C&I writeup

CONTROL & INSTRUMENT INDEX  SYSTEMS UNDER C&I DEPARTMENT  DISTRIBUTED CONTROL SYSTEM (DCS)  SYMPHONY HARMONY INFI 90 SYSTEM  COMPOSER™ SYSTEM  EMERGENCY TRIP SYSTEM (ETS)  FURNACE SAFEGUARD SUPERVISORY SYSTEM (FSSS)  LOCAL IGNITION CONTROL SYSTEM  UPS GENERAL DESCRIPTION  MULTI FLAME DETECTOR CONTROL UNIT & FLAME SCANNER  DEH SYSTEM  HART SYSTEM  MACHINE MONITORING SYSTEM (MMS)  TURBINE SUPERVISORY INSTRUMENTATION (TSI)  HPLP BYPASS  CCTV SYSTEM  RUNBACK  MIS SYSTEM (PGIM)  ENTERPRISE ASSET MAINTENANCE (MAXIMO)  GPS SYSTEM  CMS  BOILER TUBE LEAKAGE DETECTION SYSTEM

Systems Under C&I department, SgTPP  IPH SYSTEMS C&I department is entrusted for maintaining System Automation at all areas of Power Plant except CHP. The areas under their scope is as following: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Distributed Control System (Symphony Harmony 50 System, Make-ABB) with its panels, Controllers, Modules, power supply, network & HMI Operating Interface Software (Power Generation Portal, Make-ABB) maintenance, Sequence of Events generation. Operating Interface station (OIS), Engineering Work Station (EWS) & DCS communication with computer management. Logic & Interlock protection software (Composer 4.3 software, Make-ABB) maintenance and development if required. Digital Electro Hydraulic System (DEH, Make-ABB) for turbine governing system Furnace Safeguard Supervisory System PLC (FSSS, Make-ABB) with Master Fuel Trip System (MFT) 90~70 Series Genius PLC for Emergency Turbine Trip System (ETS, MakeGEIP) 3500 Turbine Supervisory Instrumentation (TSI, Make- Bentley Nevada) 90~30 Series Genius PLC for Turning Gear Automatic Control System (MakeGEIP) Different kind of field transmitters for measuring Pressure, temperature, flow, level, vibration, displacement & gauges like Pressure, temperature, level and different switches for alarm generation and enabling interlocks. Different kind of analytical instruments like Oxygen, CO, dust analyzers, SOX, NOX, Na, Si, and Conductivity etc. for hydrogen purity, humidity. Boiler tube leakage detection System (Make-Eastern Boiler Co.) & acoustic tube leakage detector sensors SMART Secondary air Damper Control (SADC) system, Make- CCI KK consisting 60Nos SAD with local control box SMART Burner Tilting System consisting 8Nos Tilt with local control box Different pneumatic final control elements used in Mill, pyrite system, single & double acting control valves for different areas. Different electrical actuators for PA fan, FD fan, ID fans. Steam Water Analytical System (SWAS) with Verasamax PLC, Make-GEIP Condensate Polishing System (CPU) Contrologix PLC, Make-Rockwell Automation Air Pre-heater gap detection system with SLC500 PLC, Make-Rockwell Automation Air Pre-heater Hot spot detection system with SLC500 PLC, Make-Rockwell Automation AROS Make 80KVA Dual Uninterruptible Power Supply (UPS) and Ni-Cd Battery Bank

22. Boiler Oil Burner System consisting LFO & HFO Burner System 23. UVISOR 600 IR Multi-flame detector Flame scanner system with Flame explorer software 24. TZIDC ABB Make SMART positioner for SADC, Burner Tilt 25. DVC 2000 & 6010 SMART Positioners for Control Valves 26. Auxiliary Boiler instrumentation and control system. 27. Flame TV for boiler flame monitoring 28. Closed Circuit TV (CCTV) server and cameras for 55 locations distributed all over the plant. 29. Online Condenser tube cleaning system (OLTC). 30. Condenser tube leakage system. 31. HPLP Bypass system (Make-CCI) control system and hydraulic controllers. 32. Highway Addressable Remote Transducer (HART) panel with Cornerstone diagnostic software to enable transmitter calibration from control room. 33. Machine Monitoring System(MMS) for monitoring vibration of different fans and pumps. 34. Large Video Screen(LVS) in Control room to display plant important data and soft annunciation.  OPH SYSTEMS 35. All Ash Slurry sump level switch, Pressure switch and gauges in Ash Handling Plant. SILO#1, 2, 3 level transmitters and NUVA feeder(dry ash system) solenoid valves and cylinders. 36. All pressure, flow, level and temperature gauges, switches and transmitters in Intake pump house, DMP, PTP and Regeneration Building and N-pit. 37. All Conductivity, pH, Si and Na Analyser in DMP and Regeneration Building for water, acid and caustic quality measurement. 38. All pneumatic solenoid valve operated on-off valves for different ion exchange vessels (ACF, SAC, WBA, SBA, MB). 39. All pneumatic control valves for degasser water tank recirculation line. 40. All pressure, temperature & level transmitters, level switches, pressure and temperature gauges for FOPH. 41. All vibration monitoring systems in intake and raw water pump house. 42. Chlorine gas leakage detection systems in RW Chlorination and CW Chlorination plants. 43. All pressure transmitters, switches and gauges in CW Chlorination plant. 44. All pressure switches and gauges in Fire fighting pump house. 45. All H2 gas leakage detection systems in H2 gas cylinder room. 46. All level switches and indicators, pressure gauges in waste water treatment plant.

 DISTRIBUTED CONTROL SYSTEM(DCS) Adopting the computer, communications and screen display techniques, carry out the data acquisition, control and protection functions etc. for production process. It is a multi-computer monitoring system based on communication and data share techniques, which possesses the following features, distributed functions, concentrated display, data, share, high reliability. It can be distributed by the hardware arrangement according to the concrete circumstances. DCS comprises of following functional segments : 1. Distributed Control System (Symphony Harmony INFI 90 System, Make-ABB) with its panels, Controllers, Modules, power supply, network & HMI 2. Operating Interface station (OIS), Engineering Work Station (EWS) & DCS communication by CNET with computer management. 3. Operating Interface Software (Power Generation Portal, Make-ABB) maintenance, Sequence of Events generation. 4. Logic & Interlock protection software (Composer 4.3 software, Make-ABB) maintenance and development if required.

 SOME DEFINITION AND ABBREVIATION ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

Distributed control System, namely DCS Date Acquisition System, namely DAS Modulation Control System, namely MCS Coordinated Control System, namely CCS Automatic Generation Control, namely AGC Sequence Control System, namely SCS Furnace Safeguard Supervisory System, namely FSSS Master Fuel Trip, namely MFT Digital Electro- Hydraulic Control, namely DEH Automatic turbine startup or shutdown control system, namely ATC Over- speed Protection Control, namely OPC Uninterrupted Power Supply namely UPS. Supervisory information system of the plant 1evel, namely SIS Turbine supervisory instruments, namely TSI The field bus control system, namely FCS

Following technical terms, definition and abbreviation is applicable to this standard 1 Distributed control System, namely DCS

Adopting the computer, communications and screen display techniques, carry out the data acquisition, control and protection functions etc. for production process. It is a multi-computer monitoring system based on communication and data share techniques, which possesses the following features, distributed functions, concentrated display, data, share, high reliability. It can be distributed by the hardware arrangement according to the concrete circumstances. 2 Date Acquisition System, namely DAS DAS is a supervision system, which is adopted digital computer system to detect the operating parameters, states for technique system and process, record, display and alarm to detecting results, calculate and analyze the operating conditions, provide operating instruction. 3 Modulation Control System, namely MCS MCS is a system that carries out the boiler, the turbine and the auxiliary system parameter automatic control. In this system, it includes the parameters automatic control and deviations alarming. For the former the, its outputs is a continuous function of inputs. It can be called the closed loop control system CCS in outward document. 4 Coordinated Control System, namely CCS UCC is a control system, which controls the boiler and the turbine as a whole, corresponds boiler and turbine to work through control loop under the automatic mode, sends the demand to boiler and turbine automatic control system in order to adapt the variation of load. 5 Automatic Generation Control, namely AGC AGC is an automatic control system that controls the power according to the power grid load demand. 6 Sequence Control System, namely SCS SCS is an automatic control system that controls a certain techniques system or main auxiliary equipment according to a certain disciplinarian (input signal condition sequence, action sequence or time sequence). 7 Furnace Safeguard Supervisory System, namely FSSS FSSS is an automatic control system for boiler ignition and oil gun action program to prevent the furnace explosion (outside explosion or inside explosion) caused by boiler extinguishing, overpressure etc. The FSSS includes the Burner Control System (BCS) and the Furnace Safety System, (FSS) 8 Master Fuel Trip, namely MFT MFT is a control measures that operates by operator or operates by the automatic protection signal to cut off all fuels for boiler.

9 Digital Electro- Hydraulic Control, namely DEH DEH is a turbine control system that consists of sensor designed by electric principle,

computer, amplifier designed by hydraulic pressure principle and hydraulic pressure servo mechanism. 10 Automatic turbine startup or shutdown control system, namely ATC ATC is an automatic control system that controls the turbine to complete the startup, synchronization procedure according to the thermal stress or other parameters of turbine. 11 Over- speed Protection Control, namely OPC OPC is a control function that can prevent overspeed. There are two ways to realize this function, acceleration limit or double positions control. The former can generates an override instruction to close down the high-pressure, mid-pressure regulating valve if turbine in overspeed operation. If the acceleration equals zero, the OPC maintain the normal speed for turbine. The later can close the high-pressure, midpressure regulating valve if the speed equals 103% of rated speed. 12 Uninterrupted Power Supply namely UPS. 13 Supervisory information system of the plant 1evel, namely SIS SIS provides the real time information and processed information, real time monitoring and management service for plant level personnel, failure judgements for dispatch center. It also supports the power unit level information process. 14 Turbine supervisory instruments, namely TSI TSI represents the instruments used for supervising state (speed, vibration, expansion, displacement etc.) 15 The field bus control system, namely FCS FCS is a distributed control system that based on field bus techniques. It connects the field measurement, control devices, into a network system according to public and normative protocols to realize the data transmission.

 Symphony Harmony INFI 90 System Harmony Rack Controllers The Harmony Rack Controllers are high-performance, high capacity process controllers. They are designed to interface with Harmony block I/O in the Symphony Enterprise Management and Control System. The Harmony rack controllers are fully compatible in functionality, communications, and packaging. The Harmony rack controllers collect process I/O, perform control algorithms and output control signals to process level devices. They also import and export process data from and to other controllers or other system nodes, and accept control commands from operators and computers connected to the network. The controllers communicate on the Control way with other rack controllers. They communicate with other system nodes on the control network (C net) via Harmony rack communication modules.

Description The Harmony rack controllers refer to a series of three controllers differentiated by their configuration memory capacity, execution speed and I/O support. The Harmony Bridge Controller (BRC-300) can support block and rack I/O simultaneously. The Harmony Multifunction Processors (IMMFP11 and IMMFP12) support only rack I/O. Each controller occupies a single slot in the module mounting unit. It consists of a single-board module that plugs into the module mounting unit. In the case of the

Harmony Bridge Controller, a Process Bus Adapter card is connected at the rear of the module to provide cable connections to the Harmony I/O subsystem and termination unit. As is standard, the module mounting unit provides built-in connections for rack modules. The Harmony rack controllers use a powerful 32-bit processor. On-board nonvolatile storage is provided for the control algorithms and user configurations. LEDs on the module front-plate display error messages and diagnostic data. One red/green LED displays module operating status. Harmony Rack Input / Output The Harmony Rack Input / Output (I/O) system utilizes a wide variety of input, output, and signal conditioning modules to interface process signals to the Symphony Enterprise Management and Control System. Module types, ranging from standard analog and digital I/O to specialty I/O such as turbine control, field bus, and sequence of events, can be combined to provide a comprehensive set of functionality to meet all market and industrial requirements.

The main components of Harmony rack I/O are I/O modules, termination units, and the I/O expander bus. The Harmony controllers and rack I/O modules communicate over I/O expander bus. Together a controller and its I/O modules form a subsystem within the Symphony system. The controller performs the actual control functions; the I/O modules process any inputs from and outputs to field devices for the controller.

The termination units provide field wiring termination for I/O modules. The controller can communicate with up to 64 I/O modules connected to the I/O expander bus. The rack I/O module types include:     

Analog input (ASI, FEC). Analog output (ASO). Digital input (DSI, DSM). Digital output (DSO). Specialized input/output (FCS, HSS, SED).

IMHSS03 Hydraulic Servo The IMHSS03 Hydraulic Servo module is a valve position control module. It provides an interface through which a Harmony controller can drive a servo valve or I/H converter to provide manual or automatic control of a hydraulic actuator. The controller utilizes function code 55 or 150 (hydraulic servo) to configure and access the module input/output channels. Typical uses for the module are positioning of steam turbine throttle and control valves, gas turbine fuel valves, inlet guide vanes, and nozzle angle. By regulating the current to the servo valve, the IMHSS03 module can initiate a change in actuator position. The hydraulic actuator can then position, for example, a gas turbine fuel valve or a steam governor valve. As the valve opens or closes, it regulates fuel or steam flow to the turbine, thus controlling the turbine speed. A linear variable differential transformer (LVDT) provides actuator position feedback to the hydraulic servo module. The IMHSS03 module is an intelligent I/O module with an onboard microprocessor, memory, and communication circuitry. In most applications, the IMHSS03 module works with the IMFCS01 Frequency Counter module. I/O Expander Bus The I/O expander bus is a high speed, synchronous, parallel bus. It provides a communication path between controllers and I/O modules. The I/O expander bus parallel signal lines are located on the module mounting unit backplane. Inserting a rack-mounted controller and I/O modules into the mounting unit connects them to the expander bus. I/O Module An I/O module interfaces and processes field device input and output signals. There are several different I/O module types available. Table 1 lists the available module types and gives a brief description. All I/O modules share the same layout and connection, configuration, and mounting methods. Refer to the Harmony Rack Input / Output data sheets for individual I/O module capabilities.

Modular Power System The Modular Power System III (MPS III) is specifically designed for powering Harmony rack modules and associated field mounted devices. The MPS III can provide 5, +15, and 24 VDC system power as well as 24, 48, and 125 VDC for field powered devices. Special features of the MPS III include: power factor correction, online power supply replacement, power and cooling status monitoring, and adaptability to various power input sources. The MPS III supplies 5 VDC, +15 VDC, -15 VDC, 24 VDC, 48 VDC, and 125 VDC power to Harmony rack components of the Symphony Enterprise Management and Control System. Figure 1 shows MPS III power system architecture.

In Figure 1, the 5, +15 and -15 VDC lines shown entering the system power bus bar are the operating voltages for rack I/O devices. The 24VDC (25.5 VDC actual voltage) line shown entering the system power bus bar is I/O power for field devices. Additionally, the power system can provide various combinations of 24, 48, and 125 VDC field power. The major MPS III components consist of a power entry panel, power chassis, power trays, system fan, and bus monitor. Bus Monitor The bus monitor checks status and generates a Power Fail Interrupt (PFI) signal in the event of a 5, +15, or -15 VDC bus failure. The bus monitor is located on the back of the power chassis.

Control NET Control Network, Cnet, is a high-speed data communication highway between nodes in the Symphony Enterprise Management and Control System. Cnet provides a data path among Harmony control units (HCU), human system interfaces (HSI), and computers. High system reliability and availability are key characteristics of this mission-critical communication network. Reliability is bolstered by redundant hardware and communication media in a way that the backup automatically takes over in the event of a fault in the primary. Extensive use of error checking and message acknowledgment assures accurate communication of critical process data. Cnet uses exception reporting to increase the effective bandwidth of the communication network. This method offers the user the flexibility of managing the flow of process data and ultimately the process. Data is transmitted only when it has changed by an amount which can be user selected, or when a predetermined timeout period is exceeded. The system provides default values for these parameters, but the user can customize them to meet the specific needs of the process under control. Harmony rack communications encompasses various communication interfaces as shown in Figure 1: Cnet-to-Cnet communication, Cnet-to-HCU communication, and Cnet-to-computer communication.

Control Network Cnet is a unidirectional, high speed serial data network that operates at a 10megahertz or two megahertz communication rate. It supports a central network with up to 250 system node connections. Multiple satellite networks can link to the central network. Each satellite network supports up to 250 system node connections. Interfacing a maximum number of satellite networks gives a

system capacity of over 62,000 nodes. On the central network, a node can be a bridge to a satellite network, a Harmony control unit, a human system interface, or a computer, each connected through a Cnet communication interface. On a satellite network, a node can be a bridge to the central network, a Harmony control unit, a human system interface, or a computer. Harmony Control Unit The Harmony control unit is the fundamental control node of the Symphony system. It connects to Cnet through a Cnet-to-HCU interface. The HCU cabinet contains the Harmony controllers and input/output devices. The actual process control and management takes place at this level. HCU connection to Cnet enables Harmony controllers to: 1. Communicate field input values and states for process monitoring and control. 2. Communicate configuration parameters that determine the operation of functions such as alarming, trending, and logging on a human system interface. 3. Receive control instructions from a human system interface to adjust process field outputs. 4. Provide feedback to plant personnel of actual output changes. Human System Interface A human system interface such as a Signature Series workstation running Maestro or Conductor Series software provides the ability to monitor and control plant operations from a single point. It connects to Cnet through a Cnet-to-computer interface. The number of workstations in a Symphony system varies and depends on the overall control plan and size of a plant. The workstation connection to Cnet gives plant personnel access to dynamic plant-wide process information, and enables monitoring, tuning, and control of an entire plant process from workstation color graphics displays and a pushbutton keyboard. Computer A computer can access Cnet for data acquisition, system configuration, and process control. It connects to Cnet through a Cnet-to-computer interface. The computer connection to Cnet enables plant personnel, for example, to develop and maintain control configurations, manage the system database, and create HSI displays remotely using Composer™ engineering tools. There are additional Composer and Performer series tools and applications that can access plant information through a Cnet-to-computer interface. Cnet-to-HCU Communication Interface The Harmony control unit interface consists of the INNIS01 Network Interface Module and the INNPM12 or INNPM11 Network Processing Module (Fig. 4). This interface can be used for a node on the central network or on a satellite network (Fig. 1). Through this interface the Harmony control unit has access to Cnet and to Controlway at the same time. Controlway is an internal cabinet communication bus between Harmony rack controllers and the communication interface modules. The HCU interface supports hardware redundancy. Redundancy requires a full set of duplicate modules (two INNIS01 modules and two INNPM12 or INNPM11 modules). The secondary network processing module (INNPM12 or INNPM11) continuously monitors the primary through a direct ribbon cable connection. A failover occurs when the secondary detects a primary module failure. When this happens, the secondary assumes responsibility and the primary is taken offline.

Cnet-to-Computer Communication Interface The Cnet-to-computer interfaces are the INICI03 and INICI12 interfaces. The INICI03 interface consists of the INNIS01 Network Interface Module, the INICT03A Computer Transfer Module, and the IMMPI01 Multifunction Processor Interface Module. The INICI12 interface consists of the INNIS01 Network Interface Module and the INICT12 Computer Transfer Module

Cnet-to-Cnet Communication Interface The Cnet-to-Cnet interfaces are the INIIR01 Remote Interface and the INIIL02 Local Interface. Figure 2 shows the remote interface and Figure 3 shows the local interface.

The local interface supports hardware redundancy. Redundancy requires a full set of duplicate modules (four INNIS01 modules and two INIIT03 modules). The secondary INIIT03 module continuously monitors the primary over dedicated Controlway. A

failover occurs when the secondary detects a primary module failure. When this happens, the secondary assumes responsibility and the primary is taken offline. Cnet-to-Cnet Local Transfer Module The INIIT03 Local Transfer Module serves as the bridge between two local Cnet communication networks. It holds the node database and is responsible for transferring all messages between networks. Messages include exception reports, configuration data, control data, and system status. This module directly communicates with the INNIS01 module of the central network and of the satellite network simultaneously. The INIIT03 module is a single printed circuit board that occupies one slot in the module mounting unit. The circuit board contains microprocessor based communication circuitry that enables it to directly communicate with its two INNIS01 modules and to interface to Controlway. Harmony Sequence of Events(SOE) Harmony sequence of events (SOE) provides distributed event monitoring, recording, and reporting capabilities for the Symphony Enterprise Management and Control System. An SOE event is a transition of a digital signal from either on to off or from off to on. A series of SOE modules collect and time-stamp these digital transition events which are then made available to the system. Figure 1 shows the distributed sequence of events system architecture.

An SOE module consists of a single printed circuit board that occupies one slot in a module mounting unit (MMU). In general, jumpers and switches on the printed circuit board and jumpers and dispshunts on the termination unit configure the module and its I/O channels. A cable connects the SOE module to its termination unit. The physical connection points for field wiring are on the termination unit.

Server Node The INSOE01 Server Node consists of the INNIS01 Network Interface module, the INSEM01 Sequence of Events Master module, and the INTKM01 Time Keeper Master module. INSEM01 The INSEM01 Sequence of Events Master module communicates with the INNIS01 Network Interface module and the INTKM01 Time Keeper Master module. The INNIS01 module is the front end for all Cnet (control network) communication interfaces and is the intelligent link between a node and Cnet. The INSEM01 module communicates directly with the INNIS01 module. The INSEM01 module is responsible for managing the distributed sequence of events system, which includes managing:  1,500 points coming from the SOE I/O modules in up to 1,000 Harmony control units (HCU).  256 complex triggers with 16 operands each.  3,000 simple triggers. The INSEM01 module monitors Harmony control units for data on an exception report basis, collects and sorts data it acquires, and provides SOE data to human system interfaces for report presentation after some predefined trigger condition occurs. Digital state transitions are collected at the HCU level by IMSED01 and INSET01 modules, then forwarded to the INSEM01 module. The INSEM01 module records the information and sorts it according to time in an internal database. When a trigger condition occurs, the human system interface is notified and data transfer occurs. INTKM01 The INTKM01 Time Keeper Master module provides time information to the INSEM01 module and to the rest of the distributed SOE system through the time synchronization link. The INTKM01 module connects to an external receiver using IRIG-B time code link. The module transmits absolute time to the rest of the system using the RS-485 time synchronization link. The INTKM01 module cable connects to an NTST01 termination unit. In this case, the termination unit provides the connection point for the external receiver signals and also the time synchronization link.

IMSET01 The IMSET01 Sequence of Events Timing module processes up to 16 digital field inputs, and receives and decodes the time synchronization link information sent by the INTKM01 module for a Harmony controller. The controller utilizes function code 241 (DSOE data interface) to interface SOE data from the IMSET01 module to the INSEM01 module, and function code 242 (SOE digital event interface) to configure and access the IMSET01 module input channels. Each channel is optically isolated, and can be individually programmed for 24 VDC, 48 VDC, 125 VDC, and 120 VAC input. The module communicates with its Harmony controller over I/O expander bus. Only one IMSET01 module can operate on an I/O expander bus segment. The module cable connects to NTST01 and NTDI01 termination units. The NTST01 unit provides for time synchronization link termination. The NTDI01 unit provides for field wiring termination. IMSED01 The IMSED01 Sequence of Events Digital Input module is similar to the IMSET01 module except that it only processes up to 16 digital field inputs for the Harmony controller. It does not process time synchronization link information. The controller utilizes function code 242 (SOE digital event interface) to configure and access the IMSED01 module input channels. Up to 63 IMSED01 modules can operate on an I/O expander bus segment along with one IMSET01 module. The NTDI01 termination unit provides for field wiring termination.  Composer™ System Composer provides a comprehensive set of engineering and maintenance tools for the Symphony Enterprise Management and Control System. Composer is designed to operate on the Microsoft® Windows NT® 4.0 (service pack four or later) platform. The working environment provided by Composer simplifies the configuration and maintenance of Symphony systems. The base product contains all the functionality necessary to create and maintain control system configurations. Applications provide users with the ability to graphically develop control system strategies, develop and maintain global configuration databases, and manage system libraries of reusable software components. Composer is designed to be compatible with INFI 90 OPEN system configurations and is capable of importing existing WinTools configurations. Once imported, these configurations can be fully integrated into Composer and utilize all its features. Composer Applications The base Composer product contains all the functionality necessary to develop and maintain Symphony control system configurations. There are two primary applications: explorer and automation architect.

Explorer The primary application of Composer is the explorer. Explorer presents the Symphony system architecture and provides an intuitive means for organizing, navigating and locating system configuration information. Explorer presents a user with two main windows: system architecture and the object exchange. System Window The system architecture window functions similar to Microsoft’s file explorer. The left pane of the window displays a hierarchical representation of the Symphony system. When a system object is selected, the right pane displays a detailed view for the selected object. The system window supports two views: the document view (Fig. 1)and the data browser view (Fig. 2). When the system window is in the document view, it will show the configuration documents that are associated with the system object that the user has selected. Configuration documents support long file names and can include control logic documents, human system interface displays, or documents created by other applications such as CAD packages or spreadsheets.

Figure 1. System Architecture - Document View

Figure 2. System Architecture - Data Browser View The ability to associate any documents with the system architecture is an important feature. This allows any information, such as P&IDs, cabinet arrangement drawings or field wiring drawings, to be managed by the configuration server and therefore accessed by Composer client applications. All that is required to edit any of these documents is to double click on the document. Composer’s explorer will automatically launch the appropriate application for the document selected. When the system window is in the data browser view, the right pane of the system architecture window will display tag information associated with the system object the user has selected. All tag information presented, is retrieved from the configuration server database that is managed by the Composer server. When working in the data browser view, users can view, define, and modify tag data for the whole system. This central repository of data is managed by Composer’s configuration server for all tag data in the entire system. The data for each tag is added to the configuration server database as each tag is defined. This eliminates the need for users to enter the same information more than once. Some notable features of the data browser view are the ability to: _ Edit tag objects in a datasheet or property page view. _ Filter the database. Filtering makes configuration easier and faster by eliminating unnecessary information from view. _ Import and export tag data. _ Navigate directly from a tag to its related configuration document. _ Perform automatic search and replace operations based on complex queries. Object Exchange The object exchange (object library) window presents the user with a view of the reusable components that can be used to create control system configurations (Fig. 3). Objects are organized in folders. Standard system components such as function codes and

standard shapes and symbols are organized under the system folder. Users are able to use these components but since they are part of the standard system objects supported by Composer, users are not permitted to delete these items from the object exchange. To support reuse, the object exchange provides library management features such as cutting, copying, and pasting of objects between different projects. This makes it easy for systems engineers to share objects among projects. Automation Architect The automation architect provides for the visual creation, editing, monitoring, and tuning of control logic. High-level control strategies can be created by dragging and dropping function codes from the object exchange to the control logic document.

Figure 3. Object Exchange Control strategies are represented graphically by the automation architect. Rather than textually programming strategies, the automation architect represents predefined control strategies as function blocks. By connecting function blocks together (Fig. 4), users are able to specify the signal flow of a control strategy and visually define the control strategy.

Figure 4. Automation Architect The automation architect stores configuration information in control logic documents. Control logic documents support grouping of multiple logic sheets in a single document. This permits users to group sheets of logic together using process partitions. For example, a single control logic document could be used to define the control strategy for a mix tank. Each control loop or motor control sheet associated with the mix tank could be assigned to the control logic document. Partitioning control logic in this manner is more process object oriented and intuitive to process engineering personnel (Fig. 5).

The monitoring and tuning capabilities (Fig. 6) of the automation architect provide the ability to troubleshoot and maintain an operational system using the same information used to create the system. By using the monitoring functionality, it is possible to obtain dynamic operating values from the Symphony system. These values are automatically presented on the same control logic documents that were used to configure the module. Composer’s tuning functionality allows the change of logic parameters as permitted by the controller. The control logic document in the Composer application and in the module are dynamically updated when tuning changes are made so that the documentation for the system accurately reflects the current configuration of the controller.

Figure 6. Monitoring and Tuning Capabilities Control Logic Templates Two of the primary goals of Composer are to reduce the cost of implementing control strategies and improve the quality of Control strategy software. To realize these goals, Composer supports a new type of document called a Control Logic Template.Control Logic Templates (Fig 7.) define reusable standard control strategies that are typically used to develop a process automation system, and can be thought of as blueprints that define the structure of a control strategy. They are maintained by the object exchange and can be used to quickly define control logic documents. The Control Logic Template Linking functionality allows users to define logic that is controlled by the template or can be modified within a logic document. Any subsequent changes made to a template can then be propagated to logic documents. When a template updates its documents it will preserve logic additions that the user has made to the document. This template management functionality provides efficient maintenance and utilization of reusable standard control logic.

 EMERGENCY TRIP SYSTEM (ETS) Sagardighi Thermal Power Project (2 × 300MW) uses PLC based Emergency Trip System (ETS) to ensure fast turbine tripping in case of some specified abnormal conditions occur in the main plant. The PLC is a (90-70) series of GE Fanuc .It takes different data continuously from many field instruments acting as trip device, processed signals from main control system (in SgTPP main control system is DCS manufactured by M/s. ABB Ltd.), Digital Electro-hydraulic system which govern opening/closing of turbine main stop valves & control valves, Turbine Supervisory Instrumentation that monitors healthiness of turbine and Instrumentation & Control power cabinet which supplies power to the control cabinet of DCS and ETS as well. Each unit of the plant contains separate ETS panel to process. The decision taken by ETS PLC is through Triple Modular Redundant (TMR) which sends trip signals to tripping device attached to turbine main stop valve and turbine control valve by voting 2 out of 3 processed signals. TMR avoids any chance of tripping due to wrong signal coming out from one of any 3 inputs. INPUT/OUTPUT OF ETS: There are two terminal blocks at the back panel of ETS, D1 and D2. All the inputs from various systems and field terminate at D1 and all the processed output signal goes out from ETS via D2. The output signals serves two purposes, i) goes to tripping devices and ii) others go to DCS for viewing different alarms like PLC failure, power failure etc. For all the tripping signals there is individual display at Power Generation Portal (Front end graphic software used for main plant operation). All the inputs to the ETS are made into three separate inputs by using diode and put into three separate Input modules. The Input modules are 06 nos. and driven by 24V DC. All the Input modules are IC660TBD024M and are sink type in nature. Each Input module has 32 channels so as to handle 32 inputs at the same time. There are 08 nos. of output modules used in each ETS. They are also of 24V DC type. Four of them are of sink type (IC660TBD024M) and others are source (IC660EBD025V) type. Two sink type output modules & two source type output modules combine to make 32 nos. of output data and rests make another 32 nos. of output data. Each unit is called a `H` type formation of output and combined digital output energies corresponding output relays. CPU, BUS & BUS CONTROLLERS: ETS system has three individual PLC units. Each PLC is having separate power supply units, one CPU (CPM790) and Three Bus Controllers (BEM791). As each input to the ETS system is made into three and is fed to three PLCs so there are three buses for whole communication. Each CPU takes all the three inputs from all the three buses. To achieve this kind of arrangement Each CPU requires three Bus Controllers. So, each bus passes through three bus controllers of different PLC, two input modules and three/two output modules. There is one 150Ω resistance used at each termination of three individual busses. Diagram below shows how architecture has been done between bus controllers of different PLC, 6nos. of DI & 8nos. of DO.

Bus Controller 1

Bus Controller 1

Bus Controller 1

Bus Controller 2

Bus Controller 2

Bus Controller 2

8

Bus Controller 3

Bus Controller 3

7

Bus Controller 3

PLC A

1

150Ω resistor

150Ω

DO

DO

PLC C

DI

Bus-3 DI

Bus-3 PLC B

2 3

DO DO DO DI PLC B

PLC C

Bus-2 DI Bus-2 PLC A

DO DO DI PLC B

PLC C

DI

Bus-1 DO Bus-1 PLC A

4 6 5

HOW TMR & DUAL OUTPUT WORKS: As discussed earlier every single input is made triple using a diode and fed to single PLC via bus and bus controllers and each bus passes through two input modules handling 1-32 nos. and 33-64 nos. of data. Each PLC CPU is configured with different addresses but same programmable logic is loaded into every PLC. The addresses given in the CPUs are also reflected to bus controllers also. So through bus controller arrangement every PLC knows what happens to the other PLCs. If one digital input changes its state the Triple Modular Redundant will vote out any possibility of getting state change to its corresponding output channel. The output modules are of `H` type combination. Each `H` consists of two source type output modules and two sink type output modules. First `H` can handle 1-32 nos. of output and second `H` can handle 33-64 nos. of output. PLCs can generate dual output source and dual sink corresponding to each output relay which energizes actuator associated to the electro-hydraulic governor to make the turbine valves quick close.

REASONS FOR TURBINE TRIP BY ETS : The emergency trip system (ETS) of steam turbine is able to start automatically the closing loop while trouble occurring with turbine, tripping occurring with generator and tripping occurring with main fuel of boiler, thus to fast close the steam inlet valves (main stop valves and control valves). The ETS is composed of mechanical-hydraulic and electricalhydraulic parts. That means the trouble can be detected in mechanical mode and electrical mode. But the closing of steam inlet valves are controlled by the hydraulic control and protection system finally. Mechanical-hydraulic emergency tripping: The emergency governor is a mechanical detector for overspeed trouble. In case the speed of turbine reaches n≥3300rpm, a stop ring will be flies out by the action of centrifugal force to actuate the emergency tripping device. The emergency tripping device changes the moving direction of the trip valve in tripping isolation valve group to drain the HP control oil. After the HP control oil is drained, the overspeed limiting control oil is also drained though the check valve. As a result the control oil pressure in dump valves for servomotors of steam inlet valves disappears and the dump valves are open. Then the pressure oil in both upper and lower chambers of servomotors is connected to the drain port through the opened dump valves to fast close the steam inlet valves. After full closing the main stop valves the limiting switch signal will be sent out to the check valves through electric control loop. Electric-hydraulic emergency tripping: This is an electric mode to detect the trouble occurring with turbine, the tripping occurring with generator and the tripping occurring with main fuel of boiler and also to send out the electric tripping signal to the mechanical tripping electric magnet 3YV at the same time. As soon as the electric tripping signal is sent to the mechanical tripping electric magnet 3YV, the latter will be energized to actuate the emergency tripping device through linkage mechanism. The following process will be performed as same as described in Mechanical-hydraulic emergency tripping system.

Electric tripping signals:

The electric tripping signals of ETS for the steam

turbine are as follows: 1. Overspeed Trip: In case the speed of turbine rises to 3300 rpm and above, the overspeed relays in overspeed monitoring channels of ETS are actuated and the tripping signal is sent out after processing by the ETS in 2 out of 3 logic through the output contact. 2. Low Lube Oil Pressure Trip: In case the oil pressure in lube line P≤0.0392MPa (which is the setting value for pressure switch), three pressure switches PSA4~PSA6 in lube oil low pressure tripping device will be reset and three normally-closed(NC) contacts will send out the tripping signal after processing by the ETS in 2 out of 3 logic. 3. Low Control Oil Pressure Trip: In case the oil pressure in fire-resistant oil line P≤7.8MPa, three pressure switches in resistant oil manifold supplied by the DEH manufacturer will be reset and three normal-open(NO) contacts will send out the tripping signal after processing by the ETS in 2 out of 3 logic. 4. Condenser Low Vacuum Trip: In case the pressure in condenser P≥19.7kPa, three vacuum switches in condenser low vacuum tripping device are actuated and three normal-open(NO) contacts will send out the tripping signal after processing by the ETS in 2 out of 3 logic. 5. Axial Position High Trip: In case the shaft displacement related to thrust bearing increases (≥ 1.2mm or ≤ -1.65mm), the contact of the axial displacement emergency relay in dual-channel axial displacement monitor will send out the tripping signal after processing by the ETS. 6. Main Fuel Trip: The steam turbine will suffer tripping by trouble with main fuel of boiler, and the signal will be supplied by the Furnace Safeguard Supervisory system (FSSS). 7. Generator Failure Trip: The steam turbine will suffer tripping by trouble with generator, and the signal will be supplied by the generator protection system. 8. Shaft Vibration High Trip: The TSI (Turbine Supervisory Instrumentation) will send out the shaft vibration in X axis at any of #1~#6 bearings is too high (≥ 0.25mm) or the shaft vibration in Y axis at any of #1~#6 bearings is too high (≥ 0.25mm). Above mentioned combination logic has been conducted in the TSI and a contact signal is sent out by the TSI to the ETS for turbine tripping. 9. EHG Failure Trip: This is the turbine tripping signal supplied by the DEH (Digital Electro-hydraulic System) and contains the turbine overspeed monitored by DEH, DEH speed signal trouble and etc. It is used to output the shut-down contact signal for turbine tripping.

10. Differential Expansion High Trip: The TSI (Turbine Supervisory Instrumentation) will send out the HP/IP differential expansion trip signal if it is ≥ 7μm or ≤ -4μm or LP differential expansion ≥15μm. Above mentioned combination logic has been conducted in the TSI and a contact signal is sent out by the TSI to the ETS for turbine tripping. 11. Remote Manual Trip: There is one manual push button in Central Control Room. If any case somebody presses it sends one tripping signal to ETS and ETS makes the turbine trip. 12. Generator Cooling Water Loss Trip: In case the cooling water flow for generator ≤ 35 T/H, three Differential Pressure switches (DP set at ≤ 29.4kPa) meant for generator cooling water flow low trip are actuated and three normalclose contacts will send out the tripping signal after processing by the ETS in 2 out of 3 logic. 13. Exhaust Temperature High Trip: In case the HP exhaust temperature ≥420˚C main plant control system will send trip signal by itself using the help of three temperature detector to ETS where it will be activated by 2 out of 3 logic.

FURNACE SAFEGUARD SUPERVISORY SYSTEM The Triguard SC300E is a high integrity safety system designed especially for use in processes with high demands on the availability, reliability and fault-tolerance of the control system; emergency shutdown systems, interlock systems, burner control, turbine control, fire and gas detection and protection systems. The Triguard SC300E safety controller is designed with Triple Modular Redundant (TMR) hardware system. This hardware architecture is combined with Software Implemented Fault Tolerance (SIFT) to achieve extremely high operational availability and function on demand performance. The three key aspects of Triguard SC300E, that permit system availabilities in excess of 99.999% (about 1 hour’s downtime in 11 years) to be realized, are: • Triple Modular Redundant architecture - TMR • Software Implemented Fault Tolerance - SIFT (with HIFT output voter) • On line hot repair facility

Architecture

Theory of operation At the input modules, field signals are filtered and then split, via isolating circuitry, into three identical signal processing paths. Each path is controlled by a microcontroller that coordinates signal path processing, testing and signal status reporting to its respective processor, via one of the I/O communications buses. Once each processor has a copy of the input state it votes on that data against the input states presented by the other two processors. The voted result is then used in the application logic. Once the application has been processed, the results of the application logic are again compared with the other two processors. These voted results are then written to the output cards by the processors. The output modules share the same microcontroller architecture as the input cards, a single result is presented to the field by passing the three processor signals through a hardware 2oo3 voting circuit. Processor modules The SC300E processors have been designed around Intel microprocessors. Key features of the processor modules are: • Intel 32 bit microprocessor • Support for up to 1Mb of battery backed static RAM for application logic storage. Error detection and correction circuitry is used to monitor all data accessed from the RAM. Onboard lithium batteries provide a backup supply to the RAM for up to 6 months in the event of system power failure. • Up to 2 Mb of EPROM programmed with Triguard SC300E’s real time operating system. EPROM can also be used for the storage of application logic.

• Buffered I/O communications bus via a special 96 way DIN41612 connector permitting the live insertion of a processor module. • Real time calendar clock circuitry used for data logging to a resolution of 10 ms. The size of a processor’s sequence of events log is typically 5000 events. • Two 8 Mbps, read-only, serial communications links used by a processor to read I/O and diagnostic information from its two processor neighbours. • Front panel mounted RS232 serial communications port used for engineering diagnostic purposes. • Watchdog circuitry and front panel mounted control switches and indicators.

Common interface All I/O modules in the Triguard SC300E share a common system interface as depicted byFigure 1-4.

