Automatic Turbine Run Up System Gyanendra Sharma Npti Delhi

AUTOMATIC TURBINE RUN UP
SYSTEM
(ATRS)
Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 1

Presentation outline
•Overview of Plant Controls
•Functions of ATRS
•Structure of ATRS
•Program Structure of ATRS and Turbine
protection

MAN-MACHINE-INTERFACE
OPERATOR
INSTRUMENTATION & CONTROL
PLANT
POWER PLANT
POWER PLANT CONTROL
CONTROL
UNIT CONTROL
BOILER TURBINE GENERATOR

INSTRUMENTATION
AND
CONTROL
MEASUREMENT MONITORING
CLOSE-LOOP OPEN-LOOP
CONTROL CONTROL
PROTECTION
ADVANTAGES OF AUTOMATION
• OPERATING PERSONNEL FREED FROM ROUTINE TASKS.

• INCORRECT INTERVENTIONS IN THE PROCESS AVOIDED.
• STRESS ON EQUIPMENT REDUCED.
• PLANT OPERATIONS GEARED FOR MAXIMUM EFFICIENCY.
• INCIPIENT FAULTS RECOGNISED QUICKLY.
• ON FAULT OCCURRENCE, IMMEDIATE AND LOGICAL INTERVENTION
POSSIBLE.

TURBINE C&I PACKAGE CONSISTS OF THE FOLLOWING SYSTEMS:
A. CONTROL SYSTEM:
ANALOG (CLOSE LOOP)
- ELECTROHYDRAULIC CONTROLLER (EHC)

- TURBINE STRESS EVALUATOR (TSE)
- LOW PRESSURE BYPASS CONTROLLER (LPBPC)
- GLAND STEAM PRESSURE CONTROLLER (GSPC)
BINARY (OPEN LOOP)
- AUTOMATIC TURBINE RUN UP SYSTEM (ATRS)

- AUTOMATIC TURBINE TESTER (ATT)
B. MONITORING & MEASUREMENT SYSTEM
- TURBINE SUPERVISORY INSTRUMENTATION (TSI)

- MEASURMENT OF PARAMETERS LIKE, TEMP.,PRESS.,LEVEL etc.
C. PROTECTION SYSTEM
HIERARCHY OF CONTROL
UNIT
CONTROL
GROUP CONTROL
(WHEN, HOW MANY,WHICH)
SUB-GROUP CONTRL-1 SUB-GROUP CONTRL-2
CONTROL INTERFACE
SWITCH GEAR (MCC)

CONCEPT OF C&I IN THERMAL POWER STATION
CRT /MMI DISPLAY UNIT IN
OPERATOR
OWS
CONTROL
ANALOG AND LOGS
BINARY
ROOM
SIGNALS
UNIT CONTROL
AUTOMATION
CLOSED FUNCTIONAL PROT- DATA PROCESS- EQUIPMENT
LOOP GROUP IVE ING, ALARM
CONTROL CONTROL LOGICS ANNUNCIATION
SIGNAL
CONDITIONING CONTROL INTERFACE PLANT INTERFACE
ALALOG, BINARY EQUIPMENT
MOTOR CONTROL CENTRE
SWITCH GEAR
PLANT (FIELD)
M M DRIVES
SIGNAL TRANSMITTER
AUTOMATIC TURBINE RUN-UP SYSTEM
TASKS PERFORMED:
• SWIFT,ACCURATE AND OPTIMUM STARTUP ( INCLUDING SYNCHRONISATION AND
LOADINING) OF TURBINE
• MAINTAINING OIL SUPPLY
• BUILDING UP AND MAINTENANCE OF VACUUM
FEATURES :
• BASED ON FUNCTIONAL GROUP CONTROL PHILOSOPHY
• EACH FUNCTIONAL GROUP ORGANISED AND ARRANGED IN ‘SUB-GROUP CONTROL’, ‘SUB-LOOP
CONTROL’, AND ‘CONTROL INTERFACE’
• OPERATING MODES AVAILABLE:
- MANUAL MODE ( OPERATOR GUIDE)
- AUTOMATIC MODE
- STEP BY STEP MODE

ATRS STRUCTURE
OIL SYSTEM, VACUUM SYSTEM, TURBINE etc.
GC
SGC SGC SGC
SLC SLC SLC
CISaturday, March 27, 2021

CI Gyanendra Sharma - NPTI Delhi 11
GROUP CONTROL: Decides WHEN, HOW MANY & WHICH SGC
shall be operating and stopped.
SUB GROUP CONTROL: Contains the sequential logics for switching
drives ON and OFF. Perform sequence in STEPS, issue commands and
get Checkbacks.
SUB LOOP CONTROL: can be switched ON & OFF manually.
Receive commands from GC, SGC and also Manual
CONTROL INTERFACE: Standard Interface between the command
transmitters and receivers in the plant, undertakes all necessary signal
processing and monitoring.
SYSTEM OPERATION MODES:
AUTOMATIC,SEMI AUTOMATIC,OPERATOR GUIDE

