INTRODUCTION

TO
CONTROL & INSTRUMENTATION
FOR
STEAM TURBINE
BY
BS RANA
DGM (CIE)
MAN-MACHINE-INTERFACE

OPERATOR

INSTRUMENTATION & CONTROL

PLANT
 POWER PLANT
POWER PLANT CONTROL
CONTROL

UNIT CONTROL

BOILER TURBINE GENERATOR

 INSTRUMENTATION
INSTRUMENTATION
AND
AND
CONTROL
CONTROL

MEASUREMENT MONITORING

CLOSE-LOOP OPEN-LOOP
CONTROL CONTROL

PROTECTION
 ADVANTAGES OF AUTOMATION

OPERATING PERSONNEL FREED FROM

ROUTINE TASKS.
INCORRECT INTERVENTIONS IN THE PROCESS
AVOIDED.
STRESS ON EQUIPMENT REDUCED.
PLANT OPERATIONS GEARED FOR MAXIMUM
EFFICIENCY.
INCIPIENT FAULTS RECOGNISED QUICKLY.
ON FAULT OCCURRENCE, IMMEDIATE AND
LOGICAL INTERVENTION POSSIBLE.
A. CONTROL SYSTEM:
ANALOG (CLOSE LOOP)

- ELECTROHYDRAULIC CONTROLLER (EHC)

- TURBINE STRESS EVALUATOR (TSE)
- LOW PRESSURE BYPASS CONTROLLER (LPBPC)
- GLAND STEAM PRESSURE CONTROLLER (GSPC)

BINARY (OPEN LOOP)

- AUTOMATIC TURBINE RUN UP SYSTEM (ATRS)

- AUTOMATIC TURBINE TESTER (ATT)

B. MONITORING & MEASUREMENT SYSTEM

- TURBINE SUPERVISORY INSTRUMENTATION (TSI)

- MEASURMENT OF PARAMETERS LIKE, TEMP.,PRESS.,LEVEL etc.

C. PROTECTION SYSTEM
 HIERARCHY OF CONTROL

UNIT
CONTROL

GROUP CONTROL
(WHEN, HOW MANY,WHICH)

SUB-GROUP CONTRL-1 SUB-GROUP CONTRL-2

CONTROL INTERFACE

SWITCH GEAR (MCC)

 CONCEPT OF C&I IN THERMAL POWER STATION
CRT /MMI DISPLAY UNIT IN
OPERATOR
OWS

CONTROL
ANALOG AND LOGS
BINARY
ROOM

SIGNALS
UNIT CONTROL
AUTOMATION
CLOSED FUNCTIONAL PROT- DATA PROCESS- EQUIPMENT
LOOP GROUP IVE ING, ALARM
CONTROL CONTROL LOGICS ANNUNCIATION

SIGNAL
CONDITIONING CONTROL INTERFACE PLANT INTERFACE
ALALOG, BINARY EQUIPMENT
MOTOR CONTROL CENTRE
SWITCH GEAR
PLANT (FIELD)

M DRIVES
SIGNAL TRANSMITTER M
BHEL SCOPE OF SUPPLY
 ATR S
AUTOMATIC TURBINE RUNUP SYSTEM
 AUTOMATIC TURBINE RUN-UP SYSTEM
TASKS PERFORMED:
PERFORMED
SWIFT,ACCURATE AND OPTIMUM STARTUP ( INCLUDING
SYNCHRONISATION AND LOADINING) OF TURBINE
MAINTAINING OIL SUPPLY
BUILDING UP AND MAINTENANCE OF VACUUM

