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AUTOMATIC TURBINE RUN UP SYSTEM (ATRS)

Presentation outline
Overview of Plant Controls Functions of ATRS Structure of ATRS

Program Structure of ATRS and Turbine protection

MAN-MACHINEINTERFACE
OPERATOR

INSTRUMENTATION & CONTROL

PLANT

POWER PLANT CONTROL


UNIT CONTROL

BOILER

TURBINE

GENERATOR

INSTRUMENTATION AND CONTROL

MEASUREMENT

MONITORING

CLOSE-LOOP CONTROL

OPEN-LOOP 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.

TURBINE C&I PACKAGE CONSISTS OF THE FOLLOWING SYSTEMS:

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


OPERATOR

CRT /MMI DISPLAY UNIT IN OWS

ANALOG AND BINARY SIGNALS

LOGS

CONTROL ROOM

UNIT CONTROL
AUTOMATION

CLOSED LOOP

FUNCTIONAL GROUP

PROTIVE

DATA PROCESSING, ALARM

EQUIPMENT

CONTROL
SIGNAL CONDITIONING ALALOG, BINARY

CONTROL

LOGICS

ANNUNCIATION
PLANT INTERFACE EQUIPMENT

CONTROL INTERFACE MOTOR CONTROL CENTRE SWITCH GEAR

PLANT (FIELD)
SIGNAL TRANSMITTER

DRIVES

AUTOMATIC TURBINE RUN UP SYSTEM


A Successful start-up of the Turbine normally requires acquisition, analysis and collation of a wide variety of information pertaining to various parameters like oil pressure, vacuum, temperature, speed etc. Start up and Shutdown sequence performed in reliable way Protect drives and related auxiliaries Uniform and sequential information to operator about the process Distinct information about the nature and location of faults In addition it is essential to know the status of the auxiliary equipment.

ATRS

AUTOMATIC TURBINE RUN-UP SYSTEM TASKS PERFORMED:


SWIFT,ACCURATE AND OPTIMUM STARTUP ( INCLUDING SYNCHRONISATION AND LOADINING) OF TURBINE MAINTAINING OIL SUPPLY BUILDING UP AND MAINTENANCE OF VACUUM
The programmable ATRS is built ON FUNCTIONAL GROUP CONTROL

FEATURES :
PHILOSOPHY
The control area is divided into clearly defined functional areas called functional groups.

EACH FUNCTIONAL GROUP ORGANISED AND HIERARCHICALLY 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

ATRS STRUCTURE
OIL SYSTEM, VACUUM SYSTEM, TURBINE etc.

GC

SGC SLC CI SLC CI

SGC SLC

SGC

GROUP CONTROL: Decides WHEN, HOW MANY & WHICH SGC shall be operating and stopped. SUB GROUP CONTROL: Contains the sequential logics for switching drives ON and OFF. Perform sequence in STEPS, issue commands and get Checkbacks. SUB LOOP CONTROL: can be switched ON & OFF manually. Receive commands from GC, SGC and also Manual CONTROL INTERFACE: Standard Interface between the command transmitters and receivers in the plant, undertakes all necessary signal processing and monitoring.

SYSTEM OPERATION MODES:


AUTOMATIC,SEMI AUTOMATIC,OPERATOR GUIDE

MONITOR & BLOCKING TIME

STEP 01

START DRIVE A

DRIVE A ON
& MONITOR & BLOCKING TIME

STEP 02

OPEN DMPR A

AUTOMATIC TURBINE RUN-UP SYSTEM


SUB GROUP CONTROL (SGC):

SGC executes commands to bring the equipment up to 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.

Operating modes
Step-by-step mode: in this mode all the criteria for a particular step are simulated manually through the VDU/Console insert and the command is issued automatically. Operator guide mode: in this mode, the sub-group only receives data from the plant and the control stations, but the output commands are blocked. The have to be issued manually commands. Automatic mode :With a single command it will run the machine.

PROGRAM STEP OF A SUBGROUP CONTROL


FROM STEP 1 STEP CRITERIA FOR STEP -2

&
BYPASS CRITERION

EXAMPLE

1
&
02
PROGRAM LOOP

WAIT
50s

MO TIME
20s

COMMAND

1 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.

AUTOMATIC TURBINE RUN-UP SYSTEM


ATRS CONTROLS:

1. ATRS is organized 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 commands to the drive control level. SLC logic is also realised in the processor module. SGC and issues

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 check backs 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 AUTOON/OFF

SEAL STEAM CONTROL(SSC)

ELECTROMECHANICAL HYDRAULIC HYDRAULIC CONTROL(EHC) CONTROL(MHC)


MANUAL ON/OFF

SUBLOOP LP-WATER INJECTION


AUTO ON/OFF

SUBLOOP DRAIN VALVE

TURBINE TRIP SYSTEM(TTS)


AUTO ON/OFF

TURBINE STRESS EVALUATOR

LP WATER INJECTION

AUTOMATIC SYNCHRONIZER
MANUAL OPEN/CLOSE

MANUAL ON/OFF

THYRISTOR VOLTAGE REGULATOR(TVR)

GENERATOR MAIN CKT. BREAKER

DRAIN VALVES

SGC-DISPLAY
4 6 8 7 5

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
1. PUSHBUTTON MANUAL ON/OFF 2.LAMP SLC OFF 3.LAMP FAULT 4.LAMP SLC ON

DRIVE INTERFACE-DISPLAY
3 4 5

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 GENERAL EXAMPLE A A

1
NAAANN 1MAJ15

2
AANNN AP001

3
AANN XB01
SIGNAL IDENTIFICATION
CONSECUTIVE NO. OF EQUIPMENT

TYPE OF EQUIPMENT NO. OF SUBGROUP PLANT GROUP (FUNCTIONAL GROUP) NO. OF UNIT

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