ADVANTAGES OF ATRS
• ELIMINATES HUMAN ERROR
• PROVIDES MAXIMUM PROTECTION AGAINST MALFUNCTIONS
• OPERATOR’S TASK LESS ARDUOUS
• ENABLES SAFE, SMOOTH, STRESS CONSISTANT AND OPTIMUM WARM-UP,
ROLLING AND SYNCHRONISATION OF TURBINE IN LEAST POSSIBLE TIME
• INCREASES PLANT AVAILABILITY
• REDUCES STARTING TIME WITHOUT IMPAIRING LIFE
• MEETS EMERGENCIES AUTOMATICALLY
• ALL PLANT OPERATING CONDITIONS CATERED TO BY CRITERIA DEPENDANT
PROGRAMMING
• INCREASED OPERATING FLEXIBILITY, SAFETY AND RELIABILITY

ATRS
AUTOMATIC TURBINE RUN UP SYSTEM
• Start up and Shutdown sequence performed in reliable

way
• Protect drives and related auxiliaries
• Uniform and sequential information to operator about the
process
• Distinct information about the nature and location of
faults

MONITOR &
STEP 01 START DRIVE A
BLOCKING TIME
DRIVE A ON
&
MONITOR & OPEN DMPR A

STEP 02
BLOCKING TIME

SUB GROUP CONTROL ( SGC):
• SGC executes commands to bring the equipment upto a particular defined
status.
• The commands are executed in a predefined sequence in the form of steps.
• Desired number of criteria act as preconditions before the SGC can take off
or execute its defined sequence.
• The functional group continues to function automatically all the time
demanding enabling criteria based on the process requirements and from
other FGs, if required.
• In case the desired criteria is not available, the system would automatically
act in such a manner as to ensure the safety of the main equipment.
• The sequence is programmed in the processor. The process signals are
acquired through the input modules and are available on the bus.

WAITING AND MONITORING TIME FOR STEPS:
Waiting Time :
It implies that the subsequent step will not be executed unless the specified
time elapses. If no waiting time is specified, the next step gets executed as
soon as the enabling criteria are fulfilled.
Monitoring Time :
It is the time required for executing the command of any step as well as the
time required for appearance of criteria for the next step. Under healthy
conditions it should happen within the specified time, otherwise an alarm
is initiated. Whenever there is uncertainty regarding the time required
for completing a particular task, such as warming-up, pulling vacuum
etc., the monitoring time is blocked.

PROGRAM STEP OF A SUBGROUP CONTROL
STEP CRITERIA FOR STEP -2
FROM STEP 1
&
BYPASS CRITERION EXAMPLE
1
&
PROGRAM LOOP
02 WAIT MO TIME 1
COMMAND
50s 20s 2
• STEP 2 ( START UP PROGRAM) WITH 2 STEP CRITERIA, 2 COMMAND

& OUTPUTS AND A MONITORING & WAITING TIME .
• WITH ADDITIONAL PROGRAM LOOP CONTROL AND A BYPASS
CRITERIA FOR STEP 1
• WAITING OR MO TIME CAN BE PROGRAMMED FOR 0.1 SEC TO 999
MIN.
• NOS. 1-49 USED FOR START-UP, 51 TO 99 FOR SHUTDOWN PROGRAM.
WAITING AND MONITORING TIME FOR STEPS:
• ATRS can be switched on at any stage after completing

certain tasks manually, if so desired. In such cases, the
SGC program quickly scans through the steps and starts
executing from the stage upto which the tasks have been
completed manually. This is achieved by incorporating
suitable overflow /bypass conditions in the logic.

• ATRS CONTROLS:
1. ATRS is organised in the following four Sub-Groups :

• Oil supply
• Evacuation
• Turbine
• HP CONTROL FLUID
2. SGC issues commands either to the SLC or directly to
the drive through the Control Interface.
3. Each of these SGCs has its subordinate SLCs and CI

modules. These SGCs in conjunction with the turbine
governing system , TSE and the auto-synchroniser
accomplish the function of start-up of the TG set.

