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Station C & I and MMI-DAS Bharat Heavy Electricals Ltd.

has been providing several power plant automation solutions, based on the well proven PROCONTROL P-13 DCