|
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 ?
@  in the simplest of
terms means ͚to auto͛ thus
avoiding manual interface
with the machine or in simpler
words ͚control without direct
interference͛.
@ is the self-
controlling operation of
machinery that reduces or
dispenses with human
communication or control
when used in normal
conditions.
p
 

  
 
ëuring first industrial
revolution, the
automation implies
replacement of Human
muscles by machine.
  |     
 
@ ÷he | made
this conversion more
simpler by making these
machine smarter and
gave room to Second
industrial revolution.

@ ›s in simple example, we
can see the tank level can
be easily controlled by the
controller and hence no
more human inteface is
required.
Y ÷


 ÷HE YESS
@ ÷his changes the perception
from maximizing quantity of
production to quality
coupled with level of
comfort and safety.
@ ›utomation thus reduces
the human sensory and
mental requirement, human
brain is hence used in
 !"
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 E
EE
 ëEF
÷
Y FY
›÷Y›÷
Y
›utomation implies
successful control,
which in turns requires
correct combination of
(
(and
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t can be as simple as
maintaining
temperature of room
at 22 degree elsius
or as complex as
guiding spacecraft to
moon.
›÷Y›÷
Y FY ÷HE Y÷Y E
From the ontroller
Viewpoint automation
is in effect a set of
computing and timing
element which combine
in group to ultimately
carryout mathematical
operation.
) )  
 
 
›utomation is the use
of control system in
concert with
information
÷echnology to control
industrial machinery
and process, thus
reducing human
intervention.
pHEE ›÷Y›÷
Y EX
S÷?

÷raditional: appliances control
(windows, seats, radio,..)
motor control (exhaust
regulations)
ritical new applications: ›
S
(anti-skip) and E S (stability),
brake-by-wire, steer-by-wire (͞X-
by-wire͟) increased safety

%
Extension limited to 2-3 m
(portal robots 10-20m)
frequent reprogramming for
new tasks, tooling
simple embedded computer,
hierarchical control
  
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enefits: educe operation costs, faster diagnostics, better

energy, management automatic train control.
÷here are more than ,- .
›V
Y
S
+  :
flight control (safe
flight envelope,
autopilot,
͞engineer͟)
flight management
flight recording
(black boxes,
turbine supervision)
diagnostics
͞fly-by-wire͟
 ›H VEH
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 .  
rotection ( ines,
transformers, generators) very
high speed response control
(remote or local) to guarantee
power flow, safe operation
(interlocking)
measurement (local and
remote), electricity bill, power
flow in grid

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nventory
ecipe management
ackaging
Sampling
›F›÷



Extreme dependency on the
availability of the control
system

onnection to
@ Supply chain management,
@ Yrder fulfilment
@ ustomer relationship and
@ ommercial accounting (S› )
  

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Actual Energy Requirement Vs Energy Supply Position in India

700000

600000

500000
MU

400000

300000

200000

100000
2002- 2003- 2004- 2005- 2006- 2007- 2008-
03 04 05 06 07 08 09

Demand 545983 559264 591373 631757 690587 739345 774324

Supply 497890 519398 548115 578819 624495 666007 689021

*Source: CEA Website

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YpE SH›EHY ë


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YE ÷ YF EH›÷ YpE
@ ÷he nion ower inistry is
encouraging merchant power plants
across the country as a means to create
additional generating capacity at a
faster rate through private sector
participation.
@ erchant power is the term used by
power companies to describe
electricity sold in the open market.
@ ower plants usually sign long-term
›s with state governments under
which they agree to sell power to state-
owned distribution utilities at a fixed
rate for a specified period.
Y EESS
 Y

@ ÷o facilitate sale of power to
power traders and third parties,
the government has established
an open access policy in power
transmission.
@
ntroduced in the Electricity ›ct,
2003, open access basically refers
to the right to transmit power
over a system belonging to a third
party.
@ pith such concerted efforts in all
areas, erchant power is
considered a favourable option
for private sector.
 ›E
ES
VY VEë

ëEVE Y E÷ YF YpE ›÷
@
ndependent ower roducer (
)
@ Engineering, rocurement & onstruction
(E ) ompany
@ onsulting Engineering ompany
@ YEs, Equipment manufacturers,
@ ontrol and
nstrumentation ompanies
@ overnment departments and ministries
@ egulatory ›uthority etc.
 . / 
/
&  
0  ,12324
*
/
&  
  
p

'   # 
/

 

