Theme:

Power plant C&I (IPC) systems

&
Tending to Zero Forced Outage
by
Internalization of Best Practices

Presentation Outline:
1.Some definitions & basics of Pressure, Flow & Temp. measurement

2. Categorization of C&I systems based on location of application

3. Division of power plant C&I systems based on functionality & type of
application
4.Evolution of C&I systems and latest trend in technology
5.NTPC at a glance and maintenance practices of C&I systems
6. Some case studies

Measurement: Pressure
Outline:

Some Definitions

Pressure Units

Manometers

Elastic Pressure Sensors

Electrical Pressure Sensors

Pressure Switches

Snubbers & Siphon Tubes

Measurement: Pressure
Terminology

Accuracy : Closeness with which an instrument reading approaches

the true value of the variable being measured.

Precision : A measure of reproducibility of the measurements; i.e.

given a fixed value of a variable, precision is a measure of the degree
which successive measurements differ from one another.

Sensitivity : The ratio of output signal or response of the instrument

to a change of input or measured variable.

Resolution : The smallest change in measured value to which the

instrument will respond.

Error : Deviation from the true value of the measured variable.

Measurement: Pressure
Repeatability refers to the ability of a pressure sensor to provide
the same output with successive applications of the same pressur
e.
Hysteresis is a sensor's ability to give the same output at a given
pressure while increasing and decreasing the pressure.

Measurement: Pressure
Pressure : Definitions

Definition: Force per unit area

Absolute pressure

Atmospheric pressure

Differential pressure

Gauge pressure

Importance : Pressure measurement is critical for safe and optimum

operation of processes such as steam generation, hydraulic equipment
operation, air compression, vacuum processing etc.

Measurement: Pressure
Zero Reference , Gauge, Absolute, Atmospheric
Pressure
Any pressure above atmosphere is called gauge pressure
Any pressure below atmosphere is a vacuum (negative gauge pressure)
Absolute pressure (psia) is measured from a perfect vacuum

Differential Pressure has no reference to either absolute vacuum or

atmospheric pressure

Measurement: Pressure
Units
The SI unit for pressure is the Pascal (Pa);1Pa= 1 Nm-2
Non-SI unit pound (Lb) per square inch (psi) and bar are commonly used
Pressure is sometimes expressed in grams-force/cm 2or as kgf/cm2 (KSC)
1 atm=1.03 ksc=14.696 psi=760mmHg=10000 mmWC
=101325 Pa
Standard pressure:Pressure of normal (standard) atmosphere is defined as
standard pressure

Measurement: Pressure
Pressure Measuring devices

Manometers
using water ,mercury and other liquids of known density
For measuring low pressures.
Mechanical/Elastic Pressure Sensors
Electrical Pressure Transducers
For measuring pressure of all ranges for telemetering purposes.

Manometer:

A simple pressure standard

May be used for gauge, differential, and absolute measurements with a suitable reference.

Useful mainly for lower pressure work because the height of the column of mercury will
otherwise become very high.

The difference in column heights gives the pressure reading

Measurement: Pressure
Elastic Pressure Sensors
The basic pressure sensing elements:
A: C-shaped Bourdon tube , B: Helical Bourdon tube , C: flat diaphragm
D: Convoluted diaphragm, E: Capsule , F: Set of bellows

Measurement: Pressure
Electrical Pressure Sensors
Potentiometer Sensor
2. Inductive
3. Capacitive
4. Piezoelectric
5. Strain Gauge
1.

Usually generate output signals in the mV

range (spans of 100 mV to 250 mV).
In transmitters, these are amplified to the
voltage level (1to 5 V) and converted to
current loops, usually 4-20 mA dc

Measurement: Pressure
Pressure Switches
Applications
Alarm (Status)
Shutdown (Hi/Lo Limits)
Control (ON/OFF)
A switch is an instrument that automatically senses some process
variable (such as pressure) and provides an on/off signal relative to
some reference point.
Set Point

Sensing
Element

Conditioning
Circuit

Bourdon Tube
Bellows
Diaphragm
Strain Gauge

Mechanical
Switch
Transistor

Measurement: Pressure
High Pressure In High Temperature
* When high process temperatures are present, various methods
of isolating the pressure instrument from the process are used.
* These include siphons, chemical seals with capillary tubing for
remote mounting, and purging.

Snubbers & its use

Chemical Seal
Siphon

Measurement: Pressure
Pressure Snubbers

To filter out pressure spikes, or to average out pressure pulses, snubbers are
installed between the process and the instrument
Instrument indicates avg pr.

Snubber

Before use

After use

when one is interested in the measurement of fast, transient pressures (such as

to initiate safety interlocks on rising pressures), snubbers must not be used, as they delay
the response of the safety system.

Measurement: Pressure
Chemical Seal or diaphragm Protector
Chemical seals are used when media can falsify the
pressure measurements due to high temperature, high
viscosity or their property to crystallise

Measurement: Pressure
Siphon
A siphon is a coiled tube. This coil provides a large cooling surface and
the trap created prevents the condensate from draining away.
A siphon is required for hot condensing. fluids, such as steam, to assure
a liquid trap.
It is used to prevent live steam from entering and damaging the device.
It is used to protect the instrument from hydraulic or thermal shocks.
The two most common forms of siphon tube are the 'U' and Pigtail
types.

Measurement: Flow
Types of flow meters:
1.
2.
3.
4.
5.

Orifice Flow meter

Vortex flow meter
Ultrasonics flow meter
Coriolis Mass Flow meter
Major issues for selecting flow meters
Orifice Flow-meters
Several sensors rely on the pressure drop
or head occurring as a fluid flows by a
resistance. The relationship between flow
rate and pressure difference is determined
by the Bernoulli equation.

Measurement: Flow

Orifice Flow-meters
An orifice plate is a restriction with an opening smaller than the pipe diameter which
is inserted in the pipe; the typical orifice plate has a concentric, sharp edged opening.

Because of the smaller area the fluid velocity increases, causing a corresponding
decrease in pressure.

The flow rate can be calculated from the measured pressure drop across the orifice
plate, P1-P3.

The orifice plate is the most commonly used flow sensor, but it creates a rather large
non-recoverable pressure due to the turbulence around the plate, leading to high
energy consumption.

Measurement: Flow
Venturi Tube

The change in cross-sectional area in the venturi tube causes a

pressure change between the convergent section and the throat, and
the flow rate can be determined from this pressure drop. Although
more expensive that an orifice plate; the venturi tube introduces
substantially lower non-recoverable pressure drops

Measurement: Flow
Pitot Tubes
Pitot tubes were invented by Henri Pitot in 1732 to measure the
flowing velocity of fluids. Basically a differential pressure (dp) flow
meter, a pitot tube measures two pressures: the static and the total
impact pressure.