 LOCAL IGNITION CONTROL SYSTEM The local ignition control system is designed by Eastern Boiler Control Co., Ltd specifically for INDIAN SAGARDIGHI 2×300MW power plant. The boiler designed by Dong Fang Boiler Group Co., Ltd specifically for INDIAN SAGARDIGHI 2×300MW power plant includes: a. Four (4) Elevations of tangential fired oil compartments, which one include: one (1) light oil gun and one (1) heavy oil gun. b. Four (4) Elevations of tangential fired coal compartments. Each oil burner is equipped with a Class 3 Special igniter, as defined by NFPA. This is a high energy spark type igniter for direct ignition of the atomized oil burner during oil burner light off. First, the light oil gun will be lit off by igniter with the commands from operator, then the heavy oil gun will be lit off by the light oil gun with the commands from operator. The igniter is also brought into service when the oil atomizer is shutdown and purged (scavenged) to remove oil from the atomizer, the oil being lit by the igniter as it is ejected from the atomizer by the purge (scavenged) steam. These typical functions will be completed in FSSS (or BMS) logic. In remote operation mode, the local ignition control system, accepted the command from FSSS (or BMS) which is a part of DCS, send drive signals to local devices of oil burner. In local operation mode, the local ignition control system, accepted the commands from operator, send drive signals to local devices of oil burner. 2 System function The local ignition control system consists of sixteen (16) local control cabinets and sixteen sets of local devices for oil burner. 2.1 Local devices of a oil burner For each oil burner, includes: ◆ Heavy oil gun insert/retract actuator drove by instrument air With a single solenoid valve and insert/retracted limit switches (DPDT) ◆ Light oil gun insert/retract actuator drove by instrument air With a single solenoid valve and insert/retracted limit switches (DPDT) ◆ Igniter insert/retract actuator drove by instrument air With a dual solenoid valve and insert/retracted limit switches (DPDT) ◆ High Energy Igniter (HEI) ◆ Light oil shut-off valve With a dual solid valve & pneumatic actuator & opened/closed limit switches (DPDT) ◆ Light oil purge valve With a single solenoid valve & pneumatic actuator & opened/closed limit switches

(DPDT) ◆ Light oil atomization valve With a dual solid valve & pneumatic actuator & opened/closed limit switches (DPDT) ◆ Heavy oil shut-off valve With a dual solid valve & pneumatic actuator & opened/closed limit switches (DPDT) ◆ Heavy oil purge valve With a single solenoid valve & pneumatic actuator & opened/closed limit switches (DPDT) ◆ Heavy oil atomization valve With a dual solid valve & pneumatic actuator & opened/closed limit switches (DPDT)

2.2 The signals from the ignition control system to DCS: ◆ Light oil valve opened ◆ Light oil valve closed ◆ Light oil atomization valve opened ◆ Light oil atomization valve closed ◆ Light oil purge valve opened ◆ Light oil purge valve closed ◆ Heavy oil valve opened ◆ Heavy oil valve closed ◆ Heavy oil atomization valve opened ◆ Heavy oil atomization valve closed ◆ Heavy oil purge valve opened ◆ Heavy oil purge valve closed ◆ Igniter insert ◆ Igniter retracted ◆ Light Oil gun insert ◆ Light Oil gun retracted ◆ Heavy Oil gun insert ◆ Heavy Oil gun retracted ◆ Local operation requirement ◆ HEI sparking 2.3 The signals from DCS to the ignition control system: ◆ Local operation permission ◆ Open command to Light oil valve ◆ Close command to Light oil valve ◆ Open command to Light oil atomization valve ◆ Close command to Light oil atomization valve ◆ Open command Light oil purge valve ◆ Close command to Light oil purge valve ◆ Open command Heavy oil valve opened ◆ Close command to Heavy oil valve closed ◆ Open command Heavy oil atomization valve opened ◆ Close command to Heavy oil atomization valve closed

◆ ◆ ◆ ◆ ◆ ◆ ◆

Open command Heavy oil purge valve opened Close command to Heavy oil purge valve closed Insert/ retract command to Igniter Insert/ retract command to Light Oil gun Insert/ retract command to Heavy Oil gun Energize HEI transformer Flame on

3.2 Igniter and oil gun insert/retract actuator

The heavy oil gun insert/retract actuator is controlled by a solenoid 5/2 valve. Once operated the “insert” valve will remain in its operated position after the pulse has been removed and until the retract solenoid is operated. The light oil gun insert/retract actuator is controlled by a solenoid 5/2 valve. Once operated the “insert” valve will remain in its operated position after the pulse has been removed and until the retract solenoid is operated. The HEI igniter insert/retract mechanism is controlled by a single acting solenoid 3/2 valve which is energized to insert the igniter pod. In the oil corner start or stop sequence, neither heavy oil gun or light oil gun need to be insertd or retracted. When advancing command which will be sent to the solenoid 5/2 valve, the oil gun is insertd via the insert/retract actuator drove solenoid 5/2 valve, the oil gun is retracted via the insert/retract mechanism drove by instrument air. Before energizing the HEI transformer, the igniter pod must to be insertd. When advancing command which will be sent to a solenoid 3/2 valve, the igniter is insertd via the insert/retract actuator drove by instrument air. When the advancing command is missing, the igniter will be retracted to the original position. 3.3 High energy igniter (HEI) The HEI is used to ignite oil gun in power plant station. It includes: ● HEI transformer ● Igniter pod ● Special cable assembly between HEI transformer and igniter pod (about six 6 meter long0 The igniter pod moves with the igniter insert/retract actuator. Its length depends on the light oil gun requirements. Before sparking in the start or stop sequence, the igniter pod need inserted in the atomizing area of light oil gun. After the sparking, the igniter pod must be retracted from the flame area as a protection against heat overload. HEI transformer accepts the energizing signal. A high tension capacitor in the HEI transformer is charged up with energy and then released via a special cable assembly to the igniter pod. The resultant arc discharge converts the energy into heat which ignites the fuel.

3.4 Oil corner shut-off valve. Atomization valve & Purge valve Both light oil shut-off valve and heavy oil shut-off valve drove by instrument air, which we supplied, is controlled by solenoid 5/2 valve. When opening command is sent to the solenoid valve, the valve is opened via the pneumatic actuator. When closing command is sent to the solenoid valve, the valve is closed via the pneumatic actuator. Both light oil atomization valve and heavy oil atomization valve drove by instrument air, which we supplied, is controlled by solenoid 5/2 valve. When opening command is sent to the solenoid valve, the valve is opened via the pneumatic actuator. When closing command is sent to the solenoid valve, the valve is closed via the pneumatic actuator. Both the light oil purge valve and heavy oil purge valve is controlled by single solenoid coil (solenoid 3/2 valve). When opening command is sent to the solenoid valve, the purge valve is opened via the pneumatic actuator. When missing the opening command, it is closed automatically. Main performance parameter of heavy oil shut-off valve or light oil shut-off valve as below: ● Control voltage:240VAC 50Hz ● Instrument air pressure:0.4~0.8 MPa ● Medium temperature: ＜250℃ ● Atomization/purge steam temperature: 220~250℃ ● Medium pressure: ＜3.2MPa Main performance parameter of heavy oil atomization valve or light oil purge valve as below: ● Control voltage:240VAC 50Hz ● Instrument air pressure:0.4~0.8 MPa ● Medium temperature: ＜250℃ ● Atomization/purge steam temperature: 220~250℃ ● Medium pressure: 0.78~1.27 MPa Main performance parameter of heavy oil purge valve or light oil purge valve as below: ● Control voltage:240VAC 50Hz ● Instrument air pressure:0.4~0.8 MPa ● Medium temperature: ＜250℃ ● Atomization/purge steam temperature: 220~250℃ ● Medium pressure: 0.78~1.27 MPa

UPS GENERAL DESCRIPTION UPS（Uninterruptible Power System） supplies reliable and interference-resistant AC power for computer control, SCADA, DCS, important protection, measuring meter and solenoid valve etc. UPS system composition in power house 1 Stabilizer panel 2 Isolation transformer panel 3 #1UPS Main panel 4 #2UPS Main panel 5 Distribution feeder panel UPS equipment： 1. 100% Static inverter 2. 100% Static switch 3. Manual bypass switch 4. 100% UPS System battery bank 5. 100% high-frequency switch module charger 6. Step-down transformer with associated Switchgear 7. voltage stabilizer and standby power switch 8. battery panel 9. UPS AC feeder panel

 UPS System description 1. The capacity of the power house UPS system is 2X80KVA for each set. The input voltage of UPS is AC 415V ±10%, 50HZ, the output of the UPS is AC 240V, 50HZ. The UPS is normally supplied by a 415V emergency PMCC circuit. When the 415V emergency PMCC fails, the UPS will be supplied by its DC 1.2V, 100Ah battery bank. Total no of batteries are 272 per UPS set. When both static inverters of UPS fail, the supply of UPS will be automatically transferred to auto bypass. 2. Two inverters are in operation on normal condition, each carries 50% UPS load. On failure of any inverter, its load gets automatically transferred to the other inverter through static transfer switch. If one inverter is out of service for any reason, then the second inverter will be working with 100% UPS load. On failure of this inverter，the auto bypass A.C. source will supply 100% UPS load automatically through static transfer switch.

UPS Battery Bank

UPS Technical Data AROS 80KVA Major Technical Data： Operating Condition 80KVA -5/50℃ Operating Temperature Storage Temperature -20/70℃ Relative Humidity 5-95% Total Efficiency >96% （ECO-MODE operation >98） Average MTBF >350,000 hours Noise 65dBA 800*740*1400 Dimension（W×D×H）MM Weight KG Rectifier Input Data Input Voltage Input Frequency Input Power Factor Inverter Electrical Data Output Voltage Output Voltage Fluctuation Range Output Voltage’s Spontaneous Response Feature Output Voltage Distortion --100% Non Linear Load Output Frequency Frequency Adjustable Range Conversion Efficiency Output Wave Form Overload Crest Factor Inverter’s Short Circuit Resistance Static Bypass Data Overload Capacity Efficiency Real Time Transfer -from mains to inverter -from inverter to mains

520 415V/AC±20% 50Hz/60Hz±10% >0.95 240V ±1% ±3%（load 0-100％ 10ms resume） 110°C 3. Turbine Over speed trip > 3300rpm 4. Main Steam temperature low trip < 430°C 5. EH safe oil pressure low 6. Manual trip push button 7. EHG failure trip (it includes any malfunction in turbine main steam valves operation or any power supply failure to DEH system like 48V DC) 8. Any ATR trip Which includes: a) any brg metal temp trip b) Any thrust brg temp trip c) Any brg drain oil temp trip > 75°C d) Rotor position trip +1.2 / -1.65

HART System HART stands for Highway Addressable Remote Transducer. It is an open protocol developed in the late 1980's to facilitate communication with Smart field devices. HART communication occurs between two HART-enabled devices, typically a field device and a control or monitoring system. Communication occurs using standard instrumentation grade wire and using standard wiring and termination practices. HART provides two simultaneous communication channels: the 4-20mA analog signal and a digital signal. The 4-20mA signal communicates the primary measured value (in the case of a field instrument) using the 4-20mA current loop - the fastest and most reliable industry standard.

MACHINE MONITORING SYSTEM(MMS) Beijing ENVADA’s EN9000 device is an online vibration monitoring and protection system for rotating machinery. It takes vibration and keyphasor data from PA fan, FD fan, ID fan, CEP, BFP, CWP, ACWP and all mills and generates annunciation for all vibration risk limit. MMS produces tripping signals equipment safety. The system continuously measures and monitors the main mechanical safety parameters of the device. 2. EN9000 Characteristics  The EN9000 uses the latest microelectronic technologies to ensure a highly integrated, strong anti-interference capability with high reliability and ease of installation.  The doubly redundant power supply guarantees the normal working of the system at any time so long as commercial electric power is available.  Each module supports hot plug & pull operation. Maintenance is achieved by module convenient replacement.  Each module is provided with a built-in microprocessor. The modules are independent and cause no interference to other modules.  The system integrates the vibration monitoring protection and fault diagnosis functions. All settings can be defined remotely and transferred by software download but each channel can be set and adjusted directly on the machine. The software provides rich functionality, with user definable display area, sensor sensitivity, alarm values, alarm delays, alarm logic and zero point definition. The delayed access and password protection are built in to prevent faulty operation and protect the fixed values from unauthorized operation.  The values and development trends of each channel can be observed on the host machine screen. Waveform and frequency analysis is provided to automatically diagnose common rotating machinery problems, including unbalance, rotor/stator rubbing, uneven expansion, abnormal axial position, oil whirl/whip, etc.  The common system computer vibration analysis and fault diagnosis software provides flexible data management, real-time status monitoring, complete signal analysis, detailed fault diagnosis and dynamic balancing. Classification of EN9000 system modules EN9000 system is of modular design that meets a wide range of needs. The system is expandable. The EN9000 modules are as follows: EN9000/RX unit EN9000/1X power supply module EN9000/40 vibration and displacement module EN9000/30 rotational speed module EN9000/20 keyphase module

EN9000/50 8-channel process module EN9000/60 20-channel process module

Power Supply Module: Each EN9000 power supply module is a half-height module and must be installed into the special purpose slot on the left side of the chassis. Two identical power supply modules are installed inside EN9000 chassis to provide a two-way redundant supply. The power supply module is installed at the lower left corner of EN9000 chassis, and it converts the AC voltage provided from the terminal board on the back of the chassis to the DC voltage ( +5V DC, +15V DC, - 24V DC) required for the normal working of other EN9000 modules. The external AC supply voltage should be specified at the time of order may be 115V AC±15% or 230V AC±15%.

Vibration sensing module: The 4-channel vibration and displacement module is numbered as EN9000/40 (it corresponds to i/o module: EN9000／04) and is able to monitor the radial vibration, radial clearances and axial displacement of rotating machinery in real time. It can be used on all sizes of rotating machinery and can be installed into EN9000 chassis to be used together with the power module and Host Machine Module. The 4-channel vibration and displacement module monitors the input signals from 4 sensors. It performs the following functions: - It buffers the voltage output from the sensor signals - It records the 4- 20mA transducer current output from the sensor signals - It displays the status of the sensor and its channel through the LED on the front panel - It transmits the monitored values and set values of the 4 channels to the central LCD. What is critical is that the relay will trip the protection switch to shut down the rotating machinery when the warning criteria are exceeded.

Important signal out from MMS panel: Alarm signals of different Equipment: 1. All ID fan, FD fan, PA fan radial bearing, thrust bearing, motor drive bearing, nondrive bearing alarms are set at 7.1mm/sec. 2. All ID fan, FD fan, PA fan radial bearing, thrust bearing, motor drive bearing, nondrive bearing tripping are set at 10mm/sec. 3. All BFP, CEP motor drive ,motor non-drive, pump drive and non-drive bearings alarm has been set at 80 microns. 4. All BFP, CEP motor drive ,motor non-drive, pump drive and non-drive bearings tripping has been set at 150 microns. 5.All mills Reductor vibration alarms set at 5.6 mm/s.

TURBINE SUPERVISORY INSTRUMENTATION(TSI) TURBINE SUPERVISORY INSTRUMENTATION is abbreviated to TSI. As the turbine capacity and the turbine capacity keep creasing, and the thermal system becomes more and more complicated, smaller stage clearance and the gland clearance are chosen in order to higher the thermal economy of unit. Since the speed of turbine is quite fast, the rotating parts and the static parts are possibly scrap without right operation or control, which may result in serious accidents like blade cracking, shaft bending, thrust pads burning, etc.. In normal operation, the mechanical parameters of the axial displacement, the thermal expansion, the differential expansion, the rotating speed, the libration, the main bearing eccentricity and etc., should be monitored and be protected. The main valve will close automatically to stop the unit when the monitored parameters over the limit.

