240-129686484 Minimum Level of Automation

Guideline Technology
Title: Power Plant Controls and Unique Identifier: 240-129686484

Instrumentation; Control
Systems; Level of
Automation; System Alternative Reference Number: N/A
Hierarchy and Control
Philosophy Guideline
Area of Applicability: Engineering
Documentation Type: Guideline
Revision: 1
Total Pages: 28
Next Review Date: February 2025
Disclosure Classification: CONTROLLED

DISCLOSURE
Compiled by Approved by Authorised by
………………………………….. ………………………………….. …………………………………..

Z.Y. Moola Dr. Craig Boesack Prudence Madiba
Chief Engineer Convenor Senior Manager
C&I Engineering Control Systems Care Group EC&I Engineering
Date: …………………………… Date: …………………………… Date: ……………………………
Supported by SCOT SC
…………………………………..
Dr. Craig Boesack
Power Plant C&I SC Chair
Date: ……………………………
SCOT Study Committee Number: SC08-03-W-21

SCOT Study Committee Name : Power Plant Control and Instrumentation
Power Plant Controls and Instrumentation; Control Systems; Unique Identifier: 240-129686484
Level of Automation; System Hierarchy and Control Revision: 1
Page: 2 of 28
CONTENTS
Page
1. INTRODUCTION ...................................................................................................................................................... 4
2. SUPPORTING CLAUSES ........................................................................................................................................ 4
2.1 SCOPE .............................................................................................................................................................. 4
2.1.1 Purpose ..................................................................................................................................................... 4
2.1.2 Applicability................................................................................................................................................ 4
2.2 NORMATIVE/INFORMATIVE REFERENCES .................................................................................................. 4
2.2.1 Normative .................................................................................................................................................. 4
2.2.2 Informative ................................................................................................................................................. 5
2.3 DEFINITIONS .................................................................................................................................................... 5
2.3.1 Disclosure Classification ........................................................................................................................... 7
2.4 ABBREVIATIONS .............................................................................................................................................. 7
2.5 ROLES AND RESPONSIBILITIES .................................................................................................................... 8
2.6 PROCESS FOR MONITORING ........................................................................................................................ 8
2.7 RELATED/SUPPORTING DOCUMENTS ......................................................................................................... 8
3. LEVEL OF AUTOMATION TECHNICAL DISCUSSION ......................................................................................... 9
3.1 CONTROL CONCEPT ...................................................................................................................................... 9
3.2 ANALOGUE (MODULATING) CONTROL ...................................................................................................... 10
3.2.1 Hierarchical levels for analogue control .................................................................................................. 10
3.2.1.1 Unit Control Level ............................................................................................................................ 10
3.2.1.2 Group Control Level (GC) analogue controls .................................................................................. 10
3.2.1.3 Sub-group Control Level (SGC) analogue control. ......................................................................... 10
3.2.1.4 Drive Control Level (For Analogue and Binary control). ................................................................. 11
3.3 BINARY (SEQUENCE) CONTROL. ................................................................................................................ 13
3.3.1 Hierarchical levels for binary control ....................................................................................................... 13
3.3.1.1 Unit Control level for binary control ................................................................................................. 13
3.3.1.2 Group Control level (GC) for binary control .................................................................................... 13
3.3.1.3 Sub-group Control level (SGC) for binary control ........................................................................... 14
3.3.1.4 Auxiliary Group Control Level (AXGC) for binary control ................................................................ 14
3.3.1.5 Drive Control Level for Binary Control. ........................................................................................... 14
3.4 LEVEL OF AUTOMATION – MINIMUM ESKOM OPERATIONAL REQUIREMENTS ................................... 16
3.4.1 Typical Unit Start-ups – Cold, Warm and Hot. ........................................................................................ 16
3.4.1.1 Unit sequencer ................................................................................................................................ 16
3.4.1.2 Unit Start-up sequences .................................................................................................................. 17
3.4.2 Typical BOP Plant Start-up operations ................................................................................................... 18
3.4.3 Unit: Normal Shut-Down .......................................................................................................................... 18
3.4.4 BOP: Normal Shut-Down ........................................................................................................................ 18
3.4.5 Unit: Emergency Shut-Down ................................................................................................................... 18
3.4.5.1 Scenario 1 - Boiler trip (with Turbine Inter-trip) and auxiliary power available. .............................. 18
3.4.5.2 Scenario 2 - Boiler trip (with Turbine Inter-trip) no auxiliary power except for essential power
for critical drives. .................................................................................................................................... 19
3.4.5.3 Scenario 3 – When power is restored after a unit black-out ........................................................... 19
3.4.5.4 Scenario 4 - When power is restored after a Power Station black-out ........................................... 19
3.4.6 Redundant Plant on standby ................................................................................................................... 19
3.4.6.1 Redundant Main Plant on standby .................................................................................................. 19
3.4.6.2 Redundant Auxiliary Plant on standby ............................................................................................ 19
3.4.7 Modes of Unit Operation ......................................................................................................................... 20
3.4.7.1 Co-ordinated Boiler Follow mode .................................................................................................... 20
3.4.7.2 Co-ordinated Turbine Follow mode ................................................................................................. 20
3.4.7.3 Other Modes of Unit Operation ....................................................................................................... 20
3.4.8 Unit Co-ordinator ..................................................................................................................................... 20
3.4.8.1 Unit Co-ordination during start-ups ................................................................................................. 20
3.4.8.2 Unit Co-ordination during load operation ........................................................................................ 21
CONTROLLED DISCLOSURE
When downloaded from the EDMS, this document is uncontrolled and the responsibility rests with the user to ensure it is in line
with the authorised version on the system.
Page: 3 of 28
3.4.8.3 Unit Co-ordination during shut-down operation .............................................................................. 21