FEATURES :
BASED ON FUNCTIONAL GROUP CONTROL PHILOSOPHY
EACH FUNCTIONAL GROUP ORGANISED AND ARRANGED IN SUB-GROUP
CONTROL, SUB-LOOP CONTROL, AND CONTROL INTERFACE
OPERATING MODES AVAILABLE:
- MANUAL MODE ( OPERATOR GUIDE)
- AUTOMATIC MODE
- STEP BY STEP MODE
 ADVANTAGES OF ATRS
ELIMINATES HUMAN ERROR
PROVIDES MAXIMUM PROTECTION AGAINST
MALFUNCTIONS
OPERATORS TASK LESS ARDUOUS
ENABLES SAFE, SMOOTH, STRESS CONSISTANT AND
OPTIMUM WARM-UP, ROLLING AND SYNCHRONISATION
OF TURBINE IN LEAST POSSIBLE TIME
INCREASES PLANT AVAILABILITY
REDUCES STARTING TIME WITHOUT IMPAIRING LIFE
MEETS EMERGENCIES AUTOMATICALLY
ALL PLANT OPERATING CONDITIONS CATERED TO BY
CRITERIA DEPENDANT PROGRAMMING
INCREASED OPERATING FLEXIBILITY, SAFETY AND
RELIABILITY
 AUTOMATIC TURBINE RUN-UP SYSTEM
SUB GROUP CONTROL ( SGC):
SGC executes commands to bring the equipment upto a particular
defined status.
The commands are executed in a predefined sequence in the form of
steps.
Desired number of criteria act as preconditions before the SGC can
take off or execute its defined sequence.
The functional group continues to function automatically all the time
demanding enabling criteria based on the process requirements and
from other FGs, if required.
In case the desired criteria is not available, the system would
automatically act in such a manner as to ensure the safety of the main
equipment.
The sequence is programmed in the processor. The process signals are
acquired through the input modules and are available on the bus.
 AUTOMATIC TURBINE RUN-UP SYSTEM
WAITING AND MONITORING TIME FOR STEPS:
Waiting Time :
It implies that the subsequent step will not be executed unless the
specified time elapses. If no waiting time is specified, the next step
gets executed as soon as the enabling criteria are fulfilled.
Monitoring Time :
It is the time required for executing the command of any step as well
as the time required for appearance of criteria for the next step.
Under healthy conditions it should happen within the specified time,
otherwise an alarm is initiated. Whenever there is uncertainty
regarding the time required for completing a particular task, such
as warming-up, pulling vacuum etc., the monitoring time is blocked.
PROGRAM STEP OF A SUBGROUP CONTROL
STEP CRITERIA FOR STEP -2
FROM STEP 1

&
BYPASS CRITERION EXAMPLE
1

&
PROGRAM LOOP

02 WAIT MO TIME 1
COMMAND
50s 20s 2

STEP 2 ( START UP PROGRAM) WITH 2 STEP CRITERIA, 2 COMMAND

& OUTPUTS AND A MONITORING & WAITING TIME .
WITH ADDITIONAL PROGRAM LOOP CONTROL AND A BYPASS
CRITERIA FOR STEP 1
WAITING OR MO TIME CAN BE PROGRAMMED FOR 0.1 SEC TO 999
MIN.
NOS. 1-49 USED FOR START-UP, 51 TO 99 FOR SHUTDOWN PROGRAM.
 AUTOMATIC TURBINE RUN-UP SYSTEM

WAITING AND MONITORING TIME FOR STEPS:

ATRS can be switched on at any stage after completing certain

tasks manually, if so desired. In such cases, the SGC
program quickly scans through the steps and starts executing
from the stage upto which the tasks have been completed
manually. This is achieved by incorporating suitable
overflow /bypass conditions in the logic.
STRUCTURE OF DCS
AUTOMATIC TURBINE RUN-UP SYSTEM
(TYPICAL CONFIGRATION OF PROCONTROL BASED ATRS)
 AUTOMATIC TURBINE RUN-UP SYSTEM
ATRS CONTROLS:
1. ATRS is organised in the following four Sub-Groups :
Oil supply
Evacuation
Turbine
HP CONTROL FLUID
2. SGC issues commands either to the SLC or directly to
the drive through the Control Interface.

3. Each of these SGCs has its subordinate SLCs and CI

modules. These SGCs in conjunction with the turbine
governing system , TSE and the auto-synchroniser
accomplish the function of start-up of the TG set.
 AUTOMATIC TURBINE RUN-UP SYSTEM
SUB-LOOP CONTROL (SLC) :
A SLC, when switched on, actuates the equipment and brings it
to the desired status as demanded by the process and there is no
sequence logic involved in it.

SLC is like a watch-dog performing an assigned duty.