3500 series: SgTPP is using 3500 series Bently Nevada vibration monitoring system. This comes with rack configuration system. One dedicated rack is there for analyzing all turbine shaft vibration. Designed using the latest in proven microprocessor technology, the 3500 is a fullfeature monitoring system. In addition to meeting the above stated criteria, the 3500 adds benefit in the following areas: • Enhanced Operator Information • Improved integration to plant control computer • Reduced installation and maintenance cost • Improved reliability • Intrinsic Safety option Enhanced Operator Information: The 3500 was designed to both enhance the operator's information and present it in a way that is easy for the operator to interpret. These features include: • Improved Data Set - Overall Amplitude - Probe Gap Voltage - 1X Amplitude and Phase - 2X Amplitude and Phase - Not 1X Amplitude • Windows® Based Operator Display Software(System1 software) Improved integration to plant control computer: • Communication Gateways supporting multiple protocols Reduced installation and maintenance cost: • Reduced cabling costs • Improved space utilization • Easier configuration • Reduced spare parts Improved reliability: • Redundant power supplies available • Triple Modular Redundant (TMR) monitors and relay cards available

• Redundant Gateway and Display Modules permitted

The following modules may be installed in the 3500 rack: Power Supply: The Power Supply is a half-height module available in AC and DC versions. One or two power supplies can be installed in the rack. Each power supply has the capacity to power a fully loaded rack. When two power supplies are installed in a rack, the supply in the lower slot acts as the primary supply and the supply in the upper slot acts as the backup supply. If the primary supply fails, the backup supply will provide power to the rack without interrupting rack operation. Any combination of power supply types is allowed. Overspeed Detection and TMR Monitors require dual power supplies. Rack Interface Module: The Rack Interface Module is a full-height module that communicates with the host (computer), a Bently Nevada Communication Processor, and with the other modules in the rack. The Rack Interface Module also maintains the System Event List and the Alarm Event List. This module can be daisy chained to the Rack Interface Module in other racks and to the Data Acquisition / DDE Server Software. The 3500 Monitoring System Computer Hardware and Software Manual shows how to daisy chain the Rack Interface Modules together. Rack Interface Modules are available in Standard, Triple Modular Redundant and Transient Data Interface versions.

Communication Gateway Module: The Communication Gateway Modules are fullheight modules that allow external devices (such as a DCS or a PLC) to retrieve information from the rack and to set up portions of the rack configuration. More than one Communication Gateway Module can be installed in the same rack. Communication Gateway Modules are available for a variety of network protocols. Relay Module: Relay Modules offer relays that can be configured to close or open based on channel statuses from other monitors in the 3500 rack. Relay modules are available in 4 channel, 16 channel, and 4 channel Triple Modular Redundant The TMR Relay Module is a half-height 4-channel module that operates in a Triple Module Redundant (TMR) system. Two half-height TMR Relay Modules must operate in the same slot. If the upper or lower Relay Module is removed or declared as not OK, then the other Relay Module will control the Relay I/O Module.

Keyphasor Module: The Keyphasor Module is a half-height module that provides power for the Keyphasor transducers, conditions the Keyphasor signals, and sends the signals to the other modules in the rack. The Keyphasor Module also calculates the rpm values sent to the host (computer) and external devices (DCS or PLC) and provides buffered Keyphasor outputs. Each Keyphasor Module supports two channels and two

Keyphasor Modules may be placed in a 3500 rack (four channels maximum). If two Keyphasor Modules are used, they must be placed in the same full-height slot and will share a common I/O module. 3500/22M Transient Data Interface The 3500 Transient Data Interface (TDI) is the interface between the 3500 monitoring system and Bently Nevada’s System 1® machinery management software. The TDI combines the capability of a 3500/20 Rack Interface Module with the data collection capability of a communication processor such as TDXnet. TDI operates in the RIM slot of a 3500 rack in conjunction with the M series monitors (3500/40M, 3500/42M, etc.) to continuously collect steady state and transient waveform data and pass this data through an Ethernet link to the host software. Static data capture is standard with the TDI, however using an optional Channel Enabling Disk will allow dynamic or transient data to be captured as well. TDI has made improvements in several areas over previous communication processors in addition to incorporating the Communication Processor function within the 3500 rack. TDI provides certain functions common to the entire rack, however the TDI is not part of the critical monitoring path and has no effect on the proper, normal operation of the overall monitor system. One TDI or RIM is required per rack. The TDI occupies only a single slot in the rack and is always located in Slot 1 (next to the power supplies). For Triple Modular Redundant (TMR) applications, the 3500 System requires a TMR version of the TDI. In addition to all the standard TDI functions, the TMR TDI also performs “monitor channel comparison”. The 3500 TMR configuration executes monitoring voting using the setup specified in the monitor options. Using this method, the TMR TDI continually compares the outputs from three (3) redundant monitors. If the TMR detects that the information from one of those monitors is no longer equivalent (within a configured percent) to the remaining two, it will flag the monitor as being in error and place an event in the System Event List. Rack Configuration Software Rack configuration soft ware is a Windows based easy to install to the racks of 3500 system host software. All the racks like power module, RIM, Transient Data Interface , keyphasor module, vibration module etc can be configured remotely through RS232 or 10/100 T base Ethernet port. For all the shaft vibration, bearing vibration, differential expansion, keyphasor, eccentricity range is defined through this Software. Alarm values and danger limit is defined to trigger relay attached to individual back pne module.

TMR Relay module can be configured to incorporate more than one parameter to have different alarm and trip events.

Type of Racks used and signals out 1. Speed module: It is a two channel speed module which senses speed of turbine and relay out the zero speed of turbine to auto start of Turning gear. 2. Over speed module: There are three nos of 3500/53 overspeed module. They are single channeled. Each module is configured to have a high limit relay out of 110% of normal turbine speed i.e. 3300rpm. Three nos of output goes to ETS to trip turbine if speed exceeds the high value. 3. Rotor position monitoring module: This is a 4 channel proximity monitoring module which measures the rotor position. The danger limit is set as (≥ 1.2mm or ≤ -1.65mm). The trip signal is generated through relay module. 4. Differential Expansion Module: This is a 4 channel position monitoring module which measures HIP differential expansion & LP differential expansion & two nos of casing expansion. Turbine trip due to differential expansion high is clubbed together and programmed in relay module. 5. Vibration monitoring module : There are 6 nos of 3500/42 proximity module for measuring X and Y direction vibration of each turbine shaft and bearing. The 4-20 mA signal out is taken to DCS and turbine trip due to high shaft vibration logic is built using Composer. 6. Eccentricity measurement: This is also a proximity module whose corresponding sensor is mounted on front pedestal of turbine.

HPLP Bypass HP bypass controller The Sulzer HP bypass controller is an integrated system with the functions signal conditioning, control and valve positioning (Figure 1). The type of operator interface can be tailored to the needs of the individual plant. The below described functions for start up as well as for shut down are fully automated. With a few standardized interface signals the Sulzer bypass controller can be tied easily into an overall plant automation. The duty of the HP bypass controller can be summarized for the different operating conditions as follows: Boiler start up The controller has to control and increase the boiler steam pressure according to the steam production of the boiler. The bypass has to divert the steam flow to the reheater, thus ensuring a proper steam flow through superheater and reheater. The bypass controller has to control the temperature of the steam to the reheater whenever steam is flowing through the bypass. Turbine start up The HP bypass controller has to control the steam pressure until the boiler master controller can take over the pressure control. Load operation The bypass is closed but the controller is ready to prevent excessive live steam pressure or excessive pressure gradients. Turbine load rejection/trip The controller opens the bypass valves, if necessary with the help of the quick opening devices, in order to prevent excessive live steam pressure and controls the pressure until the turbine picks up load again. Safety Function Regulations of various countries allow the use of the HP Bypass valves as safety valves for the HP part of the boiler without any additional conventional safety valves on the HP side. for this the HP Bypass has to be equipped with a hardwarewise fully independent safety system. Functionally this system is fully integrated into the bypass controller to ensure smooth transients between safety and control function.

Figure 2 shows the main elements of a two line HP bypass with the main control functions: Pressure controller temperature controller injection water isolation valve control safety function 1.2.1 Pressure control Figure 3 shows in more detail the structure of the pressure controller and the pressure setpoint generator. The different functions and operating modes of the pressure controller are represented again in the start up diagram of Figure 4. At the begin of a cold start the minimum opening (Ymin) is active. It ensures immediately after ignition an open path and therefore a steam flow through the superheater and reheater. When there is enough steam production to reach a predetermined minimum pressure (pmin) the controller begins to control the live steam pressure by opening the bypass valves. When the valve positions reach a predetermined value Ym (determined by the desired steam flow during boiler start up) the setpoint generator begins to increase the pressure setpoint in accordance with the steam production of the boiler, but with a limited maximum gradient.

Once the target pressure for starting the turbine (psynch) is reached, the setpoint generator switches to (fixed) pressure control. As the turbine starts to accept steam the bypass will start to close until the turbine consumes all the steam produced by the boiler and the bypass is fully closed. As soon as the bypass is closed the pressure setpoint tracks the actual pressure plus a threshold dp which keeps the bypass closed (follow mode). The maximum gradient of the pressure setpoint is still limited. If the life steam pressure exceeds this gradient, the bypass will start to open and the controller returns to pressure control mode. The pressure is controlled by the bypass until normal operation has been restored and the bypass is closed again. 1.2.2 Temperature control Regarding temperature control it should be mentioned here only that accurate control of the steam temperature under all operating conditions requires a controller well matched

to the wide range of operating conditions of a HP bypass (low load, quick opening at full load, etc.). Accurate control of the temperature under all this operating conditions is an important life conserving factor for the heavily stressed walls of the valves and piping. 1.3 LP bypass controller The Sulzer LP bypass controller is an integrated system with the functions signal conditioning, control and valve positioning (Figure 5). The type of operator interface can be tailored to the needs of the individual plant. With a few standardized interface signals the Sulzer bypass controller can be tied easily into an overall plant automation. Although independent in operation from the HP bypass controller the LP bypass controller must operate in conjunction with the HP Bypass system and allow the excess steam flow which is not admitted to the turbine to pass to the condenser. 1.3.1 Pressure Control The duty of the LP bypass pressure controller for the different operating modes can be summarized as follows: Boiler start up The controller has to control the steam pressure in the reheater system. The injection controller has, when ever the LP bypass is open, to control the desuperheating of the steam so that it can be accepted by the condenser. Load operation The bypass is closed but the controller monitors the reheat steam pressure in order to open and control the pressure whenever an unacceptable pressure increase is monitored. Condenser protection Whenever the condenser is not able to accept the steam or the injection water system is unavailable, the controller has to close the bypass through a separate safe channel in order to protect the condenser.

During load operation the first stage pressure of the turbine serves as load signal for the setpoint generator which generates a load dependent (sliding) pressure setpoint. With large bypass valves, their flow capacity at high reheater pressure can exceed the

absorption capacity of the condenser. For such cases the steam flow to the condenser must be limited by the bypass controller. If power operated reheater safety valves are provided (e.g. Sulzer MSV valves), coordinated operation of the reheater safety valves with the LP bypass can further improve plant operation for the case of turbine trip or load rejection at high load. The Sulzer LP bypass controller can provide the necessary signals for operation of the reheater safety valves. 1.3.2 Injection water control Because the steam conditions after the LP bypass de superheater are usually near or at saturation condition, the temperature after the de superheater cannot be used as control signal. The necessary injection water flow and valve position of the injection valve must therefore be calculated from the steam flow and steam conditions. The steam flow is in turn a function of the steam conditions and the valve position of the bypass valve. The LP bypass controller provides the necessary computing functions to perform this calculations and uses the calculated injection water demand as setpoint for the water flow controller.

Software description (Version 2.5) The parametrization software „PASO“ is used for adjustments and diagnosis of the positioner PVRxx. PASO is a comfortable user environment for easy adjustments, which can be done by keyboard or mouse. The communication with the positioner PVRxx is done by a serial interface RS232. The PASO can be used only in conjunction with the positioner PVRxx. The software description of the positioner PVRxx must be studied precisely in beforehand, and its instructions must be followed. 2.4 Connection to the P-card The connection between the PC, the installed PASO and the positioner PVRxx is done with the serial interface RS 232. For this, you must connect the enclosed cable into the desired port on your PC and into the RS 232 connector on the positioner PVRxx. If necessary the comunication port (COM1, 2) can be changed in the dialogue box “Configuration”. Local control and monitoring for hydraulic supply unit SHV200/350/450AS 3.1 Application The hydraulic supply units HV200AS, HV350AS and HV450AS provides pressurized oil for the operation of hydraulic actuators. The hydraulic supply units are each equipped with two main pumps, a pump for the filter circuit and a cooling fan. The controller is installed in a local control cabinet on the hydraulic supply unit. The controller monitors the hydraulic supply unit by pressure transmitter, temperature transmitter and level transmitter. The controller activate the control devices as accumulator charging valves, main-pump motors, filter-pump motor, and cooling-fan motor and the heater (optional). The operation and display elements on the control cabinet are necessary for the commissioning and are indicating detail

faulty operation on hydraulic supply unit. The control cabinet is fully wired and tested at factory. The customer has only to connect electric supply and I/O signals. Optionally one regeneration station can be connected to the control cabinet. One powered and fused output to the regeneration station (optional) is available at the control cabinet. 3.2 Signals 3.2.1 Operating and display elements Operational and fault conditions are displayed on the display elements in the cabinet door. Fault messages are always stored. When the fault is cleared the hydraulic supply unit will start operation automatically again. The fault message will be kept stored until the operator has checked locally the hydraulic supply unit and reset the fault message with the pushbutton (Reset).