Pitot tubes are used to measure air flow in pipes, ducts, stacks, and
liquid flow in pipes, open channels.

While accuracy and rangeability are relatively low, pitot tubes are
simple, reliable, inexpensive, and suited for a variety of
environmental conditions, including extremely high temperatures
and a wide range of pressures.

Measurement: Flow
Pitot Tubes
A single-port pitot tube can measure the flow velocity at only a single point
in the cross-section of a flowing stream.
The probe must be inserted to a point in the flowing stream where the flow
velocity is the average of the velocities across the cross-section, and its
impact port must face directly into the fluid flow.

Measurement: Flow
Pitot Tubes
The point velocity of approach (VP) can be calculated by taking the square root
of the difference between the total impact pressure (PT) and the static pressure (P)
and multiplying that by the C/D ratio, where C is a dimensional constant and D is
density:

The pitot tube measures the static and dynamic (or impact) pressures of the fluid
at one point in the pipe.

The flow rate can be determined from the difference between the static and
dynamic pressures which is the velocity head of the fluid flow.

Measurement: Flow
Vortex Flow-meters

This measuring principle is based on the fact that vortices are

formed downstream of an obstacle in a fluid flow, e.g. behind a
bridge pillar.

This phenomenon is commonly known as the Krmn vortex

street.

Measurement: Flow
Vortex Flow-meters
This is detected by a sensor, such as capacitive sensor and
fed to the electronic processor as a primary, digitized, linear
signal.
Capacitive sensors with integrated temperature measurement
can directly register the mass flow of saturated steam as well.

Universally suitable for measuring liquids, gases and steam

Largely unaffected by changes in pressure, temperature and
viscosity
High long-term stability (lifetime K factor), no zero-point drift
No moving parts
Marginal pressure loss

Measurement: Flow
Ultrasonic flow-meters
Swimming against the flow requires more power and more time
than swimming with the flow. Ultrasonic flow measurement is
based on this elementary transit time difference effect.

Two sensors mounted on the pipe simultaneously send and receive

ultrasonic pulses.
At zero flow, both sensors receive the transmitted ultrasonic wave at the
same time, i.e. without transit time delay.
When the fluid is in motion, the waves of ultrasonic sound do not reach the
two sensors at the same time.

Measurement: Flow
Ultrasonic flow-meters

This measured "transit time difference" is directly proportional to

the flow velocity and therefore to flow volume.

By using the absolute transit times both the averaged fluid velocity and
the speed of sound can be calculated.

Ultrasonic flow meters measure the difference of the propagation time

(transit time) of ultrasonic pulses propagating in (normally an inclination
angle around 30 to 45 is used) flow direction and against the flow
direction.

This time difference is a measure for the averaged velocity of the fluid
along the path of the ultrasonic beam

Measurement: Flow
Ultrasonic flow-meters
Advantages:

With homogeneous fluids, the principle is independent of

pressure, temperature, conductivity and viscosity

Usable for a wide range of nominal diameters Direct meter

installation on existing pipes

Non-invasive measurement

No pipe constrictions, no pressure losses

No moving parts. Minimum outlay for maintenance and upkeep

Measurement: Flow
Coriolis Mass Flow-meters

If a moving mass is subjected to an oscillation perpendicular to its

direction of movement, Coriolis forces occur depending on the
mass flow.
A Coriolis mass flow meter has oscillation measuring tubes to
precisely achieve this effect.

Coriolis forces are generated when a fluid (= mass) flows through

these oscillating tubes. Sensors at the inlet and outlet ends register
the resultant phase shift in the tube's oscillation geometry.

Measurement: Flow
Coriolis Mass Flow-meters
The processor analyzes this information and uses it to
compute the rate of mass flow.
Advantage
This principle is used in a huge range of industry sectors,
including pharmaceuticals, chemicals and petrochemicals, oil
and gas, food etc.

Measurement: Flow
Major issues for selecting flow-meters
Accuracy
Repeatability
Linearity
Reliability
Range/Span
Dynamics(Response time)
Safety
Maintenance
Cost

Measurement: Temp.
Measurement Devices

Thermocouples
Resistance Thermometers
Thermistors

Bimetallic Thermometers

Acoustic Pyrometers

Local Instruments

Measurement: Temp.
Thermocouple
IT IS BASED ON SEEBECK EFFECT WHICH SAYS THAT WHEN
HEAT IS APPLIED TO A JUNCTION OF TWO DISSIMILAR METALS
AN EMF IS GENERATED WHICH CAN BE MEASURED AT THE
OTHER JUNCTION

T/C Connection
COMPENSATING CABLE
HOT JUNCTION
TO DDC CARDS
TERMINAL END

CJC BOX

Measurement: Temp.
Thermocouple
Types of T/C:E,J,K,T,R,S,B
K (Chromel & Alumel; Ni-Cr &Ni-Al) Type: mostly used in power plant for low
temp. application )
R (Platinum & Platinum-Rhodium) Type: Used for high temp. application. Highly
resistant to oxidation & corrosion
Advantages: Disadvantages: - Low Cost
- Sensitivity low & low voltage output
- No moving parts, less likely to be broken. susceptible to noise
-Wide temperature range.
- Accuracy not better than 0.5 C
-Reasonably short response time.
- Requires a known temperature
- Reasonable repeatability and accuracy.
reference

Measurement: Temp.
RESISTANCE THERMOMETER (RTD)
THE RESISTANCE OF A CONDUCTOR CHANGES WHEN ITS TEMPERATURE IS CHANGED .THIS
PROPERTY IS UTILISED TO MEASURE THE TEMPERATURE.
Rt = Ro (1+dT)

= TEMP CO- EFFICIENT OF RESISTANCE ; dT = TEMPERATURE DIFFERENCE

When discussing RTDs, following must be considered:
WHERE

Wiring configuration (2, 3 or 4-wire)

Self-heating
Accuracy
RTD types:
Stability
1. Platinum (Range -200 C to 600 C )
Repeatability
2. Copper (Range -100 C to 100 C )
Response time
3. Nickel (Range -60 C to 180 C )

Measurement: Temp.
THERMISTORS
THERMISTORS ARE GENERALLY COMPOSED OF SEMICONDUCTOR
MATERIALS.THEY HAVE A NEGATIVE COEFFICIENT OF TEMPERATURE SO
RESISTANCE DECREASES WITH INCREASE IN TEMP.

