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Suresh Sharma

BHEL -PEM-C&I, NOIDA

TO ATMOSPHERE

COAL TO ELECTRICITY
PUMP
BOILER WET ASH FLUE GASES ESP ID FAN

FLY ASH

SEC AIR FD FAN


FURNANCE STEAM TURBINE

ASH HANDLING PLANT

C H I M N E Y ASH POND
TRANSMISSION TOWER

GENERATOR TRANSFORMER

ELECTRICITY

PRI AIR PA FAN COAL HANDLING PLANT

C O A L COAL MILL

GENERATOR

CONDENSER

CW PUMP

Cooling Tower

WATER COOLING WATER

SAFE OPERATION OF PLANT


LOWEST COST OF GENERATION LONGEST EQUIPMENT LIFE MINIMUM ENVIROMENTAL FFECTS MAXIMUM EFFICIENCY ENERGY CONSERVATION

IT IS APPLIED TO OPERATE VARIOUS COMPONENTS /


DEVICES (FINAL CONTROL ELEMENTS) OF PLANT WITHIN SAFE OPERATING ZONE IN ORDER TO GET THE DESIRED PARAMETER .

IT IS APPLIED TO GET THE PROCESS INFORMATION OF

DESIRED PARAMETERS (e.g. PRESS , TEMP , FLOW, LEVEL,


PH , CONDUCTIVITY ETC) TO FACILITATE THE CONTROL / MONITORING OF THE PROCESS.

PRIMARY INSTRUMENTS : o THEY SENSE THE PROCESS o THEY ARE MOUNTED IN FIELD o Ex SWITCHES , TRANSMITTERS , GAUGES .

SECONDRAY INSTRUMENTS : o o o THEY RECEIVE THE SIGNAL FROM PRIMARY INSTRUMENTS. MOUNTED ON CONTROL PANEL . Ex - INDICATOR,RECORDER, TEMP SCANNER .

PRESSURE MEASUREMENT : DPS TEMPERATURE MEASUREMENT : FLOW MEASUREMENT :

PT,PS, DPT,

RTD, TC FI, FS, FT

LEVEL MEASUREMENT :
POWER MEASUREMENT

LI, LS, LT

VOLTMETER,AMMETER,WATTMETER,ENERGYMETE

HOTWELL
CEP DISCH DEA O/L ECO INLET

CONDUCTIVITY
PH, CONDUCTIVITY, Na PH, DISS O2 PH, COND, HYDRAZINE

DRUM WATER
MAIN STEAM

COND, PH, SILICA


COND, PH, Na

TO ENSURE QUALITY OF DM WATER TO BOILER . TO PREVENT COROSSION .

TO REMOVE IMPURITIES TO PREVENT SCALE


DEPOSIT IN THE BOILER TUBE . TO PREVENT SILICA DEPOSIT ON THE BLADES OF

TURBINE .

MEASUREMENT OF OXYGEN, CARBON MONO OXIDE IN FLUE GASES FOR PROPER & OPTIMISATION OF COMBUSTION OF FUELS IN BOILER . MEASUREMENT OF SULPHER DIOXIDE, NITROGEN

OXIDES, DUST DENSITY IN FLUE GASES TO


MINIMISE THE ENVIROMENTAL EFFECTS .

PUMPS / FANS / BLOWERS

Unidirectional Drives

MOTORISED VALVES

Bidirectional Drives

- WITHOUT INTEGRAL STARTER - WITH INTEGRAL STARTER - WITH SMART ACTUATOR

CONTROL VALVES Analog drives - PNEUMATIC ACTUATOR - ELECTRIC ACTUATOR - HYDRAULIC ACTUATOR

INTERLOCK & PROTECTION ARE USED FOR SAFE START

UP / OPERATION / SHUTDOWN / TRIP OF ANY EQUIPMENT


OR AUXILLARY , EXAMPLES: o CW PUMP , ID FAN , FD FAN, BOILER FEED PUMP, CEP,

MILL , PA FANS , PUMPS ,


o LP / HP HEATERS , o AIR HEATERS , o REHEATER PROTECTION , o VALVE & DRAINS etc.

RELAY BASED SYSTEM .

SOLID STATE .

PRO-CONTROL .

Max DNA .

Switch A Switch B

D P U D P U I O

I O I O I O

I O I O I O

I O I O I O

I O S I G N A L S

MAN MACHINE INTERFACE PLANT INFORMATION SYSTEM AUTO CONTROL SYSTEM INTERLOCK & PROTECTION

HUMAN MACHINE INTERFACE CATERING TO SG, TG, STATION C&I AND ELECTRICAL CONTROLS
LVS (3 NOS.) 67
Operator Station # 1 Operator Engg. Stn. Station # 7 PADO STN
NETWORK PRINTERS :

Colour Inkjet A3/A4 3 Nos maxSTORIAN Shift I/C Laser B/W (A3/A4) 2 Nos

CONTROL ROOM

A3 /A4 - Laser (COLOR) 1 No.


PLEASE REFER PADO CONFIG FOR DETAILS

A3 - LASER (B/W) Typical Unit Control Panel (Minimum)


ALARM A/M STN. SET PT. STN PB STN. CONT. SWITCH ANA IND. REC

HART MANAGEMENT SYSTEM

IND.