3.4.8.4 Loading and unloading gradients .................................................................................................... 21
3.4.8.5 Fixed versus Sliding Pressure ......................................................................................................... 21
3.4.8.6 Capability computation and run-back control .................................................................................. 21
3.4.8.7 Unit Co-ordinator features - summary ............................................................................................. 22
3.4.9 Unit Islanding/Load Rejection .................................................................................................................. 22
3.5 PLANT CONTROL MODES ............................................................................................................................ 23
3.5.1 Remote Manual Control Mode ................................................................................................................ 23
3.5.2 Local Manual Control Mode .................................................................................................................... 23
3.5.3 Local Maintenance Control Mode............................................................................................................ 23
3.5.4 Local Control Station Equipment ............................................................................................................. 23
3.5.5 Local Control Panel Equipment ............................................................................................................... 24
3.5.6 Local Drive/Plant Control Level via LCS/LCP ......................................................................................... 24
4. AUTHORISATION .................................................................................................................................................. 25
5. REVISIONS ............................................................................................................................................................ 25
6. DEVELOPMENT TEAM ......................................................................................................................................... 25
7. ACKNOWLEDGEMENTS ...................................................................................................................................... 25
APPENDIX A : UNIT CO-ORDINATED COLD START-UP SEQUENCE ................................................................. 27
FIGURES
Figure 1: Hierarchical structure of a Control System .................................................................................................... 9
Figure 2: Example of an analogue hierarchical structure (Unit Control) .................................................................... 12
Figure 3: Example of a binary hierarchical structure (Unit Control) ........................................................................... 15
Page: 4 of 28
1. INTRODUCTION
The level of automation at Eskom’s existing coal-fired power station fleet is high, considering the
technologies that were available when they were built (1970s-1990s). DCS technology available today
affords the control engineer an opportunity to provide highly automated start-up and shutdown control
strategies for operations.
Changes in the industry have stimulated interest in plant automation. Base load stations are being used
in cycling service and two shift operation. Modern DCS are easily able to accommodate additional IO
required for start-up and shutdown automation and have extended functionality to be able to keep the
operator informed of start-up and shutdown progress. The demands of reliability and availability on our
plant and the introduction of legislation which governs the minimum network connection conditions (the
South African Grid Code), requires a certain level of automation from our new plant that must not
compromise on operational flexibility, reliability and availability of the plant.
Power plant automation requires significant investment for implementation and therefore, cost savings
from improved operations (Consistent best practice operation, optimised start-up and shutdown times,
real-time operator guidance) need to justify this investment.
2. SUPPORTING CLAUSES
2.1 SCOPE
This guideline covers the typical level of automation typically expected at an Eskom Coal Fired Power
Plant with a focus on the Control System hierarchical structures and operational requirements.
2.1.1 Purpose
Eskom Power Station plant designs vary widely from station to station including the level of automation
that was implemented at the station at the time of construction. This document describes to the reader
the minimum level of automation for Eskom power plants expected to achieve ESKOM’s operational
requirements for high plant reliability, availability and flexibility.
2.1.2 Applicability
This document applies to Unitised (Boiler and Turbine) and Balance of plant control systems of the coal
fleet of power stations at Eskom Holdings SOC for Greenfield (New) and Brownfield (Refurbishment)
projects. While this document provides examples for supercritical boilers, the requirements apply to drum
type boilers as well.
2.2 NORMATIVE/INFORMATIVE REFERENCES

Parties using this document shall apply the most recent edition of the documents listed in the following
paragraphs.
2.2.1 Normative
[1] VGB R 170Ce: Function-related documentation of power plant instrumentation and control in line
with operational requirements.
[2] VGB R 170B2e: Design standards for instrumentation and control equipment-Automation function.
[3] VGB B 106B4e: Identification of instrumentation and control tasks/functions in process systems
and identification of functions in instrumentation and control systems.
[4] 240-56030600: Steam Turbine Unit Islanding, Load Rejection and Speed Control Verification
Standard.
[5] 240-105453648: Fossil Fuel Firing Regulations Standard
Page: 5 of 28
2.2.2 Informative
[6] Chambers Dictionary of Science and Technology – 2007 edition.
[7] Automation of Fossil Plant Startup/Shutdown, Instrumentation and Controls Technology
Assessment, 1015710. Technical Update, March 2009, EPRI.
[8] 240 - 119416400 Generation AGC Design Standard for Power Plants
[9] The South African Grid Code as specified in the terms of the South African Electricity Regulation
Act
[10] SPC 46-8: Certification and Performance Monitoring Of Generation Reserves - System Operations
and Planning Procedure.
2.3 DEFINITIONS
Automation
Industrial closed-loop control system in which manual operation of controls is replaced by servo
operation.
Balance of Plant
The Balance of Plant refers to the supporting process plant that are common to all unitised process plant
areas of a Power Station. The balance of plant is required to be operational for the unit plants (Boiler and
Turbine) to operate. For Coal Fired Power Stations the balance of plant typically includes the following
plant areas:
 Water Treatment plant including Condensate Polishing Plant
 Coal Handling Plant
 Ash Handling Plant
 Low Pressure Services:
 Compressor Plant
 Auxiliary Cooling plant
 Demineralised, Potable and Raw Water Distribution Plant
 Fuel Oil Plant
 Flue-gas desulfurization (FGD) plant
Decentralised control system structure
A control system structure in which the software is functionally distributed at all hierarchical levels of
control.
Level of Automation
The level of automation states the general functions and the structure of automation of a power plant
(technological) process.
Operating Modes
Where local control in the plant is required, three distinct modes of operation are provided at control
system level to the control room operator: Remote (also referred to Automatic), Remote Manual and
Local Manual. Selection of the mode of control can be available at group, sub group, auxiliary group and
drive level depending on the particular process plant at hand. For the Local Manual Control Mode, a
Local Control Station (LCS) or Local Control Panel (LCP) is provided to the local operator. The LCS /
LCP typically have the following operating modes: Remote, Local and Maintenance. Sections 3.5.1,
3.5.2 and 3.5.3 detail the operating modes further.
Page: 6 of 28
Hierarchical structure
The control system is divided into several control levels forming a hierarchical structure, as shown in
Figure 1.
Unit
A unit is a steam generator, steam turbine-alternator and all the related equipment, including the step-up
transformer, operating together to produce electricity.
Unit co-ordinator
The Unit co-ordinator, residing within the highest automation level for a unit, co-ordinates the unit and
includes a unit start-up and shut-down sequencer and handling of major disturbances via capability
computation.
Supervised Fully Automatic
The term “supervised fully automatic” refers to an operating scenario where the operator monitors the
sequence steps of the fully automatic start-up or shut-down sequence. The sequence steps will typically
have hold points, where essential plant parameters to be aligned and checked or actions required by the
operator, (with the possibility of hold points being programmed) will be implemented in the start-up and
shut-down sequences.
Operator guide
A function within an automation Group or Sub-group sequencer that allows the operator to temporarily
pause a start-up or shut-down sequence at the specific step that the programme is in. This function
negates having to stop a running step programme completely and having to restart it from the first step.
Automatic Generation Control AGC – (Not to be confused with Auxiliary Group Control AXGC)
This is the automatic centralised closed loop control of generating units by means of the computerised
Energy Management System (EMS), currently TEMSE, at National Control. The AGC control system
regulates the system frequency during normal conditions by adjusting the power set-points of individual
generators.
Primary Frequency Control – Instantaneous Reserve
Primary Frequency Control is the automatic adjustment of a generator output (or customer load
reduction) in response to deviations in the system frequency, by means of the local governor control
system of the turbine. This control is proportional to the system frequency deviation. The governor dead
band is set at 0.15Hz.
Secondary frequency control – Regulating reserve
Secondary Frequency Control is mainly performed via automatic control of generator outputs to provide
a balance between the supply and demand in a control area. Automatic control is performed by the
Automatic Generation Control (AGC) system at the National Control Centre.
Dead band
With reference to Primary Frequency Control, dead band is the maximum frequency range over which
there is no automatic adjustment of the generator output or governing response.
Page: 7 of 28
Unit Islanding
Unit Islanding is the ability of a generating unit to suddenly disconnect from the Transmission System by
opening the High Voltage breaker and to control all the necessary critical parameters automatically to a
sufficient degree to maintain the turbine generator at speed and excited and supplying its own auxiliary
load.
Load Rejection
Load Rejection is the separation of a unit from the Transmission System by the opening of the generator
breaker after which the turbine returns to nominal synchronous speed.
Permissive Interlocks
Logic intended to be fulfilled in order for a drive to accept a start of stop command. e.g Start and Stop
Permissives.
Drive Protection
Logic utilised to initiate a trip of the related drive. e.g. Safety OFF.
Definition Description
Approved by The accountability of the Approver of the document is equivalent to the
specified role of Functional Responsible/Owner as identified in 240-
53114186 and 32-6 for Documents and Records Management.
2.3.1 Disclosure Classification

Controlled disclosure: controlled disclosure to external parties (either enforced by law, or
discretionary).
2.4 ABBREVIATIONS
Abbreviation Description
AGC Automatic Generation Control
AXGC Auxiliary Group Control
BOP Balance Of Plant
CPP Condensate Polishing Plant
FFFR Fossil Fuel Firing Regulations
FGD Flue-gas desulfurization
GC Group Control
HMI Human Machine Interface
IO Input/Output
LCP Local Control Panel
LCS Local Control Station
LOA Level of Automation
OEM Original Equipment Manufacturer
SGC Sub-Group Control
UC Unit Co-ordinator
Page: 8 of 28
2.5 ROLES AND RESPONSIBILITIES

Group Technology Plant Engineering C&I Plant COE Governance will develop the requirements for the
level of automation.
Group Technology Plant Engineering C&I Plant COE Design and Applications will implement the
requirements for the level of automation on projects.
2.6 PROCESS FOR MONITORING

The Engineering Discipline Managers will ensure this guideline is implemented on all projects.
2.7 RELATED/SUPPORTING DOCUMENTS

Not applicable.
Page: 9 of 28
3. LEVEL OF AUTOMATION TECHNICAL DISCUSSION
3.1 CONTROL CONCEPT

The concept and main software design principle of the control system is that it is decentralised but has a
logically hierarchical structure.
It is important to note that the configuration of the control system should not pose a multiple unit trip risk
and care should be taken to follow the principles of control system IO functional distribution and system
redundancy. The control system redundancy should mimic at least the process and electrical
redundancy principles for the plant at hand.
A Control System is typically divided into several control levels, as shown in Figure 1 below:
UNIT CONTROL
LEVEL
GROUP CONTROL
LEVEL
SUB-GROUP
CONTROL LEVEL
AUXILIARY GROUP
CONTROL LEVEL
DRIVE CONTROL
LEVEL
PLANT INTERFACES
Figure 1: Hierarchical structure of a Control System
The control system is divided into several control levels or layers. The higher the control level, the higher
the degree of automation, and the lesser the degree of manual control interventions will be necessary. A
higher level of control introduces operational comfort and brings in a higher degree of controllability and
safety to a complex process, as the system will react automatically in the specified manner, should any
abnormal condition be detected.
Each hierarchical control level has its own specific tasks and always depends on the subordinated lower
control levels. If a higher control level fails, the next lower control level will not be affected and will allow
the levels to control the power plant with full controllability and safety, but this state will require additional
supervision and/or manual interventions by the operator.
Hierarchical structures as shown in figure 1 ensure a higher level of operational flexibility. Manual
interventions at all levels of control should be possible at any time, without any specific operations
necessary on the superimposed levels, such as transfer from automatic to manual. This will eliminate the
Page: 10 of 28
operational risk of operating a complex plant in full manual mode, when the operator only requires
making a single or a limited number of operational interventions.
In the hierarchical structure the auxiliary group control level may or may not be required and will be used
where necessary.
3.2 ANALOGUE (MODULATING) CONTROL

The task of the analogue control system is to control the process variables according to set point values
and different parameters. The objective of analogue control higher up in the control hierarchy is to give
set point values to the subordinate control levels, and ultimately, to the drive controllers in such a
manner that the process requirements are fulfilled. Typically, such tasks are required for the start-up,
shut-down, steady state, load variations, disturbances and severe plant transient conditions. During all
these varying conditions, plant limitations should be adhered to.
The analogue control should be able to perform analogue and binary control actions for selection of set
point values, control parameters, control structures and process orders from the binary control. For
example, for automatic mode and set point selection during start-up or shut-down of the plant.
3.2.1 Hierarchical levels for analogue control

The hierarchical levels used for analogue controls are the:
 Unit control level (excluding BOP controls)
 Group control level
 Sub-group control level
 Drive control level
3.2.1.1 Unit Control Level

The Unit control level is the highest control level for the unit, comprising analogue control. The unit co-
ordinator resides at this level and would for example perform the master load control (MWe).
Subordinate within this level, is the main control level, which unites all functions that govern the next
subordinate group control level. The main boiler load controller (main fuel and main steam pressure
controllers), turbine controller and HP Bypass controller reside at this main control level.
3.2.1.2 Group Control Level (GC) analogue controls

The Group control level of analogue controls control the main systems of the Unit and BOP. They are,
for example:
Unit: The controllers for the Mill Loads, Combustion Air, Feed Water, Furnace Pressure, Primary Air
Pressure, Superheater and Reheater temperature control.
BOP: Water Treatment plant and Compressor Plant & Auxiliaries
The Group control level may contain a sub-group control level.
3.2.1.3 Sub-group Control Level (SGC) analogue control.

The subordinate controls of group controls reside at the Sub-group control level. Stand alone controllers
may also be found at this level.
They are for example:
Unit: Mill Primary Air flow and Mill outlet temperature controllers are subordinate controls for the Mill
Load controllers at group control level (for each mill). Stand-alone controllers such as the auxiliary steam
header pressure controller may be found here.
Page: 11 of 28
BOP: Water Treatment Plant: Demineralised water production trains, Individual Compressor and Dryers,
Coal/Ash Conveyors streams
3.2.1.4 Drive Control Level (For Analogue and Binary control).