Making use of Negative Temperature Coefficient characteristics, thermistor

and can be applied in temperature compensation, inrush current limit,
precision temp. control (temp. coefficient very large compared to RTC & T/C)
etc.
BIMETALLIC THERMOMETERS

ALL METALS EXPAND OR CONTRACT WITH TEMPERATURE

THE TEMPERATURE COEFFICIENT OF EXPANSION IS NOT THE SAME FOR ALL
METALS AND SO THEIR RATES OF EXPANSION AND CONTRACTION ARE DIFFERENT
USAGE: IN PROCESS INDUSTRIES FOR LOCAL TEMPERATURE MEASUREMENTS
OVERLOAD CUTOUT SWITCH IN ELECTRICAL APPARATUS

Measurement: Temp.
ACOUSTIC PYROMETER

Acoustic Pyrometer is a non-contact measurement device that obtains highly accurate

instantaneous gas temperature data in any area of the boiler, helping improve combustion
efficiency.

For measurement of temperatures across large spaces of known distance in a noisy, dirty and
corrosive environment such as a coal-fired utility boiler, or a chemical recovery boiler.

The Velocity of Sound in a medium is proportional to the Temperature.

LOCAL INDICATION

LIQUID IN GLASS THERMOMETER

MERCURY IN STEEL THERMOMETER

BIMETALLIC THERMOMETER

Power Plant C&I systems

1.Field instruments/ input & output instruments
a)

Various measuring instruments like Transmitters, RTD,

Thermocouples, Pr. & temp. gauges, speed & vibration
pick ups etc. (Analog inputs)

b)

Various Pr., Temp. & limit switches, for Interlock ,

protections & feedback of control element (Binary inputs)

c)

Output devices like solenoids, EP converters, Positioners

etc. for controlling final control element

d)

Final control elements like Power cylinder, Pneumatic/

motorized actuators etc.

Power Plant C&I systems

2. Control Systems
a)

Various control cabinets for acquiring field signal (both analog

& binary inputs), processing the signals as per control logic
and issuing output command to output devices (Binary &
analog).

b)

Various control desk devices like command consoles, Push

button modules, indicators, recorders, CRTs, PC based
Operator Work Stations (OWS) etc. for human machine
interface for monitoring & control of the plant

c)

Power supply system(UPS)/ chargers with battery backups to

ensure uninterrupted power supply of desired quality for the
control system

Power Plant C&I systems

3. Analyzers
The availability, reliability & efficiency of boiler unit hinge around the close
control of chemical regimes of working fluid i.e. water/steam as well as
combustion in the boiler. The instruments monitoring the chemical regimes and
combustion are generally called analytical instruments. These instruments fall
under three category
i)

Water/ Steam Analyzers

ii)

Gas analyzers

iii)

Smoke monitors

HIGH PURITY WATER IS ESSENTIAL TO MINIMISE

SCALING

CORROSION

CARRY OVER

EMBRITTLEMENT

Power Plant C&I systems

ANALYZERS AND MEASURMENT LOCATION
a)

ON LINE gas analyzers for measurement of flue gas oxygen,

carbon
mono-oxides, carbon di-oxides, oxides of sulpher & nitrogen at various
location of boiler.

b)

ON LINE analyzers for measurement of conductivity, pH, silica, dissolved

oxygen, phosphate, hydrazine, chloride, sodium etc. at various points in the
water & steam cycle of boiler & turbine area (SWAS-steam & water analysis
system).

c)

ON-LINE opacity monitors for measurement of dust concentration in flue gas

d)

ON LINE analyzers for measurement of conductivity, pH, silica, dissolved

oxygen etc. at various ION exchangers of DM plant .

Power Plant C&I systems

TYPICAL VALUES OF CHEMICAL PARAMETERS BEING MEASURED (SWAS)
SAMPLE

PARAMETER

DM WATER

a) Conductivity
b) Cation Conductivity

Condensate
pump
discharge
(CEP)

a) Conductivity
b) Cation Conductivity

Economizer
Inlet
Boiler water

a) Conductivity
b) Cation Conductivity

c) pH

S/cm
S/cm

d) Na+

ppb

e) Dissolve oxygen (DO)

ppb

c) Hydrazine

a) Conductivity
b) pH

Sat & Main steam

UNIT

S/cm
ppb
S/cm

LIMIT
<0.3
<5
<0.3

9.0-9.2
<5ppb

<10
<5
<0.3

10-20
100
9.1-9.4

c) Silica

ppb

100

a) Conductivity
b) Cation Conductivity

S/cm

<5
<0.3

Power Plant C&I systems

4. Laboratory Instruments & Setup
Activities of C&I Lab

CALIBRATION

REPAIR

TESTING

with proper documentation & records

CALIBRATION:
Pressure switch , Transmitter , Gauge

Temperature switch , Transmitter , Gauge

Flow Transmitter

Level Switch

Power Plant C&I systems

4. Laboratory Instruments & Setup
REPAIR:
1. ELECTRONIC CARDS
3. POWER SUPPLY MODULES
TESTING:
1. ELECTRONIC MODULES
2. RELAYS
3. POWER SUPPLY MODULES

Power Plant C&I systems

4. Laboratory Instruments & Setup
a)

Different standard instruments with traceability up to national standard .

These insts. include Standard Gauges, Multimeters, Resistance boxes,
mA sources, oscilloscope, signal generator etc. for calibration of
measuring instruments.

b)

Dead Weight tester, Comparator,

manometer, soldering stations etc.

c)

Test benches with standard power supply sockets (e.g. 24VDC, 48VDC,
220VDC, 110VAC, 230VAC etc.) in each bench depending on requirement.

d)

Laboratory should be air-conditioned with monitoring of temp., humidity

and barometric pressure. Also, proper provision for handling electronic
cards (floor mats, ESD protective bags/ anti static bags etc.)

Temperature bath, Vacuum pump,

Power Plant C&I systems

4. Laboratory Instruments & Setup
Essential Tools/ Infrastructure for Repairing & testing
1.
IN-CITCUIT IC TESTER
2.
ESD WORK STATION
3.
ULTRASONIC CARD CLEANER
4.
STORRAGE OSCILLOSCOPE
5.
LOGIC ANALYSER
6.
THERMOCOUPLE SIMULATOR
7.
VIDEO PATTERN GENERATOR
8.
EPROM PROGRAMMER

Power Plant C&I systems

C&I systems of Boiler
-

FSSS (Furnace safeguard supervisory system)

Open loop control system (interlock &

protections) of boiler auxiliaries

Secondary Air Damper control system (SADC)

Hydrastep for drum level measurement

Measurements, Protection & Control of Coal

Feeders

Power Plant C&I systems

FSSS
FUNCTIONS OF F.S.S.S
1.