SUB-LOOP CONTROL (SLC) :
• A SLC, when switched on, actuates the equipment and brings it to the desired
status as demanded by the process and there is no sequence logic involved in it.
• SLC is like a watch-dog performing an assigned duty.
• All mechanical equipment which need to be switched on/off based on process

consideration are hooked-up in various SLCs. Standby equipment is also
interlocked in SLCs.
• SLC can be switched on either manually or through SGC and issues commands to
the drive control level.
• SLC logic is also realised in the processor module.

CONTROL INTERFACE (CI) :
• Each remote controlled drive has a dedicated CI module which acts as a
standard interface between the transmitters and receivers in the plant and
undertakes all necessary signal processing and monitoring.
• The CI module receives manual commands from the process
keyboard/inserts, active protection signals and enabling signals from the
protective logic, as well as automatic control commands from the SGC/SLC.
• It interlocks the input commands according to their priority and validity
and then passes actuation signals to the interposing relays in the switch-gear.
• The status checkbacks received from the switchgear or actuators are
monitored, processed and transmitted to VDU/desk tiles, the protective logic
and the SGC.

CONTROL INTERFACE (CI) : (Continue--)
• These modules have the firmware which defines the standard function of
the module and its signalisation mode as well as the programmable logic for
the drive protection and the permissive interlocks. The drive level
automation tasks related to the respective drive is realised through the
programmable logic.
• The module has hardwired inputs and outputs for connection of feedback
signals and commands to the switchgear together with local bus interface for
signal exchange via the system bus.

ATRS STRUCTURAL SYSTEM:
• ATRS IS ORGANISED IN THREE SGCs :
1. SGC-TURBINE :
SGC Turbine acts directly on the following systems :
• Sub-loop Control (SLC) Drains.
• Warm up Controller.
• Starting Device of turbine governing system.
• Speed & Load Setpoint devices of turbine
governing
system.
• Auto-synchroniser.
2. SGC-OIL SUPPLY :
SGC oil supply directly acts on the following system :
• Sub-loop control (SLC) turning gear.

• SLC auxiliary oil pump 1.
• SLC auxiliary oil pump 2.
• SLC emergency oil pump.
• SLC jacking oil pump.

3. SGC-CONDENSATE & EVACUATION :
SGC- Condensate & Evacuation directly acts on the following systems :
• Sub-loop Control (SLC) condensate extraction

pumps.
• Starting ejector, if provided.
• Main ejectors / vacuum pumps (as applicable).
• Vacuum breaker.

3. SGC-HPCF :
SGC- HPCF acts on the foll :
• Sub-loop Control (SLC) HPCF

• SLC HPCF pumps
• HPCF pumps
• HPCF re-circulation pumps
• LPCF temp control valve

3. SGC-HPCF :
• Both CF PUMPS GET SWITCHED ONTHRU SLC. IN CASE
RUNNING PUMP DOES NOT DEVELOP THE REQUIRED
PRESS, THE STANDBY PUMP GETS SWITCHED ON
• AFTER GETTING THE REQUIRED CF PRESS SLC
HEATING IS PUT ON & CF CIRCULATION PUMP WHICH
FEEDS THE REGENERATION CKT IS ALSO PUT ON.
TEMP CONTOL VLV IS PUT IN AUTO MODE TO
REGULATE THE TEMP.
• CF TEMP IN THE TANK IS MAINTAINED BETWEEN 55 TO
57 C BY SWITCHING ON/OFF THE CF HEATER THRU
THE SLC. IN CASE CF TEMP IN HTR EXCEEDS > 65 C
THE HEATER IS SWITCHED OFF
• IN SHUTDOWN PROG ALL THE PUMPS ARE SWITCHED
OFF AND SLC IS PUT OFF. SLC HEATING IS KEPT ON TO
MAINTAIN THE TEMP REQUIRED FOR THE NEXT
STARTUP.
TURBINE START-UP / SHUT-DOWN CONTROL, OVERVIEW
SUB-GROUP ( TURBINE START-UP / SHUT-DOWN)

CRITERIA
CRITERIA
AUTO-
ON/OFF
SEAL ELECTRO- MECHANICAL SUBLOOP SUBLOOP
STEAM HYDRAULIC HYDRAULIC LP-WATER DRAIN
CONTROL(SSC) CONTROL(EHC) CONTROL(MHC) INJECTION VALVE
AUTO
MANUAL
ON/OFF
ON/OFF
TURBINE TURBINE
LP WATER AUTOMATIC
TRIP STRESS
INJECTION SYNCHRONIZER
SYSTEM(TTS) EVALUATOR
MANUAL
MANUAL
AUTO OPEN/CLOSE
ON/OFF
ON/OFF
THYRISTOR GENERATOR
DRAIN
VOLTAGE MAIN CKT.
VALVES
REGULATOR(TVR) BREAKER