The drive control level is the lowest hierarchical level. Its task is to control and monitor a particular drive.
The drive control level forms the link between the control room (operator) and the upper level of control
on the feedback and input side, with the switchgear installation and the process on the output side.
The drive control level contains the standard drive control function, the logic for the protection and
permissive interlocks of the individual drives, to protect the drives against damage.
The analogue and binary drive control level fulfils the following additional functions:
 Stopping of electrically actuated valves and dampers if the torque switch responds.
 Selectable stop of electrically actuated valves and dampers at their travel end position either by
torque or limit switch.
 Position and deviation from set point indication (analogue drives).
 Clear priority for manual, automatic, protective orders and for two commands given simultaneously.
For process plants, manual orders take priority. The manual commands need to be within the
process plant’s set operating limits. For such a scenario, the process plant’s operating interlocks
remain in place and will prevent the plant in operating in an unsafe condition or envelope.
 Signalisation and annunciation of disturbed status of an individual modulating drive (position control).
 Holding of position set point during transfer from automatic to manual modes of operation.
Page: 12 of 28
UNIT CONTROL LEVEL
UNIT CO-
ORDINATOR
HP BYPASS BOILER LOAD TURBINE

CONTROL CONTROL CONTROL
GROUP CONTROL LEVEL
Primary Furnace Total Air MILL A Feed Superhtr Reheater

Air Press Pressure Flow Load Mills B, C, D & E Water Temp Temp
Control Control Control Control Control control Control
Aux Steam Mill PA air

Pressure flow
Control Control
DRIVE CONTROL LEVEL
R/Heat Spray water valve LH
R/Heat Spray water valve RH

L/Hand SH Spray water valve
R/Hand SH Spray water valve

Aux Steam valve 1
Aux Steam valve 2
L/Hand PA Fan vanes
R/Hand PA Fan vanes
L/Hand ID Fan vanes
R/Hand ID Fan vanes
L/Hand FD Fan vanes
R/Hand FD Fan vanes
BFP A Speed control
BFP B Speed control
BFP C Speed control

Hot PA damper
Hot PA damper
FW Valve A control
FW Valve B control
Figure 2: Example of an analogue hierarchical structure (Unit Control)
Page: 13 of 28
3.3 BINARY (SEQUENCE) CONTROL.

Sequence control is a control method in which the control process is divided into single steps that are
processed one after another according to a pre-determined procedure. The operations to be performed
when starting a system take place on a step-by-step basis, in a pre-set sequence and are monitored
according to pre-set time intervals for execution of the commands to be performed at a given step by
means of “stepping” criteria.
The active programme step and step criteria that are not fulfilled, which prevent the programme from
advancing further, are displayed on the HMI.
The binary controls of any hierarchical level using sequential controls will always automatically
synchronise with the actual state of the process when they are initiated.
Orders or commands which are not allowed to be issued during the synchronisation process of the
sequence control, due to the process state, will be suppressed by “overrun” criteria.
The binary control system is configured such that:
 Start-up and shut-down of any process section is performed in a safe and reliable way and in the
shortest possible time.
 The drive itself or other related components are protected against damage.
 The operator receives uniform and clear information about the process under control.
 The operator has the capability to provide other operating or maintenance personnel with detailed
information about the nature and location of process plant faults when a step criterion has not been
met and the sequence has paused.
3.3.1 Hierarchical levels for binary control

The hierarchical levels used for binary controls are the:
 Unit control level
 Group control level
 Sub-group control level
 Auxiliary group control level
 Drive control level
3.3.1.1 Unit Control level for binary control

The Unit Control level is the highest binary hierarchical level if a Supervised Fully Automatic (“single
push button”) philosophy is adopted for start-up or shut-down of the unitised plant.
3.3.1.2 Group Control level (GC) for binary control

The Group Control level is the highest binary hierarchical level for BOP, and for the Unit if a Supervised
Fully Automatic (single “push button”) philosophy for start-up or shut-down of the plant is not
implemented. The GC controls a unique main group of drives in the plant or a group of main drives with
identical function. In the case of main drives with identical functions (such as 3 x 50% pumps), the GC
monitors the status of the Sub-Group Control functions below it, and it contains a selector for that main
SGC group. The selected main group is started automatically or manually via a Sub-group control.
The Group control level may be divided into several sublevels such as:
 Sub-group control level (SGC) and
 Auxiliary group control (AXGC) level
Page: 14 of 28
3.3.1.3 Sub-group Control level (SGC) for binary control

The Sub-group Control level controls a unique group of drives in the plant which are important to get the
main group started e.g. turbine oil supply.
The main characteristic of the Sub-group control level is the sequence control. It is the step-by-step
control method of a pre-set sequence and is monitored according to pre-set time intervals for execution
of the commands to be performed at a given step by means of “stepping” criteria.
The sequence steps can also stop in a pre-determined step, known as a “Hold Point”, awaiting an input
action to be decided by the operator, after which the sequence will continue from where it stopped up to
the last step of the SGC.
The SGC can also control a group of drives which are duplicated or threefold in the plant
For example, SGC can be found in :
Unit: Left hand or Right hand air/flue gas path, Boiler Feed Pump A, Boiler Feed Pump B, Boiler
Feed Pump C.
BOP: Water Treatment Plant
Condensate Polishing Plant (CPP)
The Balance of Plant process plants in the above examples, in particular, have plant sections that reside
in the units and that serve as a common plant:
The CPP plant consists of the CPP unit plant and the CPP regeneration plant in the Water Treatment
Plant area that functions as a common plant for the unit CPPs. The sequence control of the CPP plant is
however typically still fully controlled by the Water Treatment plant control system and supervised by the
Water Treatment Plant operator. A similar methodology applies for the sample analysis plant, which also
consists of unitised plant and common plant. The Water Treatment Plant control system, supervised by
the WTP operator, makes control decisions, such as increasing or decreasing the chemical dosing set-
points, based on the sample analysis measurements taken in the unitised plant.
3.3.1.4 Auxiliary Group Control Level (AXGC) for binary control

The Auxiliary Group Control level controls the auxiliary drives of a main drive. An AXGC is applied when
this auxiliary drive consists of more than one aggregate, with which it must work in conjunction with, for
example, two 100% duty L.P. Heater Drains pumps supplied where one is the duty pump and the other
the standby pump or, if the auxiliary drive does not have to work continuously to fulfil its duty.
For example:
Unit: An emergency lube oil pump or a lube oil pump which has to maintain a certain pressure in a tank.
BOP: Demineralised, Potable and Raw water distribution systems.
3.3.1.5 Drive Control Level for Binary Control.