1 rivate 1,230.00 11,800.50 0.0 10,994.70 24,025.20

2 State 27,055.70 46,672.30 0.0 2,247.70 75,975.70

3 entral 8,592.00 36,399.00 4,120.00 0.0 49,110.30

4 ÷otal 36,877.70 93,725.30 4,120.00 13,242.40 149,111.20

÷›E÷ YF YpE EE›÷
Y
›s per entral Electricity ›uthority͛s (E›)
projection for the 11th lan (2007-2012),
apacity addition required - 78,578 p
‰ (‰


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(


$
,(, -

$

›s per E› / lanning ommission

projection for 12th lan (2012-2017),
apacity addition planned - 82,200 p
comprising of:
3-(--

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oal 59.2% 21.2% 51.8%
Yil 13.9% 16.6% 03.1%
as 06.3% 22.1% 15.7%
uclear 02.5% 30.0% 19.9%
Hydro 17.8% 08.2% 07.4%
Ythers 00.3% 01.9% 02.2%
HYp YpE ›÷ pYS?
YpE ›÷ Y E›÷
Y
@ ower lant, as the
name suggest means
to generate power or
electricity.
@
n a conventional
power plant, steam
turbine rotates the
generator.
YpE ›÷ Y E›÷
Y
@ ÷his requires continuous
flow of high pressure steam.
÷he burning of coal
produces heat and this heat
boils the water in the boiler
to produce high pressure
steam.
@ ÷his steam rotates the
turbine which thereby
rotates the generator to
produce electricity based on
Faraday aw͛s, the
electricity is thus sent to
grid for transmission.
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@ ÷he operation and
maintenance of power
plant is done by
engineers of various
disciplines like
echanical, Electrical,
&
, ivil etc.
@
ut the role of &

Engineer is even more
demanding, a &

Engineer have to be very
proficient.
Y E YF &
E
EE
 YpE
›÷
@ esponsible for all
measurements made in the
plant.
@ ÷he accuracy of the
measurement determines
the efficiency of the
process, the efficiency of
each process in turn
determines the total
efficiency of the plant.
@ ÷he &
engineer has an
intimate knowledge of the
process, without which it is
neither possible to
instrument the process nor
control it.
Y EX
÷
 YpE ›÷
› ower lant is a complex
thing and its construction is
frantic, long drawn out
involves many people,
difficult conditions like dirt,
noise, extreme temperature,
complex cabling, thousands
of instruments ,systems
makes the task of &

engineer challenging and
demanding.
 ›E ›ë V›
Eë
E›SEE÷
@
n ower lant, 4
" is responsible for
measurement as close to 4
degree entigrade near
the condensor to 1200
degree centigrade inside
the boiler. ot only this the
pressure measurement
range varies from vaccum
to very high pressure.
SE E÷
V
÷ YF E›S


S÷E÷S
@ ÷he proper selection of which instrument
to be used when, i.e. we cant measure the
flow simply by conventional flowmeter at
a ain steam line at 550 degree elsius.
@ ÷he instrument mounted for this purpose
of measurement requires not only should
be accurate but also reliable and efficient.
@ For instance, ÷hermocouple can not be
used in rugged places so ֑ is used.
@ ÷he goal of 4" is to make sure
that all the measurements, calibration,
maintenance, control are done
satisfactorily well for proper functioning of
power plan
E›SEE÷ ëYE
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pH E›SEE÷ ›E
Y÷Y Eë?
@ ÷he &
engineer is responsible
for control philosophy of each
system of the power plant.

@ For instance, ÷he ÷emperature

measurement at the outlet of S
line is in the range of 550 degree
elsius, during maintenance or
trip,
ypass and control valve
plays an important role, the goal
of &
engineer is to make sure
that excess steam is properly sent
to the ondensor or deaerator for
the right purpose.

    : 
;
Y÷Y SS÷E
@ ›  is a device or set
of devices to manage, command,
direct or regulate the behavior of
other devices or systems.

