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PRESENTATION ON

PLANT CONTROLS & INST. OVERVIEW


OF
GGSR - BATHINDA (C
GGS (CPP))
OWNER : M/S HMEL
PMC : M/S EIL

BHEL-PE&SD
GGSR CPP- PLANT OVERVIEW
C&I DESIGN OVERVIEW- INSTRUMENTATION

APPLICATION DESIGN PHILOSOPHY

HAZARDOUS AREA PROTECTION INTRINSIC SAFE CONCEPT & EX-PROOF FOR SOV/
HIGHER VOLTAGE
PROCESS PARAMETER MONIROING & SMART TRANSMITTER ((4-20mA),
) 2oo3 SENSORS
CONTROL FOR CRTICAL LOOPS
INSTRUMENT FOR ALARM/SHUTDOWN SEPARATE SMART TRANSMITTER (4-20mA),
(SWITCHES ARE AVOIDED FOR RELIABILITY).
RELIABILITY)
CONTROL VALVES WITH SMART POSIT’NR WITH INTEGRAL I/P

FUEL FLOW MEASUREMENT MASS FLOW METER

FUEL TANKS LEVEL MEASUREMENT RADAR LEVEL TRANSMITTER

PROCESS SWITCHES NOT USED

TEMPERATURE MONITOING Pt-100, 3-WIRE RTDs & K-TYPE T/C

TEMPERATURE CONTROL TEMP TRANSMITTERS

Cont’d….
C&I DESIGN OVERVIEW
• INSTRUMENTATION POWER SUPPLY
APPLICATION POWER SUPPLY RATING
FIELD TRANSMITTERS 24V DC, LOOP POWERED FROM CONTROL SYSTEM

MASS FLOW METERS & RADAR 110V AC UPS


LEVEL TRANSMITTERS
SOLENOID VALVES 110V AC UPS,
UPS POWERED FROM DCS RELAY LOGIC

CONTROL VALVES 24V DC, LOOP POWERED FROM CONTROL SYSTEM

ANALYSERS 110V AC UPS


MOV INDICATIONS 24V DC POWERED FROM CONTROL SYSTEM
MOV OPEN/CLOSE COMMANDS 24V DC POWERED FROM ACTUATOR
PUMP INDICATIONS 24V DC POWERED FROM CONTROL SYSTEM
PUMP START/STOP COMMANDS 240V AC/220V DC POWERED FROM SWITCHBOARD
C&I DESIGN OVERVIEW – CONTROL SYSTEM

• maxDNA DCS IS PROVIDED FOR COMPLETE CPP CONTROL


& MONITORING FROM MAIN CONTROL ROOM
• FUNCTIONS
o PROCESS MONITORING
o PUMP & MOV OPERATIONS, SEQUENCE CONTOL OPERATIONS
o CONTROL VALVES OPERATIONS & SUB-PKG MONITORING
• INTERLOCK & SHUT DOWN SYSTEM – PART OF maxDNA DCS
• DEDICATED SYSTEMS ARE PROVIDED FOR
o GAS TURBINE - MARK-VI
o HRSG & UB FIRING SYSTEM - BMS PLC with BACK UP CONTROL DESK
o VIBRATION SYSTEMS FOR GT & ST
o PACKAGE SYSTEM FOR HSD CENTRIFUGE, COMPRESSED AIR SYSTEM,
A/C,
ABOVE SUB-SYSTEMS ARE INTEGRATED WITH PLANT DCS
ƒ …

REDUNDANCY
PROCESSOR - 1:1
POWER SUPPLY - 1:1
COMMUNICATION NETWOK - 1:1
I/O MODULES – 1:1 (CRITICAL)
CPP DCS –OPERATOR
OPERATOR INTERFACE