As in the case of analogue controls, the drive control level is also the lowest hierarchical Ievel.
Refer to section 3.2.1.4.
Page: 15 of 28
GROUP CONTROL
GROUP CONTROL BOILER FEED PUMPS
LAY00EA100
LEVEL
SELECTOR
LAY00EA111
LAY10EA000 LAY20EA000 LAY30EA000

SGC BFP SGC BFP SGC BFP
CONTROL LEVEL
A B C
SUB-GROUP
START-UP PROGRAMME
LAY10EA001
Start-
down
Shut-
up
SHUT-DOWN PROGRAMME
LAY10EA051
LEVEL
AGC
DRIVE CONTROL (DC) LEVEL
AGC & (DC) BFP A FLG L/OIL PMP

AGC & (DC) BFP A L/O ACTR PMP
AGC & (DC) BFP A EM L/OIL PMP

AGC & (DC) BP A L/O CNT
BFP A CONVERTER CLG
BFP A MAIN L/OIL PMP
BFP A DIS VLV BYP
BFP A 11 KV CB
11BBA02GS301
BFP A DIS VLV
LAB30AA003Y
BFP A DRIVE
LAB11AA001
LAB10AA003
BPA10AP071
LAB11AP001
LAC10AP202
LAC10AP203
LAC10AP201
LAC10AP001
Figure 3: Example of a binary hierarchical structure (Unit Control)
Page: 16 of 28
3.4 LEVEL OF AUTOMATION – MINIMUM ESKOM OPERATIONAL REQUIREMENTS
3.4.1 Typical Unit Start-ups – Cold, Warm and Hot.

All unit start-ups shall have the ability of being started up Supervised Fully Automatic, from a Unit start-
up sequencer, located at the highest hierarchical control level, being the Unit Control level.
Dedicated main systems which can be in operation independently from the unit operation (e. g. auxiliary
steam system, cooling water system, fuel oil supply system, etc.) will be started by the operator from
their respective group control levels, as per the overall start-up procedure. An initial fully automatic start-
up of all the auxiliary systems of the unit is not foreseen.
The term “fully automatic”, with respect to the automation of the boiler and turbine systems is understood
to be as follows:
From a defined starting point, for example the collecting vessel being at normal starting level and the
turbine on barring, the main control loops of the boiler and turbine will be co-ordinated from the unit
control level in automatic mode.
All the main systems of the boiler, main turbine and water steam cycle, which are a sequential part of the
start-up or shut-down sequence (e.g. flue gas – combustion air, primary air, feed water and turbine start-
up) will be prepared by switching the group level control to automatic or stand by, whichever is
requested by the unit sequencer.
The term “supervised fully automatic” means the operator monitors the sequence steps of the fully
automatic start-up or shut-down sequence. The sequence steps will have hold points, where essential
plant parameters to be aligned and checked or actions required by the operator, (with the possibility hold
points being programmed) will be implemented in the start-up and shut-down sequences.
The start-up of the plant is performed by an operator in the Control Room.
3.4.1.1 Unit sequencer

The Unit start-up sequencer, when initiated by the operator, will start up the main systems in sequence
or in parallel, as determined by an optimised start-up sequence. The main systems on the boiler, main
turbine and water steam cycle, shall be started via dedicated sequence controls at Group/sub-group
control level, when required in the overall start-up sequence:
Pre-programmed hold points are designed into the start-up sequence programme where the process
conditions need to be supervised and confirmed, prior to the initiation of the next commands, e.g. the
initiation of starting and shutting down of each of the oil burner levels, starting and stopping each of the
mills.
The group and sub-group controls will start the various main systems fully automatic, by initiating and or
starting subordinate auxiliary group controls and drives, without operator intervention.
Pre-selection of main plant to be started, for example whether the A, B or C feed pump is to be started
first, is done at Group Control level, and is only altered via operator selection.
Should operator intervention be required or the sequence needs to be paused, the operator is able to
temporarily halt the sequence of the affected system’s Group/ sub-group control, via an Operator Guide
function within the Group or sub-group sequencer.
During start-up, the analogue control loops will be switched from the Manual to the Automatic mode via
their respective Group/sub group sequence controllers.
Page: 17 of 28
3.4.1.2 Unit Start-up sequences

Appendix 1 contains an example of a Unit co-ordinated cold start-up sequence with all the systems that
need to be started.
Typical criteria to be fulfilled prior to a supervised fully automatic start-up are:
 Start up (collecting) vessel level is greater than minimum
 Three mills are ready for service
 All pre-start requirements, as laid down in the Fossil Fuel Firing Regulations, are fulfilled
 All other pre-start conditions in accordance with the boiler OEM operating manuals and instructions
are fulfilled
 The main turbine alternator/generator (main machine set) is on barring with the main machine set
condition monitoring system being healthy. All the main turbine auxiliary systems are in service and
healthy
 The generator is pressurised with hydrogen with the Generator Care and Generator Condition
Monitoring systems being healthy. All the generator auxiliary systems are in service and healthy.
 Auxiliary steam is available
 Demineralised water is available for make-up to the cycle. If the unit has a condensate reserve tank,
the water level in this tank should be at a level equal to or greater than the normal working level
 The condenser hot well or air-cooled condenser condensate tank is at normal working level
 The feed water tank is at the starting level as recommended by the OEM
 The condensate and feed water system is primed and ready for service, including the auxiliary
cooling system
 Redundant main plant is available and on standby; redundant condensate extraction pump and at
least one boiler feed pump
 Condensate polishing plant, sampling and dosing systems are available
 All other pre-start conditions in accordance with the turbine, turbine auxiliaries OEM’s operating
manuals and instructions are fulfilled.
During start-up and shut-down, a supercritical boiler will be transiently operated below the Benson point.
The sequences will be organised in a manner that a stop at a critical point is prohibited.
Within the stable load range from Benson point to full load, the boiler and turbine shall be capable of
operating in the fully automatic mode, i.e. from the unit control level, while the further starting of oil
burners and mills sequential controls is left to the unit sequencer, considering the defined hold points.
Page: 18 of 28
3.4.2 Typical BOP Plant Start-up operations

The Balance of Plant process plants should have the ability to start-up in Supervised Automatic mode,
from GC or SGC level. Typically, once start-up at GC level is selected, the lower hierarchical level of
SGC is placed in Automatic mode by default.
A start-up initiation of a main group via SGC will place the drives and lower level AXGC into operation
through an automatic sequence. When the last sequence step is completed, the entire main group is
deemed to be fully in operation.
Typically main groups may be in operation independently from other main groups and these can be
started by the operator from the respective group control level, as per the plant area start-up procedure.
The start-up of the Balance of Plant is performed by operators located in the Outside Plant and Water
Treatment Control rooms. One operator is dedicated to control the Coal, Ash and Low Pressure Services
plants in the Outside Control Room. The other operator is dedicated to control the Water Treatment
Plant in the Water Treatment Plant Control Room. Power Stations equipped with Flue-gas
desulfurization technology have a dedicated control room and FGD plant operator.
3.4.3 Unit: Normal Shut-Down