@ ÷here are two common classes of

control systems, with many
variations and combinations: "
8
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is also fuzzy logic, which attempts
to combine some of the design
simplicity of logic with the utility
of .

:   : 
;
Y÷Y SS÷E E›ëS ÷Y

YV›÷
Y
÷he control system
has made the human
relieved from the
tedious calculations
which sometime
leads to error, thus
allowing maximum
chances of 
.
ost control system
are complicated
enough to demand
that a controller
perform some sort of
#
 before a
control action is
initiated thus concept
from calculus and
algebra is required.
ëS
 YpE ›÷
@ ÷he control system is
responsible for controlling
action of all the
measurement.
@
n power plant this ëS
(ëistributed ontrol
System ) plays the role of
this control system.
@ ›ll interlocking, monitoring
and annunciation
operations are performed
in ëS.
phy ëS?
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FFEE÷ Y÷Y SS÷E
 YpE ›÷

ëS systems
͛s for
for process
sequential
control
control

otion ërive
controllers systems for
for motion drives
control control
  
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* 

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ë
S÷

÷Eë Y÷Y SS÷E
@ ëS refers to a control
system usually of a ,
process or any kind of
dynamic system, in which
the controller elements
are not central in location
(like the brain) but are
distributed throughout
the system with each
component sub-system
controlled by one or more
controllers.
Y E›÷
Y YF ëS
@ ÷he most common example is
a setpoint control loop
consisting of a pressure
sensor, controller, and control
valve.
@ Flow measurements are
transmitted to the controller,
usually through the aid of a
signal conditioning

nput/Yutput (
/Y) device.
@ phen the measured variable
reaches a certain point, the
controller instructs a valve or
actuation device to open or
close until the fluidic flow
process reaches the desired
setpoint.
ëS H›ëp›E

@ 
@
nput ards (4-20 m ›)
 ÷hermocouple, ÷ë, SYE
 Yutput ards(4-20 m ›, ëigital)
 ower Supply odule
 ommunication ard ables
@ &#/ 
Y E›÷Y pY S÷›÷
Y
›larm onitoring
imic Yr raphic ëisplay
÷rend ëisplay
Yperator uidance ëisplay
System and ëiagnostic
ëisplay
ontrol

ar hart
Sequence ëisplay
Fault ›nalysis ëisplay
›÷Y Y÷Y YY

@ o-ordinated ontrol
@ ÷otal ›ir ontrol
@ Super/eheater
÷emperature ontrol
@ ill out ÷emperature
ontrol
@ Hotwell/ëeaerator level
ontrol
@ ërum evel ontrol
@ Furnace ëraft ontrol

÷E Y ›ë Y÷E÷
Y
@
nterlock and protection are
used for safe
startup/operation/shutdown
/trip/ of an equipment for
auxilliaries such as
@ p ump,
ë Fan, Fë Fan,
› Fan,
F , E , ill.
@ Heater
@ Valve and ërains

Y
E Y÷Y
@
urner anagement
ontrol
@ Secondary air
ëamper ontrol
@ ›uxilliary ressure
desuperheating
system
@ Soot blower ontrol
@ H
y pass ontrol
÷

E Y÷Y SS÷E
@ ÷urbine overning
System
@ ÷urbine rotection
@ ›utomatic ÷urbine un
up System
@ ÷urbine Stress ontroller
@ bypass control
@ Sequential ontrol for
turbine ërive
F
@ enerator auxiliary
monitoring
EFY›E ›  ›÷
Y
@
oiler Efficiency
@ ÷urbine
@ H / /
÷urbine
@ Feed Heaters
@ ëeaerator
@ ondensor
@ ›ir reheater
@ nit Heat ate
ëS FY 500 p ›÷
@ umber of
inputs: 13750
@ umber of
Yutputs: 7250
@ Yperator pork
Station: 8
@ arge Video
Screen: 5
ëS

ëS÷
@ arge oil refineries have
many thousands of
/Y
points and employ very
large ) . rocesses are
not limited to fluidic flow
through pipes.

@
t can also include things

like variable speed drives
and motor control
centers, cement kilns,
mining operations, ore
processing facilities, and
many others.
 ast but not the
least, ›utomation
has made the power
plant a safe, reliable,
efficient,
comfortable,
innovative place to
work for the
generation of
electricity for the
mankind.