• OPERATOR STATIONS –9 Nos IN CONTROL ROOM


o PROVIDED FOR OPERATOR INTERFACE
o FOR PLANT START
START-UP
UP, MONITORING
MONITORING, CONTROL & SHUTDOWN
o TO VIEW PROCESS PARAMETERS, ALARMS, TRENDS, SET POINTS
o DRIVES OPERATION– A/M SELECTION, START/ STOP & SEQUENCE
CONTROL

DISTRIBUTION OF OPERATOR STATIONS

FOR HRSG - 2 Nos


FOR UB - 2Nos
FOR STEAM TURBINES - 2 Nos
FOR BOP SYSTEMS - 2 Nos
PLANT SUPERVISOR - 1 NO
Cont’d….
CPP DCS –OPERATOR
OPERATOR INTERFACE
• ENGINEERING
G GSSTATIONS
O S –2 Nos
os
o FOR PLANT GRAPHICS MODIFICATIONS/ NEW GRAPHICS BUILDING
o FOR APPLICATION SOFTWARE MODIFICATIONS
o LOGICS / SEQUENCE CONTROL MODIFICATIONS
o VALIDATTION OF LOGICS BEFORE DOWNLOADING INTO DPU.

• HISTORIAN STATION –11 No


o FOR HISTORIAN DATA COLLECTION & ARCHIVING.
o DATA QUERY FOR TRIP ANALYSIS/ REPORTS.
o DATA STORAGE INTERVAL IS PROGRAMMABLE
o ARCHIVAL STORAGE TO CD-ROM.
• maxLINK STATION –2 No
o FOR INTERFACING - MARK VI, BMS PLCs, VIBRATION MONITORING SYS
o DATA TRANSFER TO DCS OPERATOR STATIONS FROM OTHER SYS
Cont’d….
CPP DCS – PANEL MOUNTED SYSTEMS
• DISTRIBUTED PROCESS UNIT (DPU)
o PERFORMS DATA ACQUISION , DATA PROCESSING & CONTROLS
o ACQUISITION OF TREND INFORMATION
o LOGGING OF SOE
o CONTINUOUS SCANNING OF I/O MODULES
o EXECUTION OF PREDEFINED LOGICS
•maxNET & ETHERNET SWITCHES
HIGH SPEED NETWORK FOR CONNECTING DPUs, OPERATOR/ENGG
STATIONS, PRINTERS.
• SEQUENCE OF EVENT RECORDING (SOE)
o SOE FUNCTION IS INTEGRAL IN DCS.
o TIME STAMPING WITH “11 mSEC
mSEC” RESOLUTION
o SOE SIGNALS ARE TAGGED IN MAIN DATABASE

Cont’d….
CPP DCS – PANEL MOUNTED SYSTEMS
• HART MANAGEMENT SYSTEM (HMS)
o PROVIDED FOR C&I MAINTENANCE PURPOSE
o ALL TRASMITTERS & CONTROL VALVES ARE CONNECTED
o REMOTE ACCESS OF EACH FIELD INSTS. FOR PERIODIC CALIBRATION
o AUTOMATIC GENERATION OF INSTRUMENT DATABASE
- MAKE/ MODEL, DATE OF CONNECTION, DATE OF LAST CALIBRATION
& NEXT CALIBRATION
C O etc.
etc
- CALIBRATION PROCEDURE, HISTORY RECORDS
o ON LINE INSTRUMENT STATUS MONITORING

•MASTER CLOCK SYSTEM


o PROVIDED FOR TIME SYNCRONISATION WITH ALL THE CONTROL
SYSTEMS
o CONNECTED TO PLANT DCS, STG SYSTEM, MARK VI, PLCs, VMS
o UNIFIED TIME IS REQUIRED FOR MANAGEMENT REPORTING, TRIP
ANALYSIS, DATA LOGGING etc.
Cont’d….
CONTROL OVERVIEW- MAIN EQPTs
SYSTEM/EQUIPMENT PRIMARY CONTROL SECONDARY 
MONITOING
GAS TURBINE  Mark-VI CPP DCS
STEAM TURBINE
STEAM TURBINE CPP DCS ‐
BACK PR. STEAM TURBINE CPP DCS ‐
UBs FUEL,STEAM, WTR & 
UBs‐FUEL,STEAM, WTR & CPP DCS ‐
DRN SYSTEMS 
UBs – BURNER CONTROLS BMS PLC CPP DCS
HRSGs‐FUEL, STEAM, WTR &  CPP DCS ‐
DRN SYSTEMS
HRSGs BURNER CONTROLS
HRSGs‐BURNER CONTROLS BMS PLC CPP DCS
CPP DCS
GAS BOOSTER COMPRESSOR CPP DCS ‐