ETHERNET SWITCH
DIG. IND.

maxLINK

Interface Gateway to off-site PLCs, VMS, etc.

maxNET
RPUs (I/O + DPU + Network Components)
ETHERNET SWITCH
Time Sync. Signal

EQUIPMENT ROOM

RPU # 1

RPU # n

RPU # 1

RPU # n

RPU # 1

RPU # n

DPU
I/O Modules

DPU DPU
I/O Modules I/O Modules FG #BOILER FG #TURBINE

DPU
I/O Modules

DPU
I/O Modules FG #STN. C&I

DPU
I/O Modules

MASTER CLOCK SYSTEM

INTEGRATED ALARM ANNUNCIATOR

Remote I/O (Not Applicable)

FIELD

DBTC

LOCAL JB

LOCAL JB + -

CJC BOX

LOCAL JB

LOCAL JB E P POWER AMP. MOTORISED VALVES/ DAMPERS

~
MOTORS PUMPS/ BREAKERS

CONTACT INPUTS

ANALOG (4-20mA)

T/Cs

RTDs

10MBps 100MBps

CENTRAL CONTROL ROOM ELECTRONIC EQUIPMENT ROOM UPS / BATTERY ROOM SWAS ROOM COMPUTER ROOM HMI ROOM

COMPILATION OF C&I DOCUMENTS :


o PIDs OF RESPECTIVE UNITS . o INSTRUMENT SCHEDULES OF RESPECTIVE UNITS . o LOGICS o WRITE-UPS o DCS DOCUMENTS o INSTRUMENTATION CABLE SCHEDULES AND INTERCONNECTION .

CROSS- CHECKING OF ENGINEERING DRAWINGS :


o CABLE INTERFACE FROM DCS TO SWITCHGEAR/MCC FOR CORRECTNESS OF TERMINATIONS . o CABLE INTERFACE BETWEEN VARIOUS PANELS . o CABLE INTERFACE WITH FIELD INSTRUMENTS AND DRIVES o CHEKING OF INSTRUMENT SCHEDULES WITH RESPECT TO VARIOUS PIDS . o CHECKING OF LOGICS WITH RESPECT TO WRITE UPS .

AVAILABILITY BEFORE COMMISSIONING


o AVAILABILITY OF INSTRUMENT AIR IN FIELDS . o CALIBRATION AND ERECTION OF FIED INSTRUMENTS . o COMPLETION OF CABLING FROM FIELD/MCC/SWGR TO DCS o AVAILABLITY OF AIRCONDITIONING IN CONTROL ROOM PRIOR TO PANEL CHARGING . o AVAILABILITY OF POWER SUPPLIES TO DCS PANELS AND LOCAL INSTRUMENTS .

o MANPOWER AVAILBILITY FROM CONTRACTOR SIDE OF COMMISSIONING SKILLS . o AVAILABILITY OF TESTING INSTRUMENTS LIKE MULTIMETERS, CURRENT SOURCE ETC .

FIELD CHECKING
o CONTROL VALVE CALIBARION AND POSITION FEEDBACK ADJUSTMENT . o MOTORISED VALVE OPERATION, LIMIT/TORQUE SWITCH ADJUSTMENT . o INSTRUMENT MOUNTING AS PER HOOK UP DIAGRAM .

PRE POWER UP CHECKS : o CHECKING OF PANELS WITH RESPECT TO BILL OF MATERIALS . o CHECKING OF PANEL FOR LOOSNESS IN CONNECTION . o ELECTRONIC AND ELECTRICAL EARTHING . o PANEL MEGGARING . o PANEL CLEANLINESS .

POWER-UP CHECKS :
o VOLTAGE LEVEL AT INPUT OF PANEL .

o POLARITY CORRECTNESS IN CASE OF DC SUPPLY .


o FUSE HEALTHINESS .

o POWER SUPPLY AT VARIOUS LEVELS .


o POWER SUPPLY REDUNDANCY CHECKS .

PANEL CHECKS :
o PROGRAM LOADING IN THE PROCESSOR . o PROCESSOR REDUNDANCY CHECKS . o COMMUNICATION REDUNDANCY CHECKS .

DRY CHECKS :
o CONTROL VALVE OPERATION FROM CONTROL ROOM .

o MOTORISED VALVE OPERATION FROM CONTROL ROOM .


o SIMULATION OF INPUTS FROM FIELDS . o LOGIC CHECKS BY FORCING INPUT SIGNALS .

SG CONTROLS
TG CONTROLS STATION C&I CONTROLS OTHERS

SG CONTROLS
o FSSS- OIL ELEVATIONS, MILLS AND FEEDERS, FLAME SCANNERS o SADC o APRDS o HPBYPASS

TG CONTROLS
o TURBINE PROTECTION o GOVERNING o ATRS o TSI o OTHERS

STATION C&I
o BINARY LOGICS ( ID, FD, PA ,BFP, CEP AND MISC LOGICS) .

o ANALOG CONTROLS ( AIR FLOW, DRUM LEVEL, FURNCE PRESSURE AND OTHER CONTROLS) .
o CORDINATED MASTER CONTROL AND RUN BACKS .

OTHERS
o VIBRATION PANELS

o MASTER CLOCK
o HART MANAGEMENT SYSTEM

DURING TRIAL o AVAILABILITY OF PARAMETERS .

o TUNING OF AUTO LOOPS .


o GUIDANCE AND SUPPORT TO OPERATORS .

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