SGC-DISPLAY
4 6 8 7 5
1 2
3
1. PUSHBUTTON “SHUTDOWN”
2.PUSHBUTTON “STARTUP” OR “OPERATION”
3.PUSHBUTTON “AUTOMATIC ON/OFF”
4.LAMP “SHUTDOWN PROGRAM”
5.LAMP “STARTUP” OR “OPERATION” PROGRAM
6.LAMP “AUTOMATIC OFF”
7.LAMP “ AUTOMATIC ON”
8.LAMP “FAULT”

SLC-DISPLAY
2 3 4
1. PUSHBUTTON “MANUAL ON/OFF”

2.LAMP “SLC OFF”
3.LAMP “ FAULT”
4.LAMP “SLC ON”

DRIVE INTERFACE-DISPLAY
3 4 5
1 2
1. PUSHBUTTON “OFF” (CLOSE)

2. PUSHBUTTON “ON” (OPEN)
3. LAMP “ OFF” (CLOSE)
4. LAMP “FAULT”
5. LAMP “ON” (OPEN)

EXPLANATION OF KWU IDENTIFICATION SYSTEM (KKS)
ORDINAL SECTION 0 1 2 3
GENERAL A NAAANN AANNN AANN
EXAMPLE A 1MAJ15 AP001 XB01
SIGNAL IDENTIFICATION
CONSECUTIVE NO. OF EQUIPMENT
TYPE OF EQUIPMENT
NO. OF SUBGROUP
PLANT GROUP (FUNCTIONAL GROUP)
NO. OF UNIT

PROTECTION SYSTEM
FOR
STEAM TURBINE
TURBINE PROTECTION SYSTEM
TASK PERFORMED :
• PROTECTS TURBOSET FROM INADMISSIBLE OPERATING CONDITIONS
• PREVENTS DAMAGE IN CASE OF PLANT FAILURE
• FAILURE OCCURRENCE REDUCED TO MINIMUM

ADVANTAGES :
• DETECTION OF UNIT IRREGULARITIES
• PREVENTION OF UNIT OVERSTRESSING DUE TO TRIPS
• RELIEF OF OPERATING PERSONNEL FROM QUICK AND CORRECT DECISION

TAKING

HYDRAULIC ELECTRICAL EXTENDED PROT. CRITERIA

TRIP SYSTEM TRIP SYSTEM TURBINE PROT. FROM OTHER AREA
- MANUAL - LP EXH. STM. -GENERATOR

- OVER SPEED TEMP. > MAX PROTECTION
TRIP DEVICE REMOTE TRIP
1/2 ( UCB)
- VACUUM TRIP - LOW VACUUM - MASTER FUEL
DEVICE TRIP TRIP RELAY
- HAND TRIP - LOW LUBE OIL ENERGISED
LEVER(LOCAL) - FIRE PROT.
1/2 TRIP - BOILER
-BRG METAL PROTECTION
TEMP OPTD.
-AXIAL SHIFT
-HP/IP TOP/BOT
DIFF TEMP HI
GENERAL :
• The electrical trip system comprises of two identical and independent relay based
trip channels viz. electrical trip channels 1 & 2.
• Both channels are connected to different (two) trip solenoid valves.
• All command signals for turbine trip are hooked up with both the channels.
• Actuation of any of the channels energises the respective trip solenoid which in
turn trips the turbine.
• Each channel is realized in a local bus. Both the local buses are completely
independent of each other and input modules, processor module and output
modules reside on each.

GENERAL :
• Trip signals from the sensors / field instruments are conditioned and distributed to
both the channels (local buses) via hardwired modules.
• Realisation of 2 out of 3 trip logic is carried out in the local bus. On detection of a
fault in any one of the input signals to a channel, the configuration for that channel
changes from 2 out of 3 to 1 out of 2 and is annunciated. Further failure in a channel
changes the configuration to 1 out of 1.
• Trip signal from each of the local buses acts on 3 relays in 2 out of 3 combination.

CYCLIC TEST :
• Both the channels are tested periodically, even while the turbine is running.
• Cyclic testing is done automatically at preset intervals and can be blocked from the
protection cabinet, if desired.
• This testing can also be initiated manually from the cabinet.
• Only one channel can be tested at a time. Online testing is done by simulating the
trip signals and it determines faults in the input modules, processor modules,
output modules or the trip relays.
• These faults can be acknowledged from the cabinet. Next cycle test can only be
carried out after acknowledging the fault.