As in the case of start-ups, all unit shut-downs shall have the ability of being shut down Supervised Fully
Automatic, from a unit shut-down sequencer, located at the highest hierarchical Unit Control level.
The shutdown of the plant is performed by an operator from the Control Room. Pre-programmed hold
points are designed into the shut-down sequence programme, where the process conditions need to be
supervised and confirmed, prior to the initiation of the next commands. For example, the initiation of
each of the oil burner levels, stopping each of the mills, turbine steam cooling if required, the initiation of
diverting steam flow from the turbine to the HP & LP Bypasses, changing over from Benson to
Circulation, start of the turbine de-loading process and the shutting down of mills and oil burners.
Post boiler shut-down purge is typically initiated manually.
3.4.4 BOP: Normal Shut-Down

As in the case of start-ups, all plant shut-downs should have the ability of being shut down automatically
via GC and SGC of the main groups.
The shut-down of the plant area is performed by the respective operator from the Control Room. Pre-
programmed hold points are typically designed into the shut-down sequence programme, where the
process conditions need to be supervised and confirmed, all prior to the initiation of the next command.
3.4.5 Unit: Emergency Shut-Down

The following scenarios will not require any sequencer.
3.4.5.1 Scenario 1 - Boiler trip (with Turbine Inter-trip) and auxiliary power available.
The automation system must automatically safeguard the plant without any operator intervention. Trips
are usually initiated by a protection system such as the Boiler Protection System or Turbine Protection
system independent of the Control System.
Boiler: the automation system must maintain the boiler secondary air flow at the value prior to the trip
and then reduce or increase the total air flow to minimum as required by the FFFR. The Mills must
automatically be shutdown per requirements as laid down by the Boiler OEM.
Status feedbacks are required in order to obtain the releases required to proceed with the Post Boiler
Trip Purge. Under this scenario, Post Boiler Trip Purge is then manually initiated.
Page: 19 of 28
Turbine: Following a boiler trip, the turbine trip is immediately initiated automatically (turbine emergency
stop valves trip close) and the generator breaker is opened when reverse power is detected. All turbine
plant and auxiliaries are kept in service or automatically shut down, as required for safe plant shut-down.
If a restart is decided, the unit sequencer will be used to restart the unit.
3.4.5.2 Scenario 2 - Boiler trip (with Turbine Inter-trip) no auxiliary power except for essential
power for critical drives.
Boiler and turbine essential plant as defined by the boiler and turbine OEM’s will automatically be driven
to the status that is safe for the unit. This operation must not require any operator initiation.
Auxiliaries required for the safe run-down of the plant, for example emergency lube oil pumps, will be
started automatically.
3.4.5.3 Scenario 3 – When power is restored after a unit black-out

Full automation from Group Control level shall be available, so that the operator is able to initiate all the
necessary operations to ensure safe status of the unit.
3.4.5.4 Scenario 4 - When power is restored after a Power Station black-out

Full automation from Group Control level on the units and BOP shall be available, so that the operators
at the respective control stations are able to initiate all the necessary operations to ensure a safe status
for the unit.
Auxiliary steam will have to be restored manually via the auxiliary boiler.
3.4.6 Redundant Plant on standby

Where redundant components are provided, automatic transfer to the standby equipment shall be
provided should failure occur. This does not apply to mills and oil burners.
The level of automation for redundant plant is divided into a minimum of two categories - for main plant
and for auxiliary plant.
3.4.6.1 Redundant Main Plant on standby

Main plant that contains redundancy is, for example, the feed water and condensate extraction pumps.
Level of automation for this plant is done at Group and Sub-Group level. As a minimum, the SGC’s must
cater for a sequence programme that ensures the pumps reach their standby status, prior to linking with
their respective Group Controllers.
The Group Controllers must cater for fully automatic on-load (above Benson point) pump changeovers,
upon the order being given by the operator.
The Group Controllers must also cater for the automatic start and immediate take-over of the standby
plant in case of failure (trip) of the duty pumps.
3.4.6.2 Redundant Auxiliary Plant on standby

The level of automation for all plant, except main plant as described above, that contains redundancy
e.g. redundant lube oil pumps, drain pumps, valves, fans and blowers, as a minimum, is achieved at
Auxiliary Group Control level.
Page: 20 of 28
3.4.7 Modes of Unit Operation

The Units are able to be operated in two control modes; the Co-ordinated Boiler Follow mode of
operation (turbine leads and the boiler follows) and in the Co-ordinated Turbine Follow mode of
operation (boiler leads and the turbine follows).
3.4.7.1 Co-ordinated Boiler Follow mode

In Co-ordinated Boiler Follow mode, the turbine leads and controls the generated power, according to
the unit load set point generated by the unit co-ordinator, at unit control level. The boiler load set point,
generating the main fuel and boiler steam pressure set points, is also governed by the unit load set point.
The boiler firing is controlled by the fuel set point and corrected by the boiler steam pressure controller.
3.4.7.2 Co-ordinated Turbine Follow mode

In Co-ordinated Turbine Follow mode, the boiler load set point is set according to the unit load set point
generated by the unit co-ordinator, at unit control level. The turbine then controls the steam pressure
according to the generated steam pressure set point. The boiler steam pressure controller, which
normally adjusts the fuel, is rendered ineffective during this mode of operation.
3.4.7.3 Other Modes of Unit Operation

The units will also be required to supply essential ancillary services, namely Regulating Reserve
(Automatic Generation Control/Secondary Frequency Control) and Instantaneous Reserve (Primary
Frequency Control).
In order to be able to supply these reserves effectively, the units will have to operate in the Co-ordinated
Boiler Follow mode of operation (turbine leads and the boiler follows).
Only during major plant trips (capability run-backs) will the units be expected to operate in the Co-
ordinated Turbine Follow mode of operation. This mode of operation will also be possible during normal
operation when initiated by the operator. Co-ordinated Turbine Follow mode of operation will not be used
for System Operations Automatic Generation Control (secondary frequency control), due to the System
Operators stringent requirement for rapid and accurate response to load set point changes.
For both modes of operation, the unit load set point will be adjustable at the Unit Control level by the
operator. For Co-ordinated Boiler Follow mode of operation, the unit load set point will also be adjustable
from the external load dispatching system of National Control (System Operator), for Automatic
Generation Control (secondary frequency Control), from minimum to maximum load capacity. Preset
limits, according to milling plant capability and safe boiler operation, will be defined. For more information
on the Generation AGC Design Standard for Power Plants refer to [8].
The automation level for both modes of operation, Co-ordinated Boiler Follow and Co-ordinated Turbine
Follow, will be at the Unit control level and accomplished by a Unit Co-ordinator.
3.4.8 Unit Co-ordinator