FURNACE PURGE SUPERVISION

2.

OIL GUNS ON/OFF CONTROL

3.

PULVERISERS/FEEDERS ON/OFF

4.

SECONDARY AIR DAMPERS CONTROL

5.

FLAME SCANNER INTELLIGENCE

6.

BOILER TRIP PROTECTIONS

CONTROL

Power Plant C&I systems

FSSS
WHY AT ALL A PROTECTIVE SYSTEM IS REQUIRED FOR THE BOILER?
THE BOILERS FURNACE IS CONTINUOUSLY FED WITH HIGH
CALORIFIC VALUE ATOMISED FUEL WHICH IS IN THE PROCESS OF
CONTINUOUS BUT CONTROLLED COMBUSTION.
COMBUSTION-THE PROCESS
COMBUSTION IS A RAPID BURNING OF OXYGEN WITH FUEL RESULTING IN
RELEASE OF HEAT. AIR IS ABOUT 21% OXYGEN AND 78% NITROGEN BY VOLUME.
MOST FUELS CONTAIN CARBON, HYDROGEN AND SULPHUR. A SIMPLIFIED
COMBUSTION PROCESS COULD BE
CARBON+OXYGEN=CARBONDIOXIDE+ HEAT
HYDROGEN+DO =WATER VAPOUR + HEAT
SULPHUR +DO =SULPHURDIOXIDE+ HEAT
WHICH MEANS THAT THE FINAL DESIRED PRODUCT OF THE PROCESS IS
HEAT WHICH WE REQUIRE TO BOIL THE WATER

Power Plant C&I systems

FSSS
COMBUSTION-THE PROBLEM : WHEN THIS CONTROLLED BURNING GOES
OUT OF CONTROL DUE TO AN IMBALANCE IN THE FUEL/AIR RATIO, THERE IS
EITHER A FUEL RICH MIXTURE OR A FUEL LEAN MIXTURE. IN BOTH CASES
THE FLAME QUALITY BECOMES POOR. THERE IS A CHANCE OF FUEL
ACCUMULATION WHICH CAN LATER ON IGNITE SUDDENLY AND CAUSE
EXPLOSIONS.
SO FSSS IS USED FOR SAFE AND ORDERLY STARTUP AND SHUTDOWN
OF BOILER THROUGH VARIOUS INTERLOCKS AND PROTECTIONS
THE PROTECTIVE SYSTEM IN THE BOILER IS DESIGNED BASICALLY
TO PREVENT OCCURRENCE OF SUCH SITUATIONS BY TAKING ADVANCE
ACTIONS.

Power Plant C&I systems

N.F.P.A Guide line & Boiler Protection

N.F.P.A- National Furnace Protection Association,

USA

Deals with protection for various types of furnace

Protection of Pulverized fuel fired boiler is governed by

Section-85c

Different categories of protection:

a) Mandatory, b)Mandatory & automatically generated, c)

Optional but alarm has to be there

Power Plant C&I systems

BOILER FLAME & FLAME SCANNERS
It looks rather static, but in
reality the fire energy fluctuates
rapidly.
The Fuel and Oxygen in
the uncontrolled
fire constantly
burn as in small
explosions
and then sucks new Fuel
&
Oxygen to the flames. This
process causes the flame
flicker.
Flicker frequency for oil
flame is more than that of coal
flame.

Power Plant C&I systems

INTENSITY RELATIVE TO WAVELENGTH

Power Plant C&I systems

FLAME SCANNERS
-UV Scanners
-Visible Range Scanners (Safe scan-1&2)-Used for both Oil & Coal Flame
-IR Scanners (UR600 of ABB)

SAFE FLAME SCANNER

Power Plant C&I systems

C&I systems of Turbine
-

ATRS (Automatic Turbine Runup system)

Turbine Governing System

Turbovisory Instruments & turbine protections

Interlock, Protection & Control of HPBP system

Open loop control system (interlock & protections) of

turbine auxiliaries
Interlock & protections of Seal Oil & Stator water
system

Power Plant C&I systems

C&I systems for control & MIS
-Automatic Control System (ACS)
-DATA Acquisition system(DAS)
-Distributed Digital Control Monitoring
and Information System

Power Plant C&I systems

AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP
PROCESS: Process refers to the method of changing or refining raw
materials to create the desired end product. The raw materials may
undergo physical, chemical, or thermal state changes during the Process.

Process is of Two Types :

A) Continuous and B) Batch
Continuous Process is one where the change of state of Input into Output
occurs continuously.
Ex.: Power Plant Process, Petroleum Industry etc.
Batch Process is one where a Batch of the Product is produced and the
Process stops till production of next Batch is started.
Ex.: Automobile Production

Power Plant C&I systems

AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP
PROCESS CONTROL: Process control techniques are developed over the
years to have
Quality of the end product
Economy of production
Ability to cater to emergencies and bring the process to safe shutdown.
CONTROLLED CONDITION: The physical quantity or condition of a
process or machine which is to be controlled
CONTROL SYSTEM: An arrangement of elements interconnected and
interacting in such a way that it can maintain some condition of a
process or machine in a prescribed manner

Power Plant C&I systems

AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP
OPEN AND CLOSED LOOP CONTROL:

A Closed Loop Control (CLCS) is one where a Process

Variable is measured, compared to a Set Value and action is
taken to correct any Deviation or Error from Set Value. The
continuous Measurement of PV and its comparison to Set
Point closes the Loop.

An Open Loop Control(OLCS) is one where the PV is not

compared with Set Value and action taken, but action is taken
without regard to conditions of PV.

Power Plant C&I systems

AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP
OPEN LOOP CONTROL:
Open Loop Control is accomplished by the following means:

Group Control
Sub-Group Control
Sub-Loop Control
Drive Level Control
Programmable Logic Control(PLC)
Group Control : Start and Stoppage of a Group of equipment is
accomplished by Group Control(GC).
Ex. :CEP GC, Equipment Cooling GC etc.

Power Plant C&I systems

AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP
OPEN LOOP CONTROL:
Sub-Group Control : Start and Stoppage of an equipment with its
associated auxiliaries in Step-Sequence manner is done by SubGroup Control. Operator intervention is not required in Sub-Group
Control(SGC).
Sub-Loop Control: Start and Stoppage of auxiliaries of an
equipment is carried out by Sub-Loop Control(SLC)
Drive Level Control : Start and Stop or Opening and Closure of a
Drive is carried out by Drive Control. The Drive logic shall have
Protection, release ,auto and manual commands and these are
executed as per pre-determined logic.