TRIPPING CRITERIA :
1. CONDENSER VACUUM VERY LOW :

• This is a back up protection to the hydraulic low vacuum trip
device.
• The protection acts if absolute pressure in the condenser rises
above 0.3 Kg/cm2 (abs).
2. LUBE OIL PRESSURE LOW :

• The protection acts if the lube oil pressure before thrust bearing
decreases to 1.2Kg/cm2 .
• The trip signal is initiated by three pressure transmitters in 2-out-of-3-
logic.

TRIPPING CRITERIA :
3. FIRE PROTECTION :
• The protection acts in the event of any of the following
conditions :
i) Fire protection switch, either in unit control room or
in
machine hall, operated.
ii) Level in main oil tank falls to a very low value, indicating
substantial leakage of oil from the system.
The command signal under condition (ii) is initiated from

three level transmitters in 2-out-of-3 logic cofiguration.

TRIPPING CRITERIA :
4. HP EXHAUST STEAM TEMPERATURE HIGH :
• The HP exhaust steam temperature protection circuit causes the exhaust sections of
the turbine, the blading and the extraction points against overheating.
• Under extreme operating conditions the HP turbine can be run at low flow rate and
simultaneous relatively high back pressure. This prevents the steam from expanding,
which causes the exhaust steam temperature to rise ( > 5000C).
• The temperature is measured by means of three thermocouples and protection criteria
is derived in 2 out of 3 logic.

TRIPPING CRITERIA :
5. TURBINE TRIP SWITCH OPERATED :
• The protection acts when the turbine trip switch in unit control room is
operated manually.
6. TRIP COMMAND INITIATED FROM ATRS :
• The protection acts when the trip command signal is initiated from the
Automatic Turbine Run-up System .

TRIPPING CRITERIA :
7. GEN. PROTECTION OR MFT- RELAY ENERGISED :

• In the event of generator faults under Class-B trip both the turbine trip channels
are actuated to trip the turbine. In such a case the generator protection acts
through Reverse Power Relays.
• In the event of generator faults under Class-A trip or in the event of boiler "Master
fuel trip relay" energised, command signal for turbine trip shall act
simultaneously and independent of other equipment trip out sequence.
8. OPERATION OF REVERSE POWER RELAY :

• The command signal is initiated with a time delay of 10 seconds after any of the
two reverse power relays have operated.

THANK YOU

Automatic Turbine Run Up System Gyanendra Sharma Npti Delhi

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AUTOMATIC TURBINE RUN UP

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 1

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 2

INSTRUMENTATION & CONTROL

BOILER TURBINE GENERATOR

• OPERATING PERSONNEL FREED FROM ROUTINE TASKS.

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 6

- ELECTROHYDRAULIC CONTROLLER (EHC)

BINARY (OPEN LOOP)

- AUTOMATIC TURBINE RUN UP SYSTEM (ATRS)

B. MONITORING & MEASUREMENT SYSTEM

- TURBINE SUPERVISORY INSTRUMENTATION (TSI)

SUB-GROUP CONTRL-1 SUB-GROUP CONTRL-2

SWITCH GEAR (MCC)

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SGC SGC SGC

SLC SLC SLC

CISaturday, March 27, 2021

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• Start up and Shutdown sequence performed in reliable

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MONITOR & OPEN DMPR A

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• STEP 2 ( START UP PROGRAM) WITH 2 STEP CRITERIA, 2 COMMAND

WAITING AND MONITORING TIME FOR STEPS:

• ATRS can be switched on at any stage after completing

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 19

1. ATRS is organised in the following four Sub-Groups :

3. Each of these SGCs has its subordinate SLCs and CI

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 20

• SLC is like a watch-dog performing an assigned duty.

• All mechanical equipment which need to be switched on/off based on process

• SLC logic is also realised in the processor module.

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 21

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 22

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 23

ATRS STRUCTURAL SYSTEM:

• ATRS IS ORGANISED IN THREE SGCs :

ATRS STRUCTURAL SYSTEM:

SGC oil supply directly acts on the following system :

• Sub-loop control (SLC) turning gear.

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 25

ATRS STRUCTURAL SYSTEM:

3. SGC-CONDENSATE & EVACUATION :

SGC- Condensate & Evacuation directly acts on the following systems :

• Sub-loop Control (SLC) condensate extraction

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 26

ATRS STRUCTURAL SYSTEM:

SGC- HPCF acts on the foll :

• Sub-loop Control (SLC) HPCF

Saturday, March 27, 2021 Gyanendra Sharma - NPTI Delhi 27

SUB-GROUP ( TURBINE START-UP / SHUT-DOWN)

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1. PUSHBUTTON “MANUAL ON/OFF”

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1. PUSHBUTTON “OFF” (CLOSE)

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EXAMPLE A 1MAJ15 AP001 XB01

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