All mechanical equipment which need to be switched on/off based

on process consideration are hooked-up in various SLCs. Standby
equipment is also interlocked in SLCs.

SLC can be switched on either manually or through SGC and

issues commands to the drive control level.

SLC logic is also realised in the processor module.

 AUTOMATIC TURBINE RUN-UP SYSTEM
CONTROL INTERFACE (CI) :
Each remote controlled drive has a dedicated CI module which
acts as a standard interface between the transmitters and
receivers in the plant and undertakes all necessary signal
processing and monitoring.
The CI module receives manual commands from the process
keyboard/inserts, active protection signals and enabling
signals from the protective logic, as well as automatic control
commands from the SGC/SLC.
It interlocks the input commands according to their priority
and validity and then passes actuation signals to the
interposing relays in the switch-gear.
The status checkbacks received from the switchgear or
actuators are monitored, processed and transmitted to
VDU/desk tiles, the protective logic and the SGC.
 AUTOMATIC TURBINE RUN-UP SYSTEM
CONTROL INTERFACE (CI) : (Continue--)
These modules have the firmware which defines the
standard function of the module and its signalisation mode as
well as the programmable logic for the drive protection and
the permissive interlocks. The drive level automation tasks
related to the respective drive is realised through the
programmable logic.

The module has hardwired inputs and outputs for connection of

feedback signals and commands to the switchgear together
with local bus interface for signal exchange via the system bus.
 AUTOMATIC TURBINE RUN-UP SYSTEM

ATRS STRUCTURAL SYSTEM:

ATRS IS ORGANISED IN THREE SGCs :

1. SGC-TURBINE :
SGC Turbine acts directly on the following systems :
Sub-loop Control (SLC) Drains.
Warm up Controller.
Starting Device of turbine governing system.
Speed & Load Setpoint devices of turbine governing
system.
Auto-synchroniser.
 AUTOMATIC TURBINE RUN-UP SYSTEM

ATRS STRUCTURAL SYSTEM:

2. SGC-OIL SUPPLY :

SGC oil supply directly acts on the following system :

Sub-loop control (SLC) turning gear.

SLC auxiliary oil pump 1.
SLC auxiliary oil pump 2.
SLC emergency oil pump.
SLC jacking oil pump.
 AUTOMATIC TURBINE RUN-UP SYSTEM

ATRS STRUCTURAL SYSTEM:

3. SGC-CONDENSATE & EVACUATION :

SGC- Condensate & Evacuation directly acts on the following

systems :

Sub-loop Control (SLC) condensate extraction pumps.

Starting ejector, if provided.
Main ejectors / vacuum pumps (as applicable).
Vacuum breaker.
 AUTOMATIC TURBINE RUN-UP SYSTEM

ATRS STRUCTURAL SYSTEM:

3. SGC-HPCF :

SGC- HPCF acts on the foll :

Sub-loop Control (SLC) HPCF

SLC HPCF pumps
HPCF pumps
HPCF re-circulation pumps
LPCF temp control valve
 AUTOMATIC TURBINE RUN-UP SYSTEM
3. SGC-HPCF :

Both CF PUMPS GET SWITCHED ONTHRU SLC. IN CASE

RUNNING PUMP DOES NOT DEVELOP THE REQUIRED
PRESS, THE STANDBY PUMP GETS SWITCHED ON
AFTER GETTING THE REQUIRED CF PRESS SLC HEATING
IS PUT ON & CF CIRCULATION PUMP WHICH FEEDS THE
REGENERATION CKT IS ALSO PUT ON. TEMP CONTOL VLV
IS PUT IN AUTO MODE TO REGULATE THE TEMP.
CF TEMP IN THE TANK IS MAINTAINED BETWEEN 55 TO 57
C BY SWITCHING ON/OFF THE CF HEATER THRU THE
SLC. IN CASE CF TEMP IN HTR EXCEEDS > 65 C THE
HEATER IS SWITCHED OFF
IN SHUTDOWN PROG ALL THE PUMPS ARE SWITCHED
OFF AND SLC IS PUT OFF. SLC HEATING IS KEPT ON TO
MAINTAIN THE TEMP REQUIRED FOR THE NEXT STARTUP.
TURBINE START-UP / SHUT-DOWN CONTROL, OVERVIEW