Power Plant C&I systems

AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP
CLCS TERMINOLOGY:
Desired Value or Set Point : The value of the variable/parameter which needs to
be controlled at the required condition.
Process Variable(PV) : The present value of the Parameter of Process at that
particular instant. This is sometimes referred as Measured Value.
Error/Deviation : It is the Difference between Set Point and Process Variable, and
can be +ve or ve. It has three components: a) Magnitude b) Duration and c)
Rate of change.
Controller : A Controller is a device that receives data from a Measurement
Instrument, compares the data with the Set Point and if necessary, signals a
Control element to take Corrective action. This Corrective action ensures that
the PV shall always be maintained at the Set Value.
The Controller can be a) Electronic, b) Pneumatic and c) Hydraulic type.

Power Plant C&I systems

AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP

Controller types: Functionally, Controllers can be

a) Continuous and b) Step Controllers.
Depending on the control loop; controller action can be adjusted as
(i) Direct acting:-Increase of process value increases controller
output
(ii) Reverse acting:- Increase of process value decreases controller
output

Control Element : The Control or Correcting Element is the part of the

Control System that acts to physically change the Manipulated
Variable.
Ex. : Control Valves, Louvers or Dampers, Solenoids, Pump Motors
etc.

Power Plant C&I systems

AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP

Bump less Transfer : The arrangement where the transfer from auto to manual
mode does not affect the process.

Proportional Control : The Proportional (P) action responds only to a change in

the magnitude of Error(e) i.e. controller output changes by an amount which is
proportional to error.
Output change of Controller in % = (Error change in %)(Gain), where Gain is
called the Controller gain. The reciprocal of Gain is termed as Proportional
Band(PB) and is expressed in %.
Proportional Band(PB): The change in deviation required to cause the output of
the controller to change from one extreme to the other.

Integral Control : In Integral Control, the Controller output is a function of the

Duration of Error(e).

Power Plant C&I systems

AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP
Hence, the Controller output is the time Integral of Error and the time
set is Integral Action Time(IAT) i.e. IAT can be defined as time taken for
the integral action to change output by the same amount as the
proportion action .
Usually, both P and I Controls are combined and the Controllers are
tuned to minimize Error(e) and controller is termed as PI controller.
Derivative Control : Derivative or Rate Controllers output is Proportional
to the rate of change of Error(e). The Control action is termed as D. The
action is to apply an immediate response that is equal to the P+I action
that would have occurred some time in the future.

Power Plant C&I systems

AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP
Important Closed Loop Controls in a Thermal Power Plant:
a) Furnace Draft Control
b) Boiler Drum Level Control
c) HOT well & D/A level control
d) Main Steam Temperature Control
e) Air and Fuel Flow to Boiler Control
f) SH & RH spray control
g) Coordinated Master Control(CMC)
h) Turbine Speed, Pressure and Load Control

Power Plant C&I systems

AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP

Coordinated Master Control

This is an integrated automatic control of unit operation. There is a
continuous co ordination between boiler and turbine control to
maintain a balance between steam generation and steam
consumption.

Boiler Follow Mode (BFM)

Turbine Follow Mode (TFM)

Co-ordinated Master Control (CMC)

Runback Mode

Power Plant C&I systems

AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP
Boiler Follow Mode (BFM)

Unit load control from turbine local load set point

Change in turbine load set point will modulate turbine CVs

Boiler master output gets corrected to maintain throttle pr dev.

Boiler control will follow turbine control

BLI signal as feed forward signal for boiler firing rate control

Result - Boiler acts as throttle pr controller where turbine is in load controller

mode

Power Plant C&I systems

AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP
Turbine Follow Mode (TFM)

Unit target load set point goes to boiler master

Change in BLI will modulate turbine CVs

Boiler master output gets corrected to maintain Unit load dev.

Turbine control will follow boiler control

Load deviation as feed orward signal for boiler firing rate control

Result - Boiler acts as load controller where turbine is in pressure controller

mode

Power Plant C&I systems

AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP

Coordinated Master Control

Unit load is set from unit master.

Unit master demand is limited by unit capability , TSE margins and unit max/min load
set points.

Unit target load is derived from unit master after the limitations.

Unit target load is used as feed forward signal to the boiler firing rate control.

Turbine control utilises the unit load as turbine load set point after adapting the same
by steam generation delay.

In TG throttle pressure is maintained by correcting the BMD output depending on the

throttle pr dev.

Result: Balance is achieved between steam generation and steam consumption

PROPER COORDINATION BETWEEN BOILER CONTROL AND TURBINE CONTROL

Power Plant C&I systems

DATA ACQUISITION SYSYTEM-DAS
WHY DAS IS REQUIRED IN THERMAL POWER PLANTS ?

SAFE & RELIABLE OPERATION OF THE UNIT OR EQUIPMENTS

ASSIST CONTROL ROOM OPERATORS BY PROVIDING TIMELY

ANNUNCIATION OF ALL ABNORMAL CONDITIONS

PROVIDE DETAILED INFORMATION ON THE PLANT PERFORMANCE

PROVIDE MANAGEMENT WITH ACCURATE RECORDS ON THE PAST

PLANT PERFORMANCE FOR ANALYSIS

Power Plant C&I systems

DATA ACQUISITION SYSYTEM
3 MAJOR FUNCTIONS OF DAS:

DATA ACQUISITION

DATA PROCESSING

DATA REPRESENTATION

The Major Parts

Process Control Units ( PCU )

Computer Interface Unit ( CIU )
Termination Units ( TU )
Buffer Terminal Cabinets ( BTC )

Power Plant C&I systems

DATA ACQUISITION SYSYTEM
TYPES OF DATA (Input): Analog & Digital

Analog inputs:
1. Thermocouple Input ( mV )
K-Type T/C ( Cr-Al ) : For temp < 600 Deg C& used in Flue Gas path
after FSH outlet.
R-Type T/C ( Pt-Pt-Rh ) : For temp > 600 Deg C used in PSH & FSH
region of FG path.
2. RTD Input ( Resistance )
Pt-100 RTD : For Brg. Temp measurement.
Cu-53 RTD : For HT motor & Generator Stator winding temp.
measurement.

Power Plant C&I systems

DATA ACQUISITION SYSYTEM
Analog inputs:
3. 4 20 Ma Input

Coming from Pr. / Flow Transmitters.

Coming from Signal Distribution Cards of automatic
control system
4. 0 10 Volt Input
Coming from ATRS cabinets
Used for Turbine Brg. Temp. /Vibration measurement.
DIGITAL INPUTS

These are coming directly from switches or relay contacts of

other systems (FSSS, ATRS, ACS etc.)