Cont’d….
CONTROL OVERVIEW- BOP SYSTEMS
SYSTEM/EQUIPMENT PRIMARY CONTROL & SECONDARY 
MONITORING
O O G MONITOING
LCO SYSTEM‐STORAGE, FUEL FWDG for  CPP DCS ‐
GTs, HRSGs & UBs
VANADIUM DOSING SYSTEM CPP DCS ‐
HSD SYSTEM‐STORAGE, FWDG for GTs CPP DCS ‐
HSD CENTRIFUGE
HSD CENTRIFUGE CENTRIFUGE LCP CPP DCS
CPP DCS
REFINERY GAS SYSTEM CPP DCS ‐
GD‐GFD SYSTEM
GD‐GFD SYSTEM CPP DCS ‐
STEAM SYSTEM‐VHP, HP, MP & LP CPP DCS ‐
CONDENSATE SYSTEM CPP DCS ‐
FEED WATER SYSTEM‐DEAE, BFPs CPP DCS ‐
STG, BPTG DRN & BLOWDOWN SYSTEM CPP DCS ‐
UTILITIES ‐POTABLE WATER, IA, PA, N2 CPP DCS ‐
Cont’d….
CONTROL OVERVIEW-BOP SYSTEMs
SYSTEM/EQUIPMENT PRIMARY CONTROL SECONDARY 
MONITOING
COOLING WATER SYSTEM CPP DCS ‐
DM WATER CIRCULATION
DM WATER CIRCULATION CPP DCS ‐
HP NITROGEN SYSTEM CNTRL PNL CPP DCS
HP LP DOSING SYSTEM
HP, LP DOSING SYSTEM CPP DCS ‐
GAS BOOSTER COMPRESSOR CPP DCS ‐
PLANT FIRE & GAS SYSTEM 
FIRE & GAS SYSTEM DEDICATED PANEL IN CPP DCS
CPP DCS
CONTROL ROOM
COMPRESSED AIR SYSTEM CNTRL PNL IN COMP. CPP DCS
HOUSE
STEAM & WATER ANALYSIS SYSTEM  ANALYSER PNL IN SWAS CPP DCS
for HRSG, UB & BOP ROOM
FLUE GAS ANALYSIS – HRSG & UB CEMS PNL IN ANALYSER CPP DCS
ROOM
PLANT DRIVE CONTROL PHILOSOPHY

FOLLOWING TYPES OF DRIVES ARE ENVISAGED IN CPP:


CPP
o ELECTRICAL DRIVES:
¾ HT PUMPS - BFPs, CW PUMPS, FD FANS etc.
¾ LT PUMPS – FUEL FORWARDING PUMPS, DMW, DOSING PUMPS
¾ MOVs
MOV (INTEGRAL ACTUATOR TYPE) - STEAM SYS ISOLATIOMS