Tag S411 S412 S413 S414/H471 S415/H472 S416/H473 S417/H474 S418/H475 H451

Fig. 1 Control cabinet operating and display elements Operation and display Operation / Inscription alarm on Display Local operation key switch Man/Auto Lamp check pushbutton Lampcheck Alarm reset pushbutton Reset Pump 1 on/off pushbutton Pump 1 run Pump 1 Pump 2 on/off pushbutton Pump 2 run Pump 2 Filter pump on/off Filter pump Filterpump pushbutton run Cooling fan on/off Cooling fan Fan pushbutton run Heater on/off pushbutton Heater on Heater Protective switch tripped or Alarm MCC

Color

green Green green green Green Red

H452 H453 H454 H455 H456 H478 H457

supply fault Pressure too low, more than 2 minutes Pump changed after fault Level low in tank Pressure high Temperature too high Nitrogen pressure low in accumulator Hydraulic supply unit in operation

Alarm

P T >> N2 pressure HV auto

red red Red Red red

HV auto

green

H = Lamp; S = Switch 3.2.2 I/O Signal Following signals are available at control cabinet output terminals: Tag Signal Contacts Abreviatio Remark n K457 HV collective SPDT HV fault Alarm alarm K461 HV automatic SPDT operation

HV auto

Message

K462 Pressure too low

SPDT

P too low

Alarm

K463 Pressure too low

8xSPST (NO)

P too low

block the positioners

Signal (HV collective fault) is set when one of the following faults occur: ● Protective switch tripped or supply fault (MCC) ● Pressure too low, more than 2 minutes (P) ● Nitrogen pressure low in accumulator (N2 pressure) ●Transmitter fault 1 Controller The controller is switched to automatic mode (HV auto) as soon as the power supply is switched on. The controller monitors and controls the hydraulic supply unit. By remote control inputs the controller can be switched off (HV off impulse) and on (HV on impulse). Only when signal off (HV off) is present continuous, the controller is blocked in the off condition, also after a restart of the controller due to reset of power supply 2 Main pumps The main pumps supply the hydraulic oil from the tank to the accumulator. Running of the main pumps are displayed on control panel (Pump1) (Pump2). As soon as the controller is switched to automatic mode (HV auto) both pumps are

started, in order to reach the operating pressure as quickly as possible. The start up of the second pump is delayed by 3 seconds. After the monitor “Press auxiliary pump off” is crossed the standby main pump is switched off. The selected main pump remains running. If the pressure falls below “Press auxiliary pump on”, the standby main pump will be switched on again, to increase the pressure again as quick as possible. The standby pump is switched off again once the monitor “Press auxiliary pump off” has been exceeded. If the pressure falls below “Press auxiliary pump on” three times in a row without attending monitor “Press valve up”, a pump change is carried out and the fault message (P1P2) is displayed. If there is a fault on the selected main pump, automatic switch-over to the standby pump takes place and the fault message (P1P2) is displayed. If pressure drops below “Pressure too low” with 2 pumps running and does not recover within 2 minutes, both pumps will be switched off and the fault message (P60°C 2,5% / °C Application note Attention: The cabinet must not be placed in direct sunlight, in order that the internal temperature in the cabinet does not exceed the maximum permitted. If the reference ground „M“ of the PVR10 cabinet is galvanically isolated from the master process controller, the reference ground „M“ of PVN10 power supply cabinet has to be connected with protection earth PE, otherwise that connection must be removed.

CCTV SYSTEM Closed circuit television system for Sagardighi (2×300MW) power plant is designed with full digital plan. The project is for 2×300MW subcritical burning-coal steam turbine power unit. The closed circuit television system is installed to monitor and control #1 unit area, #2 unit area and common system area. The system is composed of the following units: front camera unit, transmission unit, network unit, as well as the unit for system center management, control, video record and display.

Closed circuit television system is composed of four units: 55 cameras, network transmission unit, control unit, display and record unit. Each unit includes more concrete equipments or parts. System structure schematics is as following:

` Video Manager

Control Center

Video Streamers

COLOR DOME

1#Unit 2#Unit NetWork Record Server

Common System

Switch Color CCD Camera

deco der

Video Streamers

To 1# lvs

CLIENT 1

To 2# lvs

CLIENT 2

All functions are designed with modular. User can modify and expand its functions according to actual demand. The system can set up different user levels, provide simple and practical man-machine interface with graphic window, which is extremely convenient for system administrator's operation. At the same time, using customer service network topology structure, the system administrator can easily add or subtract the actual number of motoring places, and can conveniently change the definite position of central monitoring workstation, which enhances the system utilize efficiency, and enable the whole closed circuit television system serve the power plant with high effect and great flexibility.

Camera Camera part is the front part of the TV monitoring system and “eyes “of the whole system. Its function is as follows: Camera is selected to suit to the indoor environments and agree with industry standard. The selected cameras have backlight compensation function according to the size and contrast ratio of the subject in the whole image, the compensation electrical level needed is calculated automatically. Even at some positions of monitoring point the backlight phenomenon is difficult to be avoided, the compensation function of a poor light of camera can enable the system to produce the satisfied image, too. When the camera is shot by strong light, the camera can not be damaged or focus light, and the image is neither lost. By selecting the camera with the low intensity of illumination, and the super strongly dynamic CCD can also take relatively clear pictures in the area of faint light source. The built-in synchronizer of the camera can select the synchronous way or outer synchronous way according to the conditions, and under any circumstance the image scroll won’t take place in order to keep the video signal vertical and in same phase.

Specification of System Equipments The camera of this system design selects 11 integrative and intelligent high-speed dome type cameras (ENVD2450M is Day/Night, Color &B/W versions) and 44 color CCD cameras (LTC0455/51 is Day/Night, Color &B/W versions) of BOSCH, which guarantees high performance, high sensitivity effect and high quality pictures. The cameras with Pan/Tilt and zoom lens were selected to achieve a broad field-of-view angle and basically have no dead angle in main workshop area and other system areas. Thus we can monitor a long distance object, and save the number of cameras. Under a bad environment for monitoring, the outdoor camera housing (PT5723-3) with sun shroud, thermostatic fan & heater and wiper functions was used against adverse circumstance. There are three cables for dome type camera (ENVD2450M), which includes power cable (AC24V), video cable (SYV 75-3) and RS485 control cable. An outdoor dome can be assembled for the dome type camera, which can be installed in wall-installation way

or in hanging installation way with corresponding support. The video signal of camera and the RS485 control signal of decoder are directly sent to the video Streamer (VIP X1). The camera power source AC240V of unit control room is transported to monitoring spots, then is transformed to AC24V as power source of equipments. The color CCD camera (LTC0455/50) with electric zoom lens (LTC 3384/21) is installed in outdoor camera housing or indoor full function camera housing. The camera housing is installed on electric Pan/Tilt (LTC9420/11). The decoder (LTC8566/50) provides power source for camera, lens control and Pan/Tilt control. The camera video signal and RS485 control signal of decoder are directly sent to the video Streamer (VIP X1). The camera power source AC240V of unit control room is transported to decoder which will provide power source for front equipments.

RUNBACK ( RB )  Runback function principle. RB is the short form of Runback which means the main auxiliary fault-trip due to unit’s actual power limitation. Control system still force to decrease the unit target load rate. This function called auxiliary unit fault load reduction. The perfect RB control strategy is established on the basis of coordinated control system. Every system must be internally coordinated (coordinated control system) and such ensure the balanced transition of the operation condition. The external coordinated control system such as FSSS, SCS, DEH, works very fast to stable the load to be decreased to unit output for premises of scope. The condition to RunbackI.

Unit is on coordinate mode.

II.

Power load < 180 MW.

III.

Runback push button is put into service.

Runback items running condition. The unit designs have 6 kinds of items: a) Load < 180 MW, two ID fans in operation, and one ID fan trip. b) Load < 180 MW, two FD fans in operation, and one FD fan trip. c) d) e) f)

Load < 180 MW, two PA fans in operation, and one PA fan trip. Load < 270 MW, 4 Mills in operation, and 1 mill trip. Load < 220 MW, 3 Mills in operation, and 1 mill trip. Load < 180 MW, 2 Feed water pump in operation, 1 Feed water pump trip.

When these conditions are fully qualified and any auxiliary trips then Runback happen. i.

ii.

The process after the Runback happened. The unit is in coordinate mode & operation is in constant pressure mode, boiler adjusts power, turbine adjust main steam pressure. According to normal working condition the target load of boiler [ 4 mill for 230MW, 3 mill for 180MW, feed water pump RB for 150MW, PA fan RB for 160MW, FD/ID fan RB for 180MW] corresponding coal feeding flow works as reducing fastly the load order of the boiler load. And according to the turbine pressure the governing pressure valve is to be set up. After RB happened automatically shut down all the super heater and reheater attemperating water, motor valve & governing valve (4 mills except RB).

iii.

After RB happen when 2 mills are running in every 10 seconds 1 mill automatically trip. Trip mill sequence will be F,E,D,A,B,C. if the B or C flow mill is running then BC flow light-heavy oil gun automatically put into service.

iv.

When load reduced to target value then automatically reset RB. Or after the load getting stable – manually reset mode is closed. At this time the unit coordinate control & stable pressure mode , turbine adjust unit power mode .

 Interlock protection

ID fan trip, at the same time FD fan. PA fan trip together close A/B fan interconnecting damper. FD fan trip, together open A/B fan interconnecting damper (except APH trip by same side)

Commissioning range Commissioning range including auxiliary unit systems: a) b) c) d) e)

Mill RB PA fan RB FD fan RB ID fan RB Feed water pump RB

 Provided condition before commissioning 

Condition before static test Runback function control logic configuration complete. Unit is in stop state A/B ID Fan, A/B FD fan, A/B PA fan, A-F mill, A/B air heater main motor, A/B/C feed water pump at testing start up position.



Condition before dynamic testing put into service DCS , DEH, BPS, PRP systems are in normal working position, main power supply and the backup power supply are safe & reliable. Boiler side main protection(MFT) turbine side protection(ETS) and generator main protection are already input, moreover the functions are correct & reliable. RB function control logic configuration complete, moreover passes through static test and confirm the corrections, and finished the 1st set up of all data. During dynamic test the unit is operating with the rated load over 270 MW. Analog variable governing system all are under normal operation, control quality fulfills the requirement. Analog variable load disturbance test already finished. House power changeover test finished. Take the trend group of self-providing recording parameters on the DCS .



Testing parameters record:

During testing must keep record of the following parameters. Unit target load, unit actual load, order unit actual power, main steam temperature, main steam pressure target value, main steam pressure actual value, reheat steam temperature, drum water level, furnace pressure, flue gas dust oxygen %, deareator pressure, deaerator water level, FD flow quantity, primary air pressure, boiler main control order, total air content, total coal feeding content, feed water content, main steam flow etc.

 Commissioning sequence RB function test program divided into 2 parts, one is dynamic test & other is static functions inspection. The most important objective of static test are as follows:- after the RB function, must check the relating of the equipments, transfer of control mode, parameter change whether correct or not. Finding out these problems is the basic steps towards dynamic test. The target of dynamic test is actually finding out that after RB, checking RB function is either reasonable or not, and every parameter is either appropriate or not, through such tests these will be further optional. And these

things ensure the safe & stable operation of the unit. 

Static Test When unit is shutdown, then talking turns of simulation runback condition , check operation load loop, moreover initially set up the load order change velocity according to the design data. After checking the runback working condition and other control system such s FSSS interlock system device, confirm the correction of the logic

Runback function process Passing through one kind of malfunction like simulating the control system status automatic reduction (runback) condition, except running one auxiliary unit. RB logical signal send by the main control system, FD fan, Boiler main control ,FSSS system. FSSS system requires to cut off mill and put into oil gun. RB load order repairs boiler load order. Passing through the firing rate control system, the boiler output reduce very fast , which is corresponding to the RB target value. During load reducing process the main steam pressure control system of turbine main control and the main parameter control system coordinate of MCS , these are the main parametrer of the unit, must be restored internally, and not endanger to the safe running of unit. 

Dynamic operation test a) 4 mill RB test 4 mill running, the unit load stable at 270-300 MW. Turbine, boiler main control, burner, feed water pump, steam temperature and other auxiliary control system put into service automatically. Any 1 mill stops by manual. Unit is on coordinate mode, load order automatically decrease 230MW, and decrease load rate is 80 MW / min. Observe unit running condition, record every system curve. After unit operation getting stable , restart the stopped mill. During the test parameters must monitor- FD fan current, ID fan current , furnace pressure , drum water level, burner condition, main steam temperature, reheat steam temperature. Important things to remember:

i.

Attentively monitoring boiler burner condition. If the boiler pressure deteriorate then must intervene MFT manually.

ii.

Monitoring drum water level and steam temperature. For unit’s maintenance operation if necessary then intervene MFT manually.

iii.

If main steam pressure unable to maintain then further decrease target load by manual.

b) 3 mill RB test: 3 mills in operation. Unit load stable at above 220MW. Unit, boiler main control, burners, feed water pump, steam temperature and other auxiliary control system function all are put into service. Stop one mill by manual. Alarm display “full RB”. When unit is on coordinate mode, the load order automatically decrease to 180MW. The load rate is 80 MW /min. Automatically close every superheater, reheater, desuperheating water motor operated valve and governing valve. Moreover BC &DD light-heavy oil gun automatically put into service.(If

light-heavy oil gun automatically put into service during the operation of B & C mill, then DD light-heavy oil gun automatically put into service ) Observe unit running condition, record every system curve, After unit operation is stable, restart the stopped mill. During the test parameters must monitor-- FD fan current, ID fan current furnace pressure, drum water level, burner condition, main steam temperature, reheat steam temperature. Important things to remember: i. ii. iii. 

Attentively monitoring boiler burner condition. If the boiler pressure deteriorate then must intervene MFT manually . Monitoring drum water level and steam temperature. For unit’s maintenance operation if necessary then intervene MFT manually. If main steam pressure unable to maintain then further decrease target load by manual.

FD fan RB test Unit load stable between180-300MW Unit, boiler main control, burners, feed water pump, steam temperature and other auxiliary control system function all are put into service. Until the load and steam pressure getting stable manually trip one FD fan. Alarm display “FD fan RB”. No. 1 mill automatically trip, after 10 seconds no.2 mill also trip, only left 3rd mill for operation. When unit is on coordinate mode , the load order automatically decrease to 180MW. The load rate is 150 MW /min. Automatically close every superheater, reheater, desuperheating water motor operated valve and governing valve. Moreover BC &DD light-heavy oil gun automatically put into service.(If light-heavy oil gun automatically put into service during the operation of B & C mill, then DD light-heavy oil gun automatically put into service )

 MIS SYSTEM (PGIM) 1. MIS overview A plant wide Fiber-optic 1 GBPS (minimum) high speed backbone Network & workgroups is realized in the power plant. This network is used by different users of the plant for over viewing selective Plant Graphics & data on real time basis, historical data & trends and MIS reports such as Plant Generation, Unit Heat rate, Auxiliary Power consumption, DM make up water consumption, Coal / Oil stock & consumption etc. and other day to day online maintenance, Inventory & purchase related functions. 