Power Plant C&I systems

DATA ACQUISITION SYSYTEM
DIGITAL INPUTS (TYPES)

LOW RESOLUTION : The scanning time of inputs is 1

second.
HIGH RESOLUTION : The scanning time is 1
millisecond. These are called
Sequence Of Events ( SOE )
Inputs.
PULSE INPUT
: For calculation of Total Coal
Flow, Total Air Flow etc.

Power Plant C&I systems

DATA ACQUISITION SYSYTEM
FUNCTIONS OF DAS:
Alarm Management.
Production of hardcopy print outs in different
printers.
Operator Guidance Messages.
Graphic Displays of plant sub-systems.
Trending of analog variables on recorders.
Sequence Of Events ( SOE ) recording following
unit / equipment trip conditions.
Efficiency calculations

Power Plant C&I systems

DATA ACQUISITION SYSYTEM
DATA PROCESSING: It has the following parts

COMPUTER PROCESSING UNIT ( CPU )

BULK ( SOLID STATE ) MEMORY WITH BATTERY BACKUP

MAGTAPE UNIT

COMMUNICATION CABINET & MODEM

MOVING HEAD DISC DRIVE

VIDEO HARD COPIER

TREND RECORDER

UNIT CONTROL DESK & PROG. ROOM CRT

PRINTERS

Power Plant C&I systems

DATA ACQUISITION SYSYTEM
Features:
REAL TIME VARIABLE CALCULATION
Summing, Subtraction, Maximum , Minimum, Averaging, Hourly & Daily
integration, rate of changes & comparison of limits etc.
ON-LINE DATABASE EDITION
1. Assign points to any process parameter
2. Scan, Off-scan , Delete , Activate , inactivate a process parameters ,
calculated points when reqd.
3. Change the Engg. Unit
4. Change the range , alarm limits & dead bands
5. Change the scan frequency
6. Review total analog and digital points depending on its quality flag like
alarm , channel failure , off-scan etc.

Power Plant C&I systems

DATA ACQUISITION SYSYTEM
ALARM MANAGEMENT:
All the analog points which cross their normal limits or all the
digital points which go into their alarm state come on the alarm
CRT with associated time & blink as long as the alarms remain
unacknowledged.

Alarm will come in RED colour

If all the pages are full (normally no. of alarm pages & alarm per
page is predefined) and any new alarm comes , then oldest alarm
will disappear from the alarm page as FIFO basis

Alarm print out will be available in alarm printer

Power Plant C&I systems

DATA ACQUISITION SYSYTEM
DATA REPRESENTATION:

Printed outputs of displays /collection of data in

different formats like :
1. Copy Screen
2
Alarm Print out
3. Log Print out

CRT Displays
1. Alarm CRT display
2. Utility CRT display

Power Plant C&I systems

DATA ACQUISITION SYSYTEM
DATA REPRESENTATION:
TYPES OF TREND LOG

TIME ACTIVATED

EVENT ACTIVATED

DEMAND LOGS

PRINOUTS

SOE PRINTOUT

TIME ACTIVATED LOG:

Automatic Triggered Logs

Sample frequency is 1 Hour.(Normally)
Time of trigger can be specified

Power Plant C&I systems

DATA ACQUISITION SYSYTEM
TIME ACTIVATED LOG:
Max. 15 nos. of points can be assigned
Normally printed in the logging printer in UCB
Examples :
1. Shift Log
2. Efficiency Log
3. Boiler Drum / Tube Metal Temp. Log
4. FSH / RH Metal temp. excursion Log

EVENT ACTIVATED LOG:

Automatic Triggered Logs

Used for Unit or Equipment Outage Analysis

Minimum Sample frequency is 10 seconds.

Power Plant C&I systems

DATA ACQUISITION SYSYTEM
EVENT ACTIVATED LOG:
Max. 36 points can be assigned in a log

Logs are triggered by a Trip flag

Normally printed on Logging Printer in UCB
Pre & Post triggered points can be specified
Examples :
1. Post Trip Analysis Log ( PTL )
2. TG. Shutdown Analysis Log
3. Boiler Startup Log.
4. Turbine / Generator Diagnostic Logs

Power Plant C&I systems

DATA ACQUISITION SYSYTEM
DEMAND LOG:

Not Automatic Triggered Logs

Logs can be printed on operators demand

Sample frequency is generally 1 Hour.

Logs are printed in Logging Printer in UCB

Power Plant C&I systems

DATA ACQUISITION SYSYTEM
SEQUENCE OF EVENTS ( SOE )
THE MAIN FEATURES ARE:

Determines First Cause Of Trip

Determines sequence of events or alarms

Scanning Time is 1 millisecond.

It is a Stand Alone System

Max. 256 nos. of Protection related digital points can be

assigned

Automatic Triggered when any point in alarm

Power Plant C&I systems

DDCMIS
WHAT IS DDCMIS ?

DISTRIBUTED DIGITAL CONTROL MONITORING &

INFORMATION SYSTEM

Distributed means there is no centralized control and control is spread

across multiple units

Digital means processing of process information is done in digital form

using micro-processor based hardware

MIS interfaces the human with process using computers

Power Plant C&I systems

DDCMIS
TECHNOLOGICAL BACKGROUND
PROGRESS OF INSTRUMENTATION USED TO IMPLEMENT AUTOMATIC
PROCESS CONTROL

LOCAL PNEUMATIC CONTROLLERS

MINIATURIZED AND CENTRALIZED PNEUMATIC CONTROLLERS

AT CONTROL PANELS AND CONSOLES

SOLID-STATE CONTROLLERS

COMPUTERISED CONTROLS

DISTRIBUTED MICROPROCESSOR BASED CONTROL

Power Plant C&I systems

DDCMIS
Components
MAN MACHINE INTERFACE & PROCESS
INFORMATION SYSTEM

DATA COMMUNICATION SYSTEM (DATA HIGH WAY)

CONTROL SYSTEM

Power Plant C&I systems

DDCMIS
MAN-MACHINE INTERFACE AND PLANT INFORMATION SYSTEM (MMIPS)

LATEST STATE-OF-THE-ART WORKSTATIONS AND SERVERS BASED ON

OPEN-ARCHITECTURE AND INDUSTRY STANDARD HARDWARE AND
SOFTWARE TO ENSURE BETTER CONNECTIVITY.
e.g. HARDWARE FROM COMPAQ/DIGITAL, HP, SUN MICRO-SYSTEM OR
OTHER MAJOR SUPPLIERS (LESS DEPENDENCE ON THE C&I SYSTEM
SUPPLIER IN THE LONG RUN)

OPERATING SYSTEM WINDOWS-NT, OPEN-VMS OR UNIX.