o PNEUMATIC DRIVES:
¾ CONTROL VALVES
¾ SOLENOID OPERATED VALVES

Cont’d….
PLANT DRIVE CONTROL PHILOSOPHY
TYPE OF DRIVE INDICATIONS IN DCS OPERATOR FUNCTIONS 
FROM DCS
FROM DCS

HT PUMPS & LT PUMPS • READY TO START • AUTO/MANUAL SELECTION


• PUMP RUNNING • PUMP START COMMAND
• PUMP TRIPPED • PUMP STOP COMMAND

MOTOR OPERATED VALVES • READY TO START • AUTO/MANUAL


/ SELECTION
• VALVE OPENED • OPEN COMMAND
• VALVE CLOSED • CLOSE COMMAND

CONTROL VALVES  • VALVE POSITION IN • PROCESS VALUE


(REGULATING TYPE) % • SET POINT
• CONTROLLER AUTO/MANUAL
• CONTROLLER OUTPUT IN %

ON‐OFF/ESD VALVES • VALVE OPENED • AUTO/MANUAL


/ SELECTION
• VALVE CLOSED • VALVE OPEN/CLOSE COMMAND

Cont’d….
PLANT DRIVE CONTROL PHILOSOPHY
INDICATIONS/  MESSAGE FOR PLANT OPERATOR SIG.SOURCE
COMDS
MOTOR DRIVEN PUMPS
LOCAL CONTROL - PUMP L/R SECTION LCS
STN (LCS) - START/STOP IN LOCAL MODE
READY TO START “START PERMISSIVE & MCC SWITCH MCC CKT OK+NO TH
HEALTHY“FOR DCS OPERATION BOARD O/L + REM. SECT’D

A/M
/ ‐ SELECTION MANUAL- OPERATOR INITIATION DCS HMI
AUTO - THROUGH LOGIC SEQ.

START/ STOP 
START/ STOP WHEN SELECTD IN MAN.
MAN MODE DCS HMI
COMD.
RUN INDICATION “DRIVE STARTED F/B” FOR SWITCH
OPERATOR INFORMATION BOARD
TRIP INDICATION “DRIVE TRIPPED ON THERMAL SWITCH CRITICAL
OVERLOAD” FOR OPERATOR BOARD
INFORMATION & CORRECTIVE
ACTION
Cont’d….
PLANT DRIVE CONTROL PHILOSOPHY
INDICATIONS/  MESSAGE FOR PLANT OPERATOR SIG.SOURCE
COMDS
MOTOR OPERATED VALVES (MOVS)
LOCAL CONTROL - L/R SECTION LCS
STN (LCS) - START/STOP IN LOCAL MODE
READY TO START “START PERMISSIVE & ACTR ACTR ACTR CKT OK+NO TH
HEALTHY“FOR DCS OPERATION O/L + REM. SECT’D +
NO TRQQ TRIP
A/M ‐ SELECTION MANUAL- OPERATOR INITIATION DCS HMI
AUTO - THROUGH LOGIC SEQ.

OPEN/ CLOSE  WHEN SELECTD IN MAN. MODE DCS HMI


COMD.
OPEN/ CLOSE “MOV
MOV STATUSF/B
STATUSF/B” FOR OPERATOR ACTR
INDICATION INFORMATION

Cont’d….
DRIVE CONTROL PHILOSPHY
INDICATIONS MESSAGE FOR PLANT OPERATOR SIGNAL 
SOU C
SOURCE

CONTROL VALVES (PNEUMATIC OPERATED)


A/M ‐ SELECTION MANUAL OPERATOR INITIATION
MANUAL- DCS HMI
USE OF MANUAL LOADER

AUTO - THROUGH PID & SET


POINT

CONTROL SET - BY OPERATOR TO MEET THE DCS HMI


POINT CONTROL REQTS.
- CONTROLLER NEEDS TO BE
AUTO TO FOLLOW THE SET POINT
VALVE POSITION “% OF VALVE OPENING “ FOR POSITION
OPERATOR INFORMATION TRAMITTER

Cont’d….
DRIVE CONTROL PHILOSPHY
INDICATIONS MESSAGE FOR PLANT OPERATOR SIGNAL 
SOU C
SOURCE

ON-OFF VALVES (SOLENOID OPERATED)

A/M ‐ SELECTION MANUAL- OPERATOR INITIATION


MANUAL DCS HMI
AUTO - THROUGH LOGIC SEQ.