By ABB understanding, MIS can be divided to 6 parts in this project: Plant network



MIS-DCS interface(special for customer care)



Process monitor system



Performance calculation



Boiler life calculation



Maintenance & Inventory Management system

The following is for detail.

2. Plant network

In this project, ABB provides a typical 2 level ,star style, switch network. The first level is second level switch to core switch, this is backbone network with 1GBPS bandwidth. The second level is terminal PC to second level switch, each second level switch has 24 100M ports for user. The plant network consists of:  1 core switch – WS-3750-24 + WS-3750-12G, from CISCO. 

7 second level switches – WS-2950G-24-EI, from CISCO



Servers – Real Time Server, 2 Performance and life Server, CMMS Server – IBM X346, from IBM



21 terminal PC(IBM) with UPS(APC), Printers(HP)



2 gateway PC(Advanced)



3 Firewalls(CISCO)

The 7 second level switches will be located in different building. They will connect to core switch with 1G bandwidth as main network. 1 terminal PC will be used as shift in charge PC to show analysis data to operator. The other terminal PC will connect to second level switch in their building. 1 Firewall will be used to connect internet, it’s in Maintenance department. The 2 gateway PC will connect to DCS network with firewall isolation. The PGIM database will be installed in RealTime Server(MIS Server) for process data management and store. The Performance and life Server is for performance and life calculation. The input data required for the calculation are read out from the PGIM database, calculated within the “Technical Calculation”, and then the results are written back into the PGIM real-time database. 3. MIS-DCS interface For MIS-DCS interface, ABB provides 2 gateways for 2 units, the OPC protocol will be used for connection between DCS and MIS. The 3 network adapters will be installed in the gateway, 2 connect to DCS SW for redundant configuration, 1 connects to core switch of MIS. In the gateway, the OPC Scanner will be installed and configured to communicate with PGP OPC Server (DCS side) as OPC Client; it gets process data and transfer data to PGIM database. Firewall will be used to isolate MIS from DCS for preventing illegal network access. 4. System protection In the plant network, there is a very import task for network design – system protection. Virus, illegal network access, etc., many things will menace to network system. We will use 3 security technology- Network firewall, Virus firewall and VLAN to protect network, servers and terminals.  Network firewall Network firewall is be used to isolate different part in network to prevent illegal network access. It has 2 Ethernet ports, which have different security level. According security access rule, the data flow through the firewall can be just transferred from high security port to low security port. In fact, We’ll define DCS is high security system, MIS is low security system, so data can be just transferred from DCS to MIS, and cannot be transferred from MIS to DCS, so the DCS is safe. This philosophy realizes data protection for DCS. There is also NAT technology in the network firewall, internal network use NAT to hide network address from external network.. In this project, internet will not know MIS network address in power plant, and MIS will not know DCS network address, so, the vicious network attack will be disable due to there no object - object address is invisible.



Virus firewall

Virus firewall is to prevent virus. This is software with C/S structure, it will be installed across all network. The server of virus firewall will be updated automatically from internet, other terminal in the plant network will get the newest virus library from the server. In this way, network will keep away from virus.  VLAN VLAN technology is realized in switch, it like a independent network. In the network, we will define all Sever in special VLAN; access to these servers will be controlled by Access List in third level of switch. Whatever IP, other VLAN, who is not authorized, cannot access these server. Using VLAN, Virus firewall (mentioned above), these servers is safe surely. 5. Process monitor system ABB will realize a process monitor system in MIS of this project for users to over view important, selective Plant Graphics & data on real time basis, historical data & trends, and results of calculation. The product is PGIM; it includes scanner, server and client. Process data acquisition (scanner) Scanners to acquire data from a number of different distributed control systems. In addition to this on-line data transfer, manual inputs into the system (for example for laboratory data) are also possible. The scanners permit a preprocessing of process data. Based on the incoming values, it is possible to derive events (messages) or to sum quantities using limit value checks. Counters can be implemented which will integrate, for instance, the operating hours or determine a switching frequency. This occurs when the status of binary values change. This preprocessing can be extended at any time by linking with DLL modules (Dynamic Link Library). Process Data Management (Server) PGIM includes a process data server to store: • Signal descriptions. • Current process data (real-time data). • Historical process data (long-term storage). Process data includes these stored values: • The time of acquisition. • The physical value. • Detailed status information (for example measured value disturbed). This data is retrieved from the lower-level distributed control systems and generated in PGIM. The process data server is the central element of PGIM, from which all the other functions obtain their data. It provides a high degree of safety and processing speed. Data can be compressed for long-term storage using, for example: • Average value.

• Minimum value. • Maximum value. • Last value. • Tolerance band methods. The tolerance band procedure is the default method of compression. With interface functions (API), the databases can be opened for read and write access from software applications. Common interfaces (such as OLE, SQL) ensure compatibility with the usual office environment, and common Microsoft-Office products. Process Data Evaluation (Clients) Networked computer systems are required for the management of process data on process data servers. They are also required for the distribution of data to the respective technical departments. Commercial PC’s can be used as client workstations for data evaluation, operation and configuration. The interconnected client-server structure minimizes the data flow in the network. Various specialized clients (software applications) provide fast and individual services for the specific tasks of plant management.

6. Performance calculation ABB provides “PGIM Technical performance Calculation” for performance calculation in power plant to cover customer requirements. The program “Technical performance Calculation” is used to determine online characteristic parameters of the essential plant components in energy supply plants and to compare these parameters with set points in order to achieve an improved operation of the plant. Variables such as efficiency, contamination factors, warming up ranges, etc. are calculated cyclically and compared to time-variant set points. The calculation modules provided by ABB Utilities are implemented as C-functions and combined in a Dynamic Link Library (DLL). In addition to this, own modules can be generated by the user and included as a DLL. MS-Excel, which has access to the Cfunctions, is used as configuration surface. The input data required for the calculation are read out from the Information Management System (PGIM), calculated within the “Technical Calculation”, and then the results are written back into the PGIM real-time database. The representation of the results is effected in the PGIM either in process displays or in line diagrams. Configuration of the Calculation Server (CalcServer) is effected via Excel. Subsequently, the finished configuration is transferred as a file to the CalcServer. Then there will be no feedback from the CalcServer to Excel until, e.g., the configuration is balanced or the calculations of the CalcServer are stopped. Thus, the CalcServer continues to be controlled via MS-Excel. However, Excel has not to be opened during the whole operating time of the CalcServer, but it can be quitted after configuration.

The scope of the performance calculation: Class (I) - Equipment protection calculations (software generated alarms); Class (II) - Plant/equipment efficiency, Heat rate calculations; Class (III) – Others calculations. The detail follows customer requirements in the part of technical protocol. 7. Boiler life calculation ABB provides “OPTIMAX Boiler Life” for calculation of life of boiler. The “OPTIMAX Boiler Life” application is a product in the OPTIMAX product family. It is used to calculate the total degree of exhaustion of thick-walled steam-generating components which are subject to pressure and temperature. The graphic Windows surface allows quick access to the results data of the individual components and thus allows an evaluation of the general state of the steam-generating plant. The calculations are made under consideration of the preset parameters in TRD 301 and TRD 508 plants. The data required for the calculations such as pressure, temperature, wall temperature differential, are determined as a function of time and organized into classified data prior to further processing. Based on these calculations, maintenance intervals, for example, may be increased in an optimum fashion. Scope of the Boiler Life calculation: • Drum (sphere, Cylinder) • Superheater header (inlet and outlet) • Reheater header (inlet and outlet)

 Enterprise Asset Maintenance (MAXIMO) Driven by the demanding and changing business practices requiring advance technological solutions and the worsening situation caused by the limitations of old technology and design concept, Sargardighi Thermal Power Plant had been reviewing various solutions to meet business requirements and gain competitive advantages by harvesting the technological advances. MRO SOFTWARE is offering a system blueprint for the next generation Enterprise Asset Maintenance (EAM) System taking future business and technological changes into consideration. The proposed system acts as an operational system with management decision support facilities. It meets the objective of providing timely and integrated information to Engineering management and engineers to make sound decisions on strategic issues. On the technical side, the system environment is flexible enough to take advantages of technical advances to enables users to respond quickly to sudden and rapid changes of business environments. MAXIMO Maximo is a computerized asset maintenance system that provides asset management, work management, materials management, and purchasing capabilities to help companies maximize productivity and extend the life of their revenue-generating assets.

Maximo allows your company to create a strategy for maintenance, repair,and operations related to both Enterprise Asset Management (EAM) and Information Technology Asset Management (ITAM). Maximo stores and maintains data about your company’s assets, facilities, and inventory. You can use this information to help you schedule maintenance work, track asset status, manage inventory and resources, and analyze costs. Maximo.s software suite can be configured to meet the needs of a variety of different businesses, including: 

Manufacturing and utilities production



Hotels, universities, and other facilities



Buses, trains, aircraft, and other fleet vehicles



Information technology (IT) assets

Maximo helps companies to improve the availability and performance of their revenue-generating assets while decreasing operating costs, without increasing safety issues. Maximo lets you:  Record service requests and all related records and communications from the initial request to problem resolution.  Track work orders and failures to better schedule preventive maintenance.  Track information technology (IT) assets and their configurations across a network.  Track inventory use to find optimum stock levels. The goal is to maximize availability of items for upcoming work, while also reducing unnecessary inventory and associated carrying costs.  Track purchasing of inventory stores and materials for work orders. To assist in creating budgets, you can use Maximo to track costs for labor, materials, services, assets, and tools used to complete work orders.  Reduce on-the-job injuries and accidents by identifying hazards in the workplace and precautions needed to increase safety.

Maximo can automate processes that are repetitive or happen on regular intervals, for example, preventive maintenance, periodic inspections, or reordering inventory items.

Maximo.s applications are grouped into modules. The applications in a module have similar purposes, for example, applications related to purchasing are grouped together. Some applications, such as Work Order Tracking, function individually, while others, such as Precautions, create records designed to be used in conjunction with records created in other applications. Depending on your job description and security permissions, you may have access to some or all of the Maximo modules and applications. Chapters that appear later in this guide describe the main modules and applications in more detail.

2. Asset Management As utilities refocus on the fundamentals, many are increasing their investment in work management systems. The scope of work management projects is growing to include supply chain management, condition-based maintenance, advanced planning and scheduling for spare parts, automated workforce scheduling/optimization, and mobile computing. All help to drive operational efficiency and raise the return on assets. Best practices are being introduced and becoming integral to more efficient work management in a number of ways. Best practices build integrity-based checks and balances into the system. Standardizing processes throughout the enterprise improves not only the asset performance but also worker productivity and safety. Because power plant is an asset-intensive enterprise, asset performance is the basic and key factor to ensure the successful management of a cetain enterprise. So how to improve the asset management of a power plant is very important and the first task to an excellent management. Function Design  Track asset, associated costs, histories, and failures of a serialized piece of asset as it moves throughout a plant or facility.  Build the asset hierarchy, an arrangement of buildings, departments, asset, and subassemblies. It provides a convenient way to roll up maintenance costs so that you can check accumulated costs at any level, at any time. It also makes it easy to find a particular asset number.  Use the Drilldown to view location or asset information. You can locate and select any piece of asset by scrolling down through a location hierarchy to a particular location and then viewing the asset there, or by scrolling down through an asset hierarchy.  Use Asset Modeling to determine relationships between a piece of asset, its physical location and the systems with which it may be associated.

 Create hierarchies identifying operating locations as part of multiple systems. Asset can be used in more than one location.  Associate subassemblies (child asset) and/or spare parts (inventory items) with the current asset record, thereby building the asset hierarchy.  View PMs (Preventative Maintenance’s) and service information for the selected asset number.  Build failure code hierarchies to record asset problems for analysis. Set measurement points, perform trending and defect analysis through Condition Monitoring. This can display all the measurement points for the selected asset, including: high and low warning and action values; value and date of the last reading; date of the last work order generated in response to an unacceptable reading. Readings that fall between the lower and upper warning limits can be considered safe.  MAXIMO allows you to report actual meter values for multiple meters on the current piece of asset. You can give meters more or less importance (weight) so that it has a greater or lesser effect on the average units per day that MAXIMO calculates. You can specify whether or not a meter should get updated when the meter on the asset’s parent is updated.  MAXIMO provide Routes in the following ways: apply the route to a preventive maintenance record to generate inspection-type work orders for all work assets listed as stops on the route; apply the route to a work order, and generate child work orders for each work asset listed as a stop on the route; create a route on which you specify that child work orders generated for the route stops are treated as "details" on the parent work order. When you print the parent work order, you see the detail-type work orders as work order operations on the parent work order. You can also associate job plan with route.  Use the Specification of asset to associate the selected asset to a specification template, it helps classify assets into a hierarchy of up to five levels, making it easier to locate asset.  Assign stores, repair shops, and vendors as location records to facilitate continual tracking of asset as it is moved.

 Analyze the potential for failure based on a piece of asset’s location and the possible effects on systems with which it is associated. You can setup your own failure code system for tracing and analysis.  Enquiry associate asset information, include cost, warranty, running status, calculate total down time for a piece of asset.  Apply calendar to any asset, so you can estimate run time and planned down time and idle time.

Interface and Field Design You use the Assets application to create and store asset numbers and corresponding information, such as parent, location, vendor, up/down status, and maintenance costs for each asset. Tabs in the Assets application let you build the asset hierarchy, an arrangement of buildings, departments, assets, and subassemblies. The asset hierarchy provides a convenient way to roll up maintenance costs so that you can check accumulated costs at any level, at any time. It also makes it easy to find a particular asset number. The Assets application contains the following tabs: List: to search Maximo for asset records.

Asset: to view, modify, add, or delete the main record for an asset.

Spare Parts: to create the asset hierarchy and view the subassemblies and parts of an asset.

Specifications: to enter or view the specification for the asset as recorded in the Classifications application.



