImproved Interface to plantImproved accesbility of plantdata to engineering andmanagement personals.Historical Storage and RetrivalSystemSafe operation of PlantLowest Cost of GenerationLongest Equipment LifeMinimum Environmental EffectMaximum EfficiencyEnergy Conversation


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PLC s forsequential

control

M otioncontrollersfor motioncontrol

DC S systemsfor process

control

D rivesystems fordrivescontrol

DI FFER ENT CONTROL SYSTEM IN PO W ER PLANT


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DCS ARCHITECTURE

DISTRIBUTED CONTROL SYSTEM


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DI STRIBUT ED CONTROL SYSTEM

DC S refers to a controlsystem usually of a ,process or any kind of dynamic system, in whichthe controller elementsare not central in location(like the brain) but aredistributed throughoutthe system with each

component sub-systemcontrolled by one or morecontrollers.

OP ERATION O F DC S


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The most common example isa setpoint control loopconsisting of a pressuresensor, controller, and controlvalve.Flow measurements are

transmitted to the controller,usually through the aid of asignal conditioningInput/ O utput ( I/ O ) device.W hen the measured variablereaches a certain point, thecontroller instructs a valve oractuation device to open orclose until the fluidic flowprocess reaches the desiredsetpoint.

OP ERATION O F DC S

DC S HARD W AR E


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S H E

Controller cardInput C ards (4-20 m A )Thermocouple, RTD , SO EO utput C ards(4-20 m A , D igital)P ower Supply M oduleC ommunication C ard CablesController with I/O card


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AUTO CONTROL LOOP


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C o-ordinated C ontrolTotal A ir C ontrolSuper/ ReheaterTemperature

ControlM ill out Temperature

C ontrolHotwell/ D eaerator levelC

ontrolD rum Level C ontrolFurnace D raft C ontrol

INT ERLOCK AND PROT ECTION


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INT ERLOCK AND PROT ECTION

Interlock and protection areused for safestartup/operation/shutdown

/trip/ of an equipment forauxilliaries such asC W P ump, ID Fan, F D Fan,PA Fan, B FP, C EP, M ill.

HeaterValve and D rains

BOIL ER CONTROL


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BOIL ER CONTROL

B urner M anagementC ontrolSecondary airD amper C ontrolA uxilliary P ressuredesuperheatingsystemSoot blower C ontrolHP B y pass C ontrol


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DC S IN INDU STRY


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DC S IN INDU STRYLarge oil refineries havemany thousands of I/ O points and employ verylarge DCS. P rocesses arenot limited to fluidic flowthrough pipes.

It can also include thingslike variable speed drivesand motor controlcenters, cement kilns,mining operations, oreprocessing facilities, andmany others .

L t b t t th


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Last but not theleast, A utomationhas made the powerplant a safe, reliable,efficient,comfortable,

innovative place towork for thegeneration of electricity for themankind .


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Power Plant Automation-Internet