SUB-GROUP ( TURBINE START-UP / SHUT-DOWN)

CRITERIA
CRITERIA
AUTO-
ON/OFF
SEAL ELECTRO- MECHANICAL SUBLOOP SUBLOOP
STEAM HYDRAULIC HYDRAULIC LP-WATER DRAIN
CONTROL(SSC) CONTROL(EHC) CONTROL(MHC) INJECTION VALVE
AUTO
MANUAL
ON/OFF
ON/OFF

TURBINE TURBINE
LP WATER AUTOMATIC
TRIP STRESS
INJECTION SYNCHRONIZER
SYSTEM(TTS) EVALUATOR

MANUAL MANUAL
AUTO OPEN/CLOSE
ON/OFF
ON/OFF

THYRISTOR GENERATOR
DRAIN
VOLTAGE MAIN CKT.
VALVES
REGULATOR(TVR) BREAKER
 SGC-DISPLAY
4 6 8 7 5

1 2

3
1. PUSHBUTTON SHUTDOWN
2.PUSHBUTTON STARTUP OR OPERATION
3.PUSHBUTTON AUTOMATIC ON/OFF
4.LAMP SHUTDOWN PROGRAM
5.LAMP STARTUP OR OPERATION PROGRAM
6.LAMP AUTOMATIC OFF
7.LAMP AUTOMATIC ON
8.LAMP FAULT
 SLC-DISPLAY
2 3 4

1. PUSHBUTTON MANUAL ON/OFF

2.LAMP SLC OFF
3.LAMP FAULT
4.LAMP SLC ON
 DRIVE INTERFACE-DISPLAY

3 4 5

1 2

1. PUSHBUTTON OFF (CLOSE)

2. PUSHBUTTON ON (OPEN)
3. LAMP OFF (CLOSE)
4. LAMP FAULT
5. LAMP ON (OPEN)
 EXPLANATION OF KWU IDENTIFICATION SYSTEM (KKS)

ORDINAL SECTION 0 1 2 3
GENERAL A NAAANN AANNN AANN

EXAMPLE A 1MAJ15 AP001 XB01

SIGNAL IDENTIFICATION
CONSECUTIVE NO. OF EQUIPMENT
TYPE OF EQUIPMENT
NO. OF SUBGROUP
PLANT GROUP (FUNCTIONAL GROUP)
NO. OF UNIT
PROTECTION SYSTEM

FOR

STEAM TURBINE
 TURBINE PROTECTION SYSTEM

TASK PERFORMED :

PROTECTS TURBOSET FROM INADMISSIBLE

OPERATING CONDITIONS

PREVENTS DAMAGE IN CASE OF PLANT FAILURE

FAILURE OCCURRENCE REDUCED TO MINIMUM

 TURBINE PROTECTION SYSTEM

ADVANTAGES :

DETECTION OF UNIT IRREGULARITIES

PREVENTION OF UNIT OVERSTRESSING DUE TO TRIPS

RELIEF OF OPERATING PERSONNEL FROM QUICK AND

CORRECT DECISION TAKING
 TURBINE PROTECTION SYSTEM

HYDRAULIC ELECTRICAL EXTENDED PROT. CRITERIA

TRIP SYSTEM TRIP SYSTEM TURBINE PROT. FROM OTHER AREA

- MANUAL - LP EXH. STM. -GENERATOR

- OVER SPEED
REMOTE TRIP TEMP. > MAX PROTECTION
TRIP DEVICE
1/2 ( UCB)
- VACUUM TRIP - LOW VACUUM - MASTER FUEL
DEVICE TRIP TRIP RELAY
- HAND TRIP - LOW LUBE OIL ENERGISED
LEVER(LOCAL) - FIRE PROT.
1/2 TRIP - BOILER
-BRG METAL PROTECTION
TEMP OPTD.
-AXIAL SHIFT
-HP/IP TOP/BOT
DIFF TEMP HI
-HP EXHAUST
 TURBINE PROTECTION SYSTEM
GENERAL :

The electrical trip system comprises of two identical and

independent relay based trip channels viz. electrical trip
channels 1 & 2.
Both channels are connected to different (two) trip solenoid
valves.
All command signals for turbine trip are hooked up with both the
channels.
Actuation of any of the channels energises the respective trip
solenoid which in turn trips the turbine.
Each channel is realized in a local bus. Both the local buses are
completely independent of each other and input modules,
processor module and output modules reside on each.
 TURBINE PROTECTION SYSTEM
GENERAL :
Trip signals from the sensors / field instruments are conditioned
and distributed to both the channels (local buses) via hardwired
modules.