PROVISION OF LVS

CONNECTION TO OTHER SYSTEM THROUGH STATIONWIDE WAN

Power Plant C&I systems

DDCMIS
MMIPIS FUNCTIONALITIES

VARIOUS PLANT EQUIPMENT OPERATION

OPERATOR INFORMATIONS THROUGH VARIOUS DISPLAYS

ALARMS, LOGS, HISTORICAL AND LONG TERM STORAGE.

PERFORMANCE AND OTHER CALCULATIONS

Power Plant C&I systems

DDCMIS
DATA COMMUNICATION SYSTEM

LOCAL SYSTEM BUS It is just lines on the backplane of control

panel to which all the modules are connected directly. It serves as
communication medium between the modules.

INTRAPLANT BUS(IPB) It is a coaxial cable which runs through

all the panels of control system and interconnects them.

LOCAL AREA NETWORK(LAN) It is a network of computers

which are connected to a single point (HUB).
FOR ALL BUSES REDUNDANCY IS PRESENT

Power Plant C&I systems

DDCMIS
CONTROL SYSTEM
FUNCTIONAL DIVISION
SG-C&I SYSTEM
TG-C&I SYSTEM
BOP-C&I SYSTEM
HARDWARE COMPONENTS
POWER SUPPLY
CONTROL PANEL
ELECTRONIC MODULES

Power Plant C&I systems

DDCMIS

Power Plant C&I systems

DDCMIS
SG-C&I SYSTEM
BURNER MANAGEMENT SYSTEM (BMS)
SOOT BLOWER CONTROL SYSTEM (SBC)
SECONDARY AIR DAMPER CONTROL SYSTEM (SADC)
AUXILIARY PRDS CONTROLS (APRDS)
TG-C&I SYSTEM
ELECTRONIC TURBINE PROTECTION (ETP)
AUTOMATIC TURBINE RUN-UP SYSTEM (ATRS)
AUTOMATIC TURBINE TESTING SYSTEM (ATT)
ELECTRO- HYDRAULIC TURBINE CONTROL SYSTEM (EHTC)
TURBINE STRESS CONTROL SYSTEM (TSC)
LP BYPASS SYSTEM (LPBP)
HP BYPASS SYSTEM(HPBP)
GLAND STEAM PRESSURE CONTROL
GENERATOR AUXILIARY MONITORING PANEL (GAMP)

Power Plant C&I systems

DDCMIS
BOP-C&I SYSTEM
CONSISTS OF OPEN LOOP CONTROL SYSTEM (OLCS) AND CLOSED LOOP
CONTROL SYSTEM (CLCS)

OLCS - THE SEQUENCE CONTROL, INTERLOCK OF ALL THE PLANT SYSTEMS WHICH ARE
NOT COVERED IN THE SG-C&I AND TG-C&I. THIS INCLUDES MAJOR AUXILIARIES LIKE FD/ID/PA
FANS, AIR-PREHEATER, BFP/CEP/CWP/ BCWP , DMCWP/CLCWP AND ELECTRICAL BREAKERS.

CLCS

- THE MODULATING CONTROL FOR VARIOUS IMPORTANT PLANT PARAMETERS, LIKE

FW FLOW (DRUM LEVEL), FURNACE DRAFT, COMBUSTION CONTROL (FUEL FLOW AND AIR
FLOW), PA HDR PRESSURE CONTROL, DEAERATOR/HOTWELL/HEATER LEVEL CONTROLS
ETC.

Power Plant C&I systems

DDCMIS
WHY DDCMIS ?

VERY HIGH FLEXIBILITY FOR MODIFICATION

VERY HIGH SELF-DIAGNOSTIC

IN CONTROL STRATEGY

VERY LOW DRIFT (ONLY IN I/O CARDS) , HENCE

FREQUENT RE-CALIBRATION

MUCH HIGHER RELIABILITY (BASED ON MTBF)

BETTER LONG TERM SUPPORT DUE TO

MUCH BETTER OPERATOR INTERFACE

NO NEED OF

CHANGING TECHNOLOGY

Power Plant C&I systems

DDCMIS
SALIENT FEATURES OF DDCMIS

INTEGRATED PLANT CONTROL FOR SG, TG AND BALANCE OF

PLANT CONTROL
IT MAY BE REMEMBERED THAT HISTORICALLY THE TERM DDCMIS
USED REFER TO THE SO-CALLED BOP-C&I . THE SG-C&I, i.e. FSSS etc.
TG-C&I i.e. ATRS, TURBINE PROTECTION etc. ORIGINALLY WERE NOT
CONSIDERED UNDER DDCMIS OR DCS AS PER MANY SUPPLIERS. ONLY
RECENTLY THE TYPE OF SYSTEMS FOR ALL THE SYSTEMS HAVE
BECOME SIMILAR (WITH SOME DIFFERENCE WHICH WILL BE DISCUSSED
LATER), WE TEND TO CONSIDER THESE SYSTEMS UNDER DDCMIS.

Power Plant C&I systems

DDCMIS

SALIENT FEATURES OF DDCMIS

INTEGRATED PLANT OPERATION THROUGH FULLY INTERCHANGEABLE

OPERTAOR WORK STATIONS (OWS) FOR SG, TG AND BALANCE OF
PLANT

PROVISION OF EXTENSIVE SELF-DIAGNOSTICS

USE OF LARGE VIDEO SCREENS FOR PROJECTIONS OF VARIOUS

PLANT MIMICS ETC.

PROVISION OF FAULT ALARM ANALYSIS TO GUIDE THE OPERATOR TO

THE MOST LIKELY EVENT

PROVISION OF ADEQUATE RELIABILITY AND AVAILABILITY WITH

PROPER REDUNDANCY IN SENSOR, I/O AND CONTROLLER LEVELS.