A Unit Co-ordinator contains the sophisticated control algorithms and logics to affect complete control
co-ordination between the boiler and turbine. This co-ordination function is required for start-ups, load
operation, shut downs and disturbances.
3.4.8.1 Unit Co-ordination during start-ups

During start-ups, the firing rate and the pressure set point are generated in a start-up controller. This
controller will control until the boiler and turbine are ready for co-ordination i.e. when the boiler is in
Benson operation and the HP Bypass valves have closed. Once the bypass valves have closed, the unit
Page: 21 of 28
will be ready for Co-ordinated Boiler Follow mode of operation, provided the boiler firing and turbine load
demands are matched.
3.4.8.2 Unit Co-ordination during load operation

During load operation, when the boiler is in Benson operation and the HP Bypass valves have closed,
the unit must be able to operate in either the pre-selected Co-ordinated Boiler follow or Co-ordinated
Turbine follow modes of operation.
Advanced control, using model based co-ordinated control for the boiler and turbine is recommended.
Caution must be exercised in that the model based control does not unduly retard the turbine load
demand during load set point changes, as there are stringent requirements from the System Operator in
terms of load responses to changes in load set point.
3.4.8.3 Unit Co-ordination during shut-down operation

Unit co-ordination is required up to the point where the HP Bypass system is placed into operation during
shut-down.
3.4.8.4 Loading and unloading gradients

Loading and unloading gradients of both the boiler and turbine during all stages of operation, start-ups,
load operation and shut-downs, are automatically determined by the allowable thermal margins of the
boiler and turbine.
3.4.8.5 Fixed versus Sliding Pressure

For supercritical boilers with sliding pressure control capability, the default mode of operation is the
sliding pressure mode of operation (modified sliding pressure if applicable).
3.4.8.6 Capability computation and run-back control

The unit co-ordinator will contain the unit capability computation and all the run-back logics required for a
successful unit run-back, in cases of major plant failure (e.g. loss of one of the boiler feed pumps and
failure of the standby pump to start successfully). The automation level required is that the initiation, run-
back and settling of the unit occurs automatically and without any operator intervention. The only
operator intervention allowed is for the acceptance of transient alarms.
During run-back operation, the unit will switch from Co-ordinated Boiler Follow to Co-ordinated Turbine
Follow automatically. The turbine will control the pressure, while the boiler will deload rapidly to the new
and safe boiler load condition, which can be handled by the remaining plant in service.
Page: 22 of 28
3.4.8.7 Unit Co-ordinator features - summary

In summary, the unit co-ordinator will contain the following control loops and/or features:
 A Start-up fuel set point elaboration
 An on-load set point controller for unit load, adjustable from the superimposed load dispatcher
(Automatic Generation Control/Secondary frequency control)
 The boiler fuel set point during both modes of operation (boiler follow and turbine follow)
 The load set point for the turbine during boiler follow mode of operation
 The steam pressure set point computation for the boiler, turbine and HP bypass controllers
 The acceptance of signals from the boiler and turbine stress evaluators, which will limit the boiler and
turbine loading gradients if the allowable thermal margins of the boiler or turbine are consumed.
 The Run-back set point of fuel and automatic adjustment of the pressure set point during major plant
disturbances
 Pre-selection for Automatic Generation Control On/Off
 Pre-selection for Primary Frequency Control On/Off
 Pre-selection for Co-ordinated Boiler or Turbine Follow modes
3.4.9 Unit Islanding/Load Rejection

The unit co-ordinator will also contain the capability computation and all the run-back logics required for
a successful Unit Islanding and/or Load Rejection. The automation level required is that the run-back
initiation to a pre-determined boiler load and settling of the unit occurs automatically, with operator
supervision only and without any undue operator intervention.
During this severe transient, the only operator intervention expected is for the acceptance of transient
alarms. Re-synchronisation to the grid after Islanding/Load Rejection and subsequent loading of the unit
is accomplished by only one operator, at Group/sub-group control level.
Unit co-ordination is not required during Unit Islanding or load rejection as the boiler load is set to a pre-
determined level and the turbine controller maintains the turbine at nominal speed with or without
auxiliary generated load.
Page: 23 of 28
3.5 PLANT CONTROL MODES

Where local control facilities are required three distinct modes of operation are typically provided:
Automatic, Remote Manual and Local Manual. Selections of modes of control will be available at group,
sub group and drive level as indicated below.
3.5.1 Remote Manual Control Mode

In Remote Manual mode, the control room operator at the control room’s HMI initiates control of the
individual devices. Selection of this mode is from the Control Room HMI. All the safety and process
interlocks remain active in this mode. This mode will be selectable from either group or sub group level
where devices are reporting to the group or sub group.
3.5.2 Local Manual Control Mode

In local manual mode, the control of devices is initiated from the field mounted LCS or LCP. Control on
the Unit and Balance of Plant is primarily centralized and to achieve this control mode, in normal
operational circumstances, the control room operator selects the "Local" mode at the control room HMI,
which provides a release signal to the LCS or LCP. The control functions are then activated so that the
Local Plant Operator is allowed to initiate control of the individual devices. In this mode all the safety and
process interlocks remain active. This mode will be selectable from group or sub group level where
devices are reporting to the group or sub group.
3.5.3 Local Maintenance Control Mode

In local maintenance mode, the control of devices is initiated from the field mounted Local Control
Station. To achieve this function the control room operator selects the "Maintenance" mode at the control
room HMI, which provides a release signal to the Local Control Station. The control functions are then
activated so that the Local Plant Operator is allowed to initiate control of the individual control devices in
the field. In this mode all the process interlocks are inactive with the safety interlocks still active. This
mode will be selectable from sub group level where devices are reporting to the sub group. Examples of
plant areas with this mode include the Coal and Ash plant conveyors.
3.5.4 Local Control Station Equipment

Each LCS will be equipped with the following minimum functions, and these functions form an integrated
part of the Control System:
 Local/Remote/Maintenance selector switch

 Emergency stop pushbutton
 Lamp test pushbutton
 Local indication lamp
 Open/Close (Stop/Start) pushbuttons
 Open/close (Stopped/Running) indicating lamps
 Fault acknowledge pushbutton
 Fault indication lamp
Plant areas that have exposed or moving machinery are required to include an Emergency Push button
on the LCS. The Emergency Push button should be hardwired directly to the Electrical Switchgear of the
Page: 24 of 28
affected drive(s) to trip the drive and a signal sent to the control system in parallel for information
purposes.
3.5.5 Local Control Panel Equipment