OPEN/ CLOSE 
OPEN/ CLOSE WHEN SELECTD IN MAN.
MAN MODE DCS HMI
COMD.

OPEN  “VALVE IS FULLY OPENED F/B”


/ FOR VALVE LIMIT
INDICATION OPERATOR INFORMATION SWITCH

CLOSE  “VALVE IS FULLY CLOSED F/B” FOR VALVE LIMIT


INDICATION OPERATOR INFORMATION SWITCH
SIGNAL WIRING
ANALOG SIGNALS

FIELD RACK ROOM CONSOLE


ROOM

DPU

AO
E/P

Cont’d….
SIGNAL WIRING

MCC SIGNALS

MCC RACK ROOM CONSOLE


ROOM

DI

Motor f/b DPU

DO

Motor cmd
SIGNAL WIRING

MOV SIGNALS

FILED ACTR RACK ROOM CONSOLE


ROOM

DI

MOV f/b DPU

DO

MOV cmd
PLANT CONTROL FUNCTIONS

• BOP FUEL SYSTEMS


o IMPLEMENTED IN PLANT DCS
o CONTROL FUNCTIONS
- FUEL TANK LEVEL CONTROL
- FUEL FORWARDING PUMP CONTROLS & AUTO CHANGEOVER
- FILTER SYSTEM DP
- FUEL PRESSURE AND RECIRCULATION
- FUEL FLOW MEASUREMENT
- DRAIN SYSTEM CONTROL & MONITORING
- GAS ESD VALVE CONTROL
- GAS SCRUBBER LEVEL CONTROL
- GAS PRESSURE CONTROLS

Cont’d….
PLANT CONTROL FUNCTIONS

• BOP WATER SYSTEMS


o IMPLEMENTED IN PLANT DCS
o CONTROL FUNCTIONS
- DEARATOR LEVEL CONTROL
- BFP CONTROLS FOR HRSG, UB & EXPORT
- FEED CONTROL STATION
- COOLING TOWER CONTROLS
- CONDERSER COOLING WATER SYSTEM
- AUX.
AUX COILING WATER SYSTEM
- CONDERSATE STORAGE TANK LEVEL CONTROL
- ST CONDENSER LEVEL CONTROL
- CEP CONTROLS
- BLOW DOWN SYSTEMS

Cont’d….
PLANT CONTROL FUNCTIONS

• BOP STEAM SYSTEMS


o IMPLEMENTED IN PLANT DCS
o CONTROL FUNCTIONS
- VHP- TO - HP STEAM PRDS
- HP - TO – MP STEAM PRDS
- MP – TO – LP PRDS SYSTEM
- AUX. STEAM PRDS CONTROL
- VHP/ HP HEADER VENT CONTROL

Cont’d….
PLANT CONTROL FUNCTIONS
• HRSG
SG CO
CONTROLS
O S
o IMPLEMENTED IN PLANT DCS
o DEDICATED SYSTEM FOR BURNER CONTROLS
o CONTROL FUNCTIONS
- DRUM LEVEL CONTROLS
- SUPERHEAT STEAM TEMP. CONTROL
- COMBUSTION CONTROL
- DIVERTER CONTROL
- MONITORING OF FEED WATER & STEAM PARAMETERS
- FLUE GAS PATH TEMP.
- FUEL FLOW MESUREMENT
- STEAM & WATER ANALYSIS – pH , CONDUCTIVITY,
CONDUCTIVITY SILICA
- FULE GAS – NOX, SOX, CO MEASUREMENT
- HRSG PROTECTION & TRIP LOGICS
- SCANNER & SEAL AIR FAN CONTROLS
- DRAIN & VENT SYSTEMS Cont’d….
PLANT CONTROL FUNCTIONS