Realization of 2 out of 3 trip logic is carried out in the local bus.

On detection of a fault in any one of the input signals to a
channel, the configuration for that channel changes from 2 out of
3 to 1 out of 2 and is annunciated. Further failure in a channel
changes the configuration to 1 out of 1.

Trip signal from each of the local buses acts on 3 relays in 2 out
of 3 combination.
 TURBINE PROTECTION SYSTEM
CYCLIC TEST :
Both the channels are tested periodically, even while the turbine
is running.

Cyclic testing is done automatically at preset intervals and can

be blocked from the protection cabinet, if desired.

This testing can also be initiated manually from the cabinet.

Only one channel can be tested at a time. Online testing is done

by simulating the trip signals and it determines faults in the input
modules, processor modules, output modules or the trip relays.

These faults can be acknowledged from the cabinet. Next cycle

test can only be carried out after acknowledging the fault.
TURBINE PROTECTION SYSTEM
 TURBINE PROTECTION SYSTEM
TRIPPING CRITERIA :

1. CONDENSER VACUUM VERY LOW :

This is a back up protection to the hydraulic low vacuum trip
device.
The protection acts if absolute pressure in the condenser rises

above 0.3 Kg/cm2 (abs).

2. LUBE OIL PRESSURE LOW :

The protection acts if the lube oil pressure before thrust bearing
decreases to 1.2Kg/cm2 .
The trip signal is initiated by three pressure transmitters in 2-out-of-3-
logic.
 TURBINE PROTECTION SYSTEM
TRIPPING CRITERIA :

3. FIRE PROTECTION :
The protection acts in the event of any of the following
conditions :
i) Fire protection switch, either in unit control room or in
machine hall, operated.
ii) Level in main oil tank falls to a very low value, indicating
substantial leakage of oil from the system.

The command signal under condition (ii) is initiated from

three level transmitters in 2-out-of-3 logic cofiguration.
 TURBINE PROTECTION SYSTEM
TRIPPING CRITERIA :

4. HP EXHAUST STEAM TEMPERATURE HIGH :

The HP exhaust steam temperature protection circuit causes the

exhaust sections of the turbine, the blading and the extraction points
against overheating.
Under extreme operating conditions the HP turbine can be run at low
flow rate and simultaneous relatively high back pressure. This prevents
the steam from expanding, which causes the exhaust steam
temperature to rise ( > 5000C).
The temperature is measured by means of three thermocouples and
protection criteria is derived in 2 out of 3 logic.
 TURBINE PROTECTION SYSTEM
TRIPPING CRITERIA :

5. TURBINE TRIP SWITCH OPERATED :

The protection acts when the turbine trip switch in unit control
room is operated manually.

6. TRIP COMMAND INITIATED FROM ATRS :

The protection acts when the trip command signal is initiated

from the Automatic Turbine Run-up System .
 TURBINE PROTECTION SYSTEM
TRIPPING CRITERIA :

7. GEN. PROTECTION OR MFT- RELAY ENERGISED :

In the event of generator faults under Class-B trip both the turbine
trip channels are actuated to trip the turbine. In such a case the
generator protection acts through Reverse Power Relays.
In the event of generator faults under Class-A trip or in the event of
boiler "Master fuel trip relay" energized, command signal for
turbine trip shall act simultaneously and independent of other
equipment trip out sequence.

8. OPERATION OF REVERSE POWER RELAY :

The command signal is initiated with a time delay of 10 seconds after
any of the two reverse power relays have operated.
THANK YOU
HAVE A NICE DAY