DCS Application in Thermal Power Plant

DCS APPLICATION
IN
THERMAL POWER PLANT
Thermal Power Plant
• Converts heat energy into electric power.
• Water heated turns to steam and spines a steam

turbine, which drives an electric generator.
• After it passes through turbine, steam condensed in a

condenser and recycled to where its heated.
• INPUT VARIABLES IN THERMAL POWER PLANT
* Fuel
* Combustion air
* Feed water flow
* Spray water flow
* Steam flow(turbine)
• OUTPUT VARIABLES IN THERMAL POWER PLANT
* Electrical Megawatt(output)
* Throttle steam pressure
* Super heater steam temperature
* O2 in fuel gas
* Furnace draft
* Drum level
Automation Strategy
BASIC FEATURES
1) Distributed Hierarchical System Structure which
involves
* complex function to be executed in main computer
along with MIS.
* reliable and flexible DDC systems for unit control.
* programmable controllers for sequence control.
* independent diagnostic function and protection.

Automation Strategy
2) Software for power plant automation and other
application function like plant logging, trip review,
performance calculation, and plant diagnostics.
3) Man-Machine Interface.
3) Communication
Automation Strategy
Factors to be considered in
power plant
1) Single loop doesn’t improve the availability of the plant
it’s extremely important to restrict the failure to a part of
plant, it doesn’t prompt single loop approach.
2) To minimize the effect of failure of the control system on

the plant, its important to functionally distribute the control
loops including the binary control. To improve system
availability the critical processor should be made redundant
Factors to be considered
in power plant
3) In PP redundancies are built in at main auxiliary level.
The failure of an important auxiliary like a fan, pump etc
may lead to the reduction of load but not to an unit trip.
Thus it’s important to consider structural redundancy of
plant. The system architecture should strike on optimal
balance between increased reliability and cost
effectiveness.
4)The functional distribution of the binary controls should

be made in relation to regulatory control loops. The binary
controls of the main auxiliaries related to regulatory control
loops should be performed in the same multi-loop
controller, enables faster interaction between these two.
Sub units of DCS for PP
1) Unit Control System for Automation Boiler Control
2) Diagnostic Function and Protection
3) Unit Control System for Turbine Governor
4) Unit Control System for Turbine Automation Start up

System
Automation Boiler Control
• Fuel controller, air controller and main controller can be
implemented on mc connected by I/O bus.
• Sub-controllers are provided for each major sub-control

loop and a main controller supervises each sub-
controller.
• Back-up control of main controller can also be provided

for better reliability.
• Manual/auto change over station are shown with each

actuator and manual over-ride control is possible in
emergency.
• Automatic boiler control is very important function of
boiler control.
• Perform functions such as furnace purge, sequential
control, emergency trip and continuous monitoring of
burner.
• Main functions are
* Automatic shut down of igniters and burners on
operator or computer command.
* Continuous monitoring of burner and igniters.
• Additional functions are all flame out and critical flame
out conditions of burner, open/close of air register.
• Input taken through magnetic relays and transmitted to
actuators in the form of relay contacts.
Diagnostic Function and
Protection
Diagnostic Function and
Protection
• Microcontroller checks the level and rate of change of
input signal.
• It also checks the level and error of output signal.
• In case of malfunctioning diagnosed, the module is
transferred to manual mode to prevent malfunction of
actuator.
• At the same time, alarm is generated on main system
and fault indication on module is put on.
Digital Electro Hydraulic
Governor
• Perform speed governing run up and load control by
controlling the position of the main stop
valve(MSV),steam control valve(SCV) and intercept
(ICV).
• Main input signal are speed, valve position, main stream
pressure, first stage inner shell pressure, re-heat bowl
steam pressure, condenser vacuum and generator
output.
• Diagram shows it’s electrical and mechanical interfaces.
Governor
Governor
Governor
• 2 counters-low speed
counter and high speed
counter to determine the
wide range speed.
• Turbine at low speed,
delay in detection for a
second
Turbine Speed Governor
• Turbine speed calculation is one of the important function
of governor.
• Main feature of the scheme
* turbine speed can be counted accurately in digital
form in 0- rated range(wide range).
* 3 detectors are provided, the signal where the
mutual difference between these 3 signal is smallest
is taken as true value by CPU logic operation.
* reasonability check is performed, the turbine which
is subjected to inertia, cannot show abrupt speed
change.
Governor
Valve Actuation
• Consist of hydraulic cylinder servo valve, solenoid and
dump valve for trip.
• High pressure operating oil from valve actuator is sent to
the hydraulic cylinder via shut off valve.
Governor
Automatic Start up System
Automatic Start up System
• Mc calculates the actual turbine rotor thermal stress by

heat transfer calculation around the rotor.
• The thermal stress decides the turbine start up

procedure
• Advanced control systems are used to control the turbine

speed or load or both so that thermal stress don’t
exceeds allowable limit.
Man-Machine Interface
• Important criteria is operator interface , as a window to
system utilisation.
• Main types of display used
overview display
x-y plot
performance display
alarm summary and history
logs and report display
mimic graphic display
group parameter display
Software System
• Key component for successful power plant automation.
• Establish high performance and reliable automation system.
• In an automation TPP, following on line functions need to be
performed by software
1. complex algorithm-
(boiler nd turbine start up, sub loop set point calculations)
2. total timing decision- (sub-looped sequence trigger)
3. direct digital control- (boiler and turbine load control, burner
control, generator excitation control )
4. sequence control of plant control.
Communication
• IEEE 802 standards
• Communication among the processor and to the

operator so its so important.
• IEEE 802.3 CSDMA/CD is used as the main

communicton system
THANK YOU

DCS Application in Thermal Power Plant

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DCS APPLICATION

• Water heated turns to steam and spines a steam

• After it passes through turbine, steam condensed in a

* reliable and flexible DDC systems for unit control.

* programmable controllers for sequence control.

* independent diagnostic function and protection.

2) To minimize the effect of failure of the control system on

4)The functional distribution of the binary controls should

2) Diagnostic Function and Protection

3) Unit Control System for Turbine Governor

4) Unit Control System for Turbine Automation Start up

• Sub-controllers are provided for each major sub-control

• Back-up control of main controller can also be provided

• Manual/auto change over station are shown with each

• Mc calculates the actual turbine rotor thermal stress by

• The thermal stress decides the turbine start up

• Advanced control systems are used to control the turbine

• Communication among the processor and to the

• IEEE 802.3 CSDMA/CD is used as the main

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