GPS SYSTEM

CEMS G-CEM1000 CO Monitor Basic Principles The G-CEM1000 uses an in-situ probe set into a duct to measure CO concentration in the flue gases. The probe includes a section that allows the diffusion of flue gases into the measurement zone or the dispersion of zero/purge air out of the tube and into the duct. The analyser uses infrared gas cell correlation technology to determine the CO levels in the flue gases as they diffuse into the measurement chamber. The diffusion cell enables accurate measurements to be made in high flue gas dust levels exceeding several gram/m3. As with conventional cross-duct analysers, this probe configuration does not require the extraction of a sample from the gas stream and makes its measurement by analysing the way in which infrared radiation, transmitted through the measurement section of the probe, is modified by the gases present. The transceiver unit containing the infrared source and detector system, required to measure the received light energy after its passage through the gas, is totally isolated from the flue gas. There is, therefore, no contact between the analyser electronics and the flue gas. Correctly installed and commissioned, this provides the opportunity to achieve very low maintenance factors and totally eliminates any possibility of altering the composition of the flue gases to be measured. The probe is inclined downward at an angle of 5o to encourage condensation to gather at the lower end and then dissipate in the stack. For smaller duct sizes, the G-CEM1000 may be supplied with a shorter probe and in this case, as build-up of condensate should be less, the probe may be mounted horizontally.

The general arrangement of the G-CEM1000 monitor is illustrated below in Figure 1.

The remaining components of the G-CEM1000 are :

 A Power Supply Unit (PSU) to accept mains input voltages and provide 48V supply for the analyser.  A Data Display Unit (DDU) into which is routed the cabling from the PSU & junction box. The unit incorporates a LCD and may be mounted local to the analyser or remotely.  A Junction Box through which is routed the cabling from the analyser & DDU. The unit should be mounted local to the analyser. Although G-CEM1000 monitors can be used for process gas analysis, they have been primarily designed to monitor pollutant emissions from industrial stacks. Legislation governing such emissions usually requires data to be reported in very specific formats. G-CEM1000 analysers are therefore designed to fulfil this requirement without the need for external data manipulation. Although differing in detail from country to country, the essential demands of legislation are common world-wide. 2. Analogue and Logic Outputs The DDU is equipped with two 0/4-20mA analogue outputs, fully configurable from the keypad. Volt-free SPCO contact outputs (50V/1A) are provided for data valid and measurement alarm levels. 3. Analyser Protection G-CEM1000 monitors are designed for outdoor installation and all units are constructed to IP68 standards, designed for ambient temperatures from -20o to +60oC. For outdoor installation, an optional weather shield is recommended for the transceiver.

Measurement Principles CO absorbs infrared energy. The spectrum has the typical characteristics of a diatomic gas and comprises a number of fine absorption bands. The CO spectrum is centred on a wavelength of 4.7μm. This type of spectrum allows the principle of gas cell correlation to be employed in the spectrographic analysis to determine the concentration of gas present. If a sample of a high concentration of CO is inserted into an infrared beam, the fine absorption bands in the CO spectrum will reach a saturation point where they are capable of absorbing all the energy in the beam corresponding to those wavelengths. The presence of further amounts of gas will not result in any further absorption and thus attenuation of the infrared beam, whereas without the high concentration sample, even small amounts of CO would produce an attenuation of the beam. By taking a ratio of measurements of the attenuation of an infrared beam with and without a high concentration sample of the gas being measured, a function can be derived which is dependent solely upon the concentration of the gas to be measured.

Because the technique uses a sample of the gas itself as a highly specific filter, the measurement has extremely high immunity to other interfering gases. 2.1. Measurement Elements An infrared beam is generated from a small, black-body emitter. Radiation from this source is focussed by a lens onto a mirror. The reflected energy is received and focussed by a second lens onto a highly sensitive infrared detector. Immediately in front of the detector is a ‘band-pass’ filter for CO. Immediately in front of this filter is a wheel that generates two optical paths; one has a sealed gas cell containing 100% pure CO; the other optical path is clear. The wheel is rotated by a stepper motor at a constant speed of 1Hz, under the control of a supervisory processor. As each of the two channels sweeps across the infrared beam the processor digitises the detector output to produce two detector signals, D1 measurement and D2 reference. These values are used to compute parameters YCO that are unique functions of CO. Detector Operation The detector is a two-stage Peltier-cooled lead selenide element. Lead selenide has a very high sensitivity to infrared energy. However, in order to obtain the necessary response for the CO measurement at a wavelength of 4.7μm, the element must be cooled to a temperature of approximately -20oC. This is achieved by the encapsulated thermoelectric Peltier cooler. The detector element temperature is monitored by an integral thermistor. The thermistor resistance is monitored by the supervisory processor and is used to control the current, and hence the power, applied to the Peltier cooler to achieve a stable detector temperature at around -20oC. The detector itself is a photo-conductive device. A series of pre-amplifiers mounted within a shielded metal enclosure ensures a stable, fast response output suitable for digitisation by the processor. Stepper Motor Control The supervisory processor develops a frequency signal which is used to drive the stepper motor. Accurate timing of this signal ensures that the gas cell wheel operates at exactly 1Hz. By counting the pulses in the frequency drive to the motor the processor knows exactly when to digitise the detector output signal in order to obtain the two signals necessary for the calculation of CO concentration. Once each revolution, a small pin on the gas wheel interrupts an optical switch to act as a reference point for the processor to begin counting pulses for the next revolution of the wheel. Diagnostic Data Each second, detector values D1 measured and D2 reference, are measured and smoothed to maximise signal-to-noise ratio. From the smoothed values the following parameter is calculated : YCO = 80000 – SCCO . D1 measured/D2 reference where SCCO is a calibration constant.

This parameter is a unique function of CO and from it the processor computes the concentration level of CO in ppm in the measurement path.

G-CEM 4000 Multi-Gas Analyser G-CEM4000 Basic Principles The G-CEM4000 analyser uses an in-situ probe set into a duct to measure the concentration of gases of interest. Figure 2 illustrates the arrangement. The in-situ tube includes a section that allows the diffusion of flue gases into the measurement zone or the dispersion of purge or calibration gas out of the tube and into the duct. This section of the tube is the analysers’ measurement cell. The analyser is capable of simultaneous measurement of up to six different gases (plus water vapour as a seventh measurement if required). As with conventional cross-duct analysers, this probe configuration does not require the extraction of a sample from the gas stream and makes its measurement by analysing the way in which infrared radiation, transmitted through the measurement section of the probe, is modified by the gases present.

The transceiver unit containing the infrared source and detector system, required to measure the received light energy after its passage through the gas, is totally isolated from the flue gas. There is, therefore, no contact between the analyser electronics and the flue gas. Correctly installed and commissioned, this provides the opportunity to achieve very low maintenance factors and totally eliminates any possibility of altering the composition of the flue gases to be measured. The remaining components of a G-CEM4000 analyser are : • The Gas Control Unit (GCU) that controls the input of zero and span calibration gases into the analyser. It contains the necessary compressed air filtration and drying

equipment to ensure high quality air supply for the zero calibration and probe purge functions. The analyser power supply and Station Control Unit (SCU) are also housed within the GCU. The function of the SCU is as an emissions data processing unit, communications centre for the monitor and controller of the zero and span calibration functions. The SCU also acts as a data logging device in which hours emission and diagnostic data is stored for retrieval in the case of loss of main data logging in the remote pc or DCS system. • A Junction Box through which is routed the cabling from the transceiver and the temperature, pressure and oxygen sensors and the cable to the GCU. The unit should be mounted local to the analyser. • The Central Data Controller (CDC) that accepts data from 1 to 16 SCUs and processes the data for onward transmission to a remote pc or SCADA system.

Normalisation Emission limits are always defined under standard conditions of temperature, pressure and air dilution (air dilution is defined using the waste gas CO or O concentration). Most 2

2

legislation also requires concentrations to be reported on a dry basis; i.e. water vapour in the flue gas is not permitted to dilute the measurement. The correction of the measurement from ‘as measured conditions’ to ‘standard’ conditions is known as ‘normalisation’. Like all cross-duct analysers, G-CEM4000 analysers measure concentrations of pollutant ppm (parts per million by volume) or %, under the conditions at the measurement position. This basic ppm measurement is always corrected for the duct pressure and presented as vpm by the analyser. G-CEM4000 analysers have the capability for the outputs and display 3

to be configured in vpm (or %) or mg/m (which is a mathematical conversion depending on the molecular weight of the gas being measured and the flue gas temperature), or in 3

mg/Nm (i.e. ’normalised’ to the required standard conditions). When the outputs are required to be normalised to a pre-defined O concentration as 2

opposed to a CO level, then an external O 4-20mA signal representing Oxygen levels can 2

2

be input into the G-CEM4000. All other normalising parameters i.e. pressure, temperature, and CO are measured as standard by the G-CEM4000 2

D-CEM2000 Dust Monitor Introduction Dust and smoke emissions have for a long time been recognised as major atmosphere pollutants, particularly since such emissions from stacks are clearly visible to an observer. There has been a requirement for monitoring, and quantifying these emissions, for some time and a variety of instruments have been marketed throughout the world for this purpose. Instruments in the past have, however, generally proved to be unreliable, falling rapidly into disuse or to be so expensive and complex as to be affordable only by the very large users, such as power stations. The CODEL D-CEM2000 seeks to overcome these

problems by providing a reliable, simple to use instrument with low maintenance requirements.

2.2. Transceiver Units Two identical transceivers are mounted on opposite sides of the stack. The transceivers each contain a sensing head comprising a light source, a detector and associated optical assembly; a calibration mirror and rotary valve and the electronics associated with control and measurement. Should the power fail, integral power-packs return the valves to a closed position to protect the sensing heads. 2.3. Signal Processor Unit (SPU) The D-CEM2000 SPU receives its 48V DC power from the SCU via the 4-core SmartBUS serial data link. Signals from the two transceivers are processed to derive the transmissivity values and compute the opacity output. Diagnostic communication is provided via the SCU and a laptop computer operating SmartCOM software. Gain adjustments for the transducer detector signals are provided by trim potentiometers in this processor. Details for adjustment can be found in Section 7. Commissioning. 2.4. Station Control Unit (SCU) The SCU provides 48V DC power for the analysers on its local data bus. Power input to the SCU is 86 to 264V AC maximum. The power supply is housed in one side of the SCU and the 48V DC power rail is fed through internally into the processor section of the device. The SCU is linked to the analyser by means of a 4-wire data bus (local data bus). This bus carries 48V power to the analyser as well as two serial communication lines referred to as MOSI (Master Out/Slave In) and MISO (Master In/Slave Out). On this data bus the SCU acts as the Master Device and the analyser as a Slave device.

Measurement Principle

Consider the two identical transceiver units positioned at either side of the flue (or duct), unit 1 and unit 2. The transmissivity of light from unit 1 to unit 2 (unit 1 transmitting) can be represented by the equation :  12 = K1 (D21/D11) where : K1 = gain constant to produce = 1 (100% transmissivity, clean air condition) D11 = the detector output at unit 1 (internal reference level) D21 = the detector output at unit 2 The transmissivity of light from unit 2 to unit 1 (unit 2 transmitting) can also be represented by the equation : 21 = K2 (D12/D22) where : K2 = gain constant to produce = 1 D12 = the detector output at unit 1 D22 = the detector output at unit 2 (internal reference level) This is demonstrated schematically in Figure 3.

Overall transmissivity of the system () can, therefore, be represented as: = 12 . 21 = K1 (D21/D11) . K2 (D12/D22) which can be rewritten as : = K1K2 (D21/D22) . (D12/D11) As the two bracketed terms above are measured from only one of the transceiver units, the output of the instrument is independent of drift of either detector.

V-CEM5000 Flow Monitor Introduction

Correcting measurements to standard temperature, oxygen levels, etc., allows the density of emissions to be normalised (e.g. mg/Nm3), but in order to obtain a measurement of total emissions for pollution monitoring (e.g. kg/hr), it is necessary to measure flow. Many methods require direct contact with the hot dirty gases resulting in high maintenance costs and potential unreliability. The CODEL Model V-CEM5000 Gas Velocity Monitor utilises an infrared cross-correlation technique that requires no contact with the flue gases. The method used resembles flow measurement with chemical dye or radioactive tracers, where the velocity is derived from the transport time of the tracer between two measuring points a known distance apart. However, instead of an artificial tracer being added, the naturally occurring fluctuations of the infrared energy in the gas stream are used as the tracer. Fully purged transducers with no moving components make the system highly reliable and minimise maintenance requirements. The instrument is ideally suited to monitoring the flow rate of hot, dirty gases.

2.2. Transducer Units Each transducer unit consists of a broad band infrared detector, a lens to focus the radiation received on the detector and a pre-amplification circuit board, all housed within a fully sealed, epoxy-coated aluminium enclosure. The transducers are supplied with air purge units to maintain the cleanliness of the transducer windows.

2.3. Signal Processor Unit (SPU) The V-CEM5000 signal processor receives its 48V DC power from the SCU via the 4-core Smartbus serial datalink. Signals from the two transducers are processed and correlated to derive the transmission time of the gas flow from the first transducer to the second and thus compute the gas velocity. Diagnostic communication is provided via the SCU and a laptop computer operating SmartCom software.

3. Measurement Principle Gas flow is rarely laminar. Turbulence in the flow produces a series of swirling eddies and vortices that are transported with the bulk flow. Infrared radiation, emitted by a hot gas system, is characterised by a flickering signal resulting from the swirling effect of these vortices. Two infrared detectors, placed a small distance apart, will produce very similar flickering signals, but with a displacement in time equivalent to the time taken for the bulk gas flow to carry the vortices from the first detector to the second. The V-CEM5000 uses a cross-correlation technique to measure this time displacement and hence the flow. The two signals from the infrared transducer units are defined as A(t) and B(t) as shown below.

The time-of-flight (and hence the flow velocity) of the naturally occurring turbulent eddies within the flow stream can be determined by cross-correlating the two signals as shown in the following equation :

where is a variable time delay imposed on the signal A(t). Using this function a correlogram can be computed which has a maximum when the time-of-flight and ‘t’ are equal.

 BOILER TUBE LEAKAGE DETECTION SYSTEM