• UB CONTROLS
o IMPLEMENTED IN PLANT DCS
o DEDICATED SYSTEM FOR BURNER CONTROLS
o CONTROL FUNCTIONS
- DRUM LEVEL CONTROLS
- SUPERHEAT STEAM TEMP.
TEMP CONTROL
- COMBUSTION CONTROL
- FURNACE DRAFT CONTROL
- FD FAN & DAMPER CONTROL
- MONITORING OF FEED WATER & STEAM PARAMETERS
- FUEL FLOW MESUREMENT
- STEAM & WATER ANALYSIS – pH , CONDUCTIVITY, SILICA
- FULE GAS – NOX, SOX, CO MEASUREMENT
- DRAIN & VENT SYSTEMS

Cont’d….
PLANT CONTROL FUNCTIONS

• STEAM TURBINE CONTROLS


o IMPLEMENTED IN PLANT DCS
o CONTROL FUNCTIONS
- TURBINE GOVERNOR
- OVER SPEED CONTROL & PROTECTION
- TERBINE PROTECTION & TRIP LOGICS
- LO SYSETM
- MONITORING OF STEAM PARAMETERS

Cont’d….
PLANT CONTROL FUNCTIONS

• MARK VI SYSTEM - FOR GAS TURBINE


o DEDICATED CONTROL SYSTEM FOR GAS TURBINE
o HMIs FOR OPERATOR INTERFACE
o ENGG STATION FOR S/W MODIFICATIONS
o CONTROL FUNCTIONS
- GAS TURBINE START UP CONTROLS
- SPEED CONTROLS wrt TO LOAD
- TURBINE FIRING TEMP
TEMP. CONTROL
- OVER-SPEED CONTROL
- GT PROTECTION & SHUTDOWN INTERLOCKS
- FUEL 3-
3 WAY VALVE CONTROL
COMMUNICATION SYSTEM

• PUBLIC ADDRESS SYSTEM


o FOR TWO-WAY COMMUNICATION IN CPP FIELD & CONTROL ROOM.
o MASTER CALL STATION IN CONTROL ROOM
o FIELD CALL STATIONS IN STRATEGIC LOCATIONS.
- GT AREA
- HRSG AREA
- UB AREA
- STEAM TURBINE AREA
- FUEL PUMP HOUSE,
HOUSE COOLING TOWER,
TOWER BFPS,
BFPS COMP.
COMP AIR etc.
etc
• TELEPHONE SYSTEM
o EPBAX BASED TELEPHONE SYSTEM
o TELEPHONE IN CONTROL ROOM, OPERATOR ROOMS & OFFICE ROOMS
o LOCAL ROOMS, SWAS ROOMS ARE PROVIDED WITH TELPHONES.

Cont’d….
PLANT COMMUNICATION SYSTEM
PLANT COMMUNICATION SYSTEM
DESIGN TEAM

EQUIPMENTS C&I DESIGN CONTROL IMPLEMENTATION


GAS TURBINE BHEL-HYD (GT DIV.) BHEL-HYD (GT DIV.)
MARK-VI BHEL-EDN (B’LORE) BHEL-EDN
STEAM TURBINE BHEL HYD (T&C)
BHEL-HYD BHEL HYD (T&C)
BHEL-HYD
HRSG-FW & STEAM BHEL-TRY(HRSG DIV.) BHEL-EDN
HRSG-BMS BHEL-TRY(HRSG
( DIV.)) BHEL-TRY(HRSG
( DIV.))
UB-FW & STEAM BHEL-TRY(HRSG DIV.) BHEL-EDN
UB-BMS BHEL-TRY(HRSG DIV.) BHEL-TRY(HRSG DIV.)
GBC BHEL-HYD (T&C) BHEL-EDN
FUEL- GT,HRSG & UB BHEL-HYD(PE & SD) BHEL-EDN
FW, STEAM & UTILITIES BHEL-HYD(PE & SD) BHEL-EDN
COMP. AIR SYSTEM BHEL-HYD(PE & SD) BHEL-HYD(PE & SD)
& BHEL
BHEL-EDN
EDN
CPP DCS BHEL-EDN BHEL-EDN