The LCP includes the functions of the LCS, with the added benefit of providing the local operator much
more process information of the plant that the operator is controlling. The LCP typically provides the
operator information on process alarms, overall plant status, status of applicable interlocks, sequence
control conditions and other information that is deemed necessary to control the local process plant. The
LCP typically presents the information via a digital software MIMIC, although hardware MIMICs are also
found in some plant areas.
3.5.6 Local Drive/Plant Control Level via LCS/LCP

For most Balance of Plant areas, the local operation via the LCS/LCP is intended primarily for the
Maintenance mode. The exception to this is primarily the Water Treatment and CPP Plants where the
Station Chemist conducts regular monitoring and the operator makes interventions via the LCP.
However, all plants as a whole are normally run in fully automatic (remote) control mode.
There are Balance of Plant areas that do not have process storage or an operational buffer and are vital
to the units operation, an examples is the Main Cooling Water plant. These plants are classified as
critical and their unavailability could lead to a MUT, even if unavailable for only a short period of time. It
is recommended, that for the critical Balance of Plant areas, the LCSs and LCPs are configured to have
an automatic release to Local Mode should the control room HMI fail and allow the local operators to
monitor and control the plant further with all process interlocks in place. As a further save guard, it is
recommended that the LCSs and LCPs for the critical plants are tying into the process or automation
layer of the control system and not at the application layer to minimize the risk of LCSs or LCPs
becoming unavailable due to an application server failure.
Page: 25 of 28
4. AUTHORISATION
This document has been seen and accepted by:
Name & Surname Designation
Craig Boesack C&I Plant COE
Andre Van Den Berg C&I Plant COE
Charles Kigozi C&I Plant COE
Christoph Kohlmeyer C&I Plant COE
Eugene Motsoatsoe C&I Plant COE
Isaac Sibiya C&I Plant COE
Khaya Sobuwa C&I PEI
Mlondi Nkambule C&I Plant COE
Ndoda Mazibuko C&I Plant COE
Pravin Govender C&I Plant COE
Xolelwa Siboza C&I Plant COE
Mapula Majola C&I Plant COE
Paul Du Plessis C&I PEI
5. REVISIONS
Date Rev. Compiler Remarks
November 2018 0.1 Z Y Moola Initial draft as mandated through SCOT Charter. Medupi
specific LOA (N. Baruffa) revised to fleetwide document and
combined with BOP LOA and Plant Control Modes
documents.
January 2020 0.2 Z Y Moola Comments Update after Review Process
January 2020 1 Z Y Moola Final Document for Authorisation and Publication
6. DEVELOPMENT TEAM
The following people were involved in the development of this document:
 Zubair Y Moola
 Nerino Baruffa
 Christoph Kohlmeyer
7. ACKNOWLEDGEMENTS
The following people were involved in the development of Medupi Level of Automation document which
was used as the basis for this Fleetwide Guideline:
 Nerino Baruffa (PEI – C&I Engineering)
 Zubair Moola (GTD – C&I Engineering)
 Karlheinz Jordan (Integration Consultant – EVONIK)
 Volkmar Bobon (Project Manager – EVONIK)
Page: 26 of 28
 Schalk Van Der Merwe (GTD – C&I Engineering)

 Bradley Doorsamy (GTD – C&I Engineering)
 Cyril De Beer (GTD – Turbine Engineering)
 Gary De Klerk (GTD – Turbine Engineering)
The following people were involved in the development of the BOP Level of Automation document which
was combined with the Medupi specific document to produce this fleet wide guideline.
 Paul du Plessis (C&I PEI)
 Nerino Baruffa (C&I PEI)
 Jorge Nunes (C&I PEI)
Page: 27 of 28
APPENDIX A: UNIT CO-ORDINATED COLD START-UP SEQUENCE
Page: 28 of 28

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Guideline Technology

Title: Power Plant Controls and Unique Identifier: 240-129686484

Documentation Type: Guideline

Next Review Date: February 2025

Disclosure Classification: CONTROLLED

Compiled by Approved by Authorised by

………………………………….. ………………………………….. …………………………………..

Date: …………………………… Date: …………………………… Date: ……………………………

SCOT Study Committee Number: SC08-03-W-21

3.4.8.3 Unit Co-ordination during shut-down operation .............................................................................. 21

2.2 NORMATIVE/INFORMATIVE REFERENCES

2.3.1 Disclosure Classification

2.5 ROLES AND RESPONSIBILITIES

2.6 PROCESS FOR MONITORING

2.7 RELATED/SUPPORTING DOCUMENTS

3. LEVEL OF AUTOMATION TECHNICAL DISCUSSION

3.1 CONTROL CONCEPT

3.2 ANALOGUE (MODULATING) CONTROL

3.2.1 Hierarchical levels for analogue control

3.2.1.1 Unit Control Level

3.2.1.2 Group Control Level (GC) analogue controls

3.2.1.3 Sub-group Control Level (SGC) analogue control.

3.2.1.4 Drive Control Level (For Analogue and Binary control).

HP BYPASS BOILER LOAD TURBINE

Primary Furnace Total Air MILL A Feed Superhtr Reheater

Aux Steam Mill PA air

R/Heat Spray water valve LH

R/Heat Spray water valve RH

R/Hand SH Spray water valve

Aux Steam valve 2

L/Hand PA Fan vanes

R/Hand PA Fan vanes

L/Hand ID Fan vanes

R/Hand ID Fan vanes

L/Hand FD Fan vanes

R/Hand FD Fan vanes

BFP A Speed control

BFP B Speed control

BFP C Speed control

3.3 BINARY (SEQUENCE) CONTROL.

3.3.1 Hierarchical levels for binary control

3.3.1.1 Unit Control level for binary control

3.3.1.2 Group Control level (GC) for binary control

3.3.1.3 Sub-group Control level (SGC) for binary control

3.3.1.4 Auxiliary Group Control Level (AXGC) for binary control

3.3.1.5 Drive Control Level for Binary Control.

LAY10EA000 LAY20EA000 LAY30EA000

AGC & (DC) BFP A FLG L/OIL PMP

AGC & (DC) BFP A EM L/OIL PMP

BFP A CONVERTER CLG

BFP A MAIN L/OIL PMP

BFP A DIS VLV BYP

3.4 LEVEL OF AUTOMATION – MINIMUM ESKOM OPERATIONAL REQUIREMENTS

3.4.1 Typical Unit Start-ups – Cold, Warm and Hot.

3.4.1.1 Unit sequencer

3.4.1.2 Unit Start-up sequences

3.4.2 Typical BOP Plant Start-up operations

3.4.3 Unit: Normal Shut-Down

3.4.4 BOP: Normal Shut-Down

3.4.5 Unit: Emergency Shut-Down