Power Plant C&I systems

Global & National Power Scenario
Global:
Global electricity consumption 69% higher in 2020 than 2003
80% of energy provided from thermal sources
Emerging trend from Thermal to Hydel and Renewable Energy sources

Indian:
Total installed capacity only 1362 MW in 1947
Per Capita consumption 631 units (2005-06) only with installed capacity of 1,77,000 MW
GDP growth of 8%, power growth required 10%
To add 1,00,000MW capacity by 2017
Liberalizations of the sector

Power Plant C&I systems

NTPC at a glance:

Installed Capacity 34199 MW

Target 75000MW by 2017
Performance:
Annual Availability 91.62%
Annual PLF 88.29%
11 stations among top 20 in the country

NTPC Practices to achieve goal

KEY THRUST AREAS
Zero Human Error
Implementation of trip committee recommendations judiciously / rigorously
Identification of trip committee recommendations of other stations
which are relevant and implement them
Implementation of operation memorandum wherever applicable
Dissemination of information about best practices followed across
NTPC and other Power Stations
Providing proper environment for C&I equipment to reduce probability of
card and equipment failure

C&I Trip Trend

2009-10: FORCED OUTAGE DISTRIBUTION (COAL)

INFERENCE : 2009-10 C&I OUTAGE ANALYSIS

Major factors contributing to C&I outage in

2009-10:
1.Control System related failure
2. Field Device Failure
3. Soft ware/Card Failure
4. Power Supply/Relay failure
5. Human error

BEST PRACTICES COMPILED/ADOPTED IN NTPC C&I

All unit protections are provided with 2/3 logic and audio visual alarm is
provided on 1/3 to operator on actuation of any one sensor wherever possible
with proper approval.
Use of headless RTD in tripping circuit of ID/PA/FD fans & BFPs.
Resistance mapping of critical solenoids including cable during overhauls and
monitoring trend to identify any defects.
Marking of trip related devices and Junction Boxes marked in RED color.
Regular calibration of all important instruments which have a bearing on unit
safety, reliability and efficiency. Instruments are calibrated against standard
instruments with traceability to NABL.

BEST PRACTICES COMPILED/ADOPTED IN NTPC C&I

For handling of electrostatic sensitive electronic hardware,

electrostatic bags, wrist straps and other ESD handling devices
are employed in control panels and lab. All Laboratories are
provided with ESD proof workstations.
Disable removable drives of servers and workstations.
Single source responsibility for software backup of DCS and
storage in fire proof cabinets in two different locations.
Detailed work instruction are prepared and followed for
working on all trip related devices.

BEST PRACTICES COMPILED/ADOPTED IN NTPC C&I

A single source responsibility is fixed for the generation and
maintenance of system passwords so as to maintain system
security
Internal quality inspection for critical checks during overhauls
to ensure quality in overhaul works
Near miss situations are monitored and analyzed. The
learning from this area used to formulate strategies to avoid
spurious outages.
All power supply voltages are monitored with a fixed
periodicity and maintained within /- 10% of the rated value.

BEST PRACTICES COMPILED/ADOPTED IN NTPC C&I

Fuses used in UPS and protection circuits are replaced with
new fuses of same rating and type during every overhaul
Earth voltages in control panels are monitored on a
predetermined frequency and the values are recorded for
trending
All bus terminators are checked during every overhaul for
ensuring integrity of bus communication in DDCMIS systems
Load testing of power supplies for critical applications and
replacement of power supply modules or electrolytic capacitor
and power transistors used in power supply if found
deteriorated.

Other important actions taken for forced outage reduction

Rerouting of control & power cables in hot zones
Panel power supply monitoring in regular intervals.
CER/UCB temperature and humidity monitoring online.
Insisting for performance of the A/C system
Checking and tightening power supply cables during overhaul
Ensuring healthiness of cabinet cooling fans.

Other important actions taken for forced outage reduction

Panel cooling fans supply segregation from system supply

with MCB / fuse.
Cleaning of air filters on panels periodically
Servo valve replacement/ servicing in hydraulic drives.
Individual fuse protection in 220VDC MFT for HOTV,
LOTV, HORV, Scanner emergency air damper solenoids

Looking from WBPDCL Santaldih Perspective

KEY THRUST AREAS

1.Commissioning of non commissioned systems

a)Soot blowing Steam Pr. Control valve:
Status- Actuator damaged while commissioning. BHEL has placed PO on
OEM M/s MIL for procurement of damaged parts
b)

Commissioning of SWAS analyzers:

Status-Procurement of Reagents for reagent based measurement (i.e. Silica

etc.) is in process.
Suggested to take up with OEM (Forbes Marshall) through BHEL for
commissioning of electrode based measurements (i.e. conductivity etc.)

Looking from WBPDCL Santaldih Perspective

c) Electromatic Relief Valve (ERV):
Status- Solenoid Installed and cabling done
d) APH Rotor stop alarm:
Status- Issue pending with BHEL for longtime. Alternative scheme
through DDCMIS suggested by fixing proximity switch on APH rotor
shaft at support brg. end.

e) APH fire detection alarm:

Status- Issue pending with BHEL for longtime. Alternative scheme by
measuring APH metal temp. using thermocouples in Air & Gas path
may be thought of.

Looking from WBPDCL Santaldih Perspective

f) Commissioning/testing of Back up (Back up of MAX DNA
system work stations)Push Button console for unit control:
Suggested to test the operation of various push buttons at the time of Start
up/ Shutdown of unit jointly with operation.

2. Rectification of long pending problems:

a) Problem of SADC systems
Status: Operation of some of the dampers erratic and needed frequent
adjustment due to unreliable performance of actuator/positioner
Suggested to procure 04 nos. actuator with positioner of reputed
manufacturer for replacement in one elevation on trial basis

Looking from WBPDCL Santaldih Perspective

b) High PA flow to Mills:
In auto PA flow of all mills are about 30% more than characteristic flow.
PA flow curve for sliding set point may be set as per mill design.
Also provision of manual set point may be explored to cater poor coal
quality

3. Setting up of C&I Lab with requisite facilities

4.Enhancing reliability of Field Instruments
a)

Proper glanding/ sealing of field instruments, control valves, routing

& dressing of cables, ensuring cleanliness & closure of all LIEs etc.

Looking from WBPDCL Santaldih Perspective

b)

Replacement of unreliable instruments by quality instruments

c) Marking of protection related JBs to avoid human error

Regular walk down check in various areas to ensure the healthiness of field
instruments.

5. Sealing & Cable dressing in MAX DNA panels during unit Shutdown
6. Disabling various ports for removable drives of MAX DNA work
stations for system reliability
7. Installation of ON Line printers of MAX DNA system for daily LOGs.
Daily LOGs are essential for analysis of different plant parameters by
O&E dept.

Looking from WBPDCL Santaldih Perspective

8. Cleanliness of NETWORK ROOM & EWS room to be ensured.
Monitoring of Temp. & Humidity of CER, UCB , NETWORK & EWS
rooms.
9.Implementation of regular cleaning schedule & preventive mtc. Schedule
for Boiler, Turbine and common systems
10.Prepartion of detail job list for unit overhauling
11. Review of spares status and timely action for procurement for
breakdown(corrective), preventive and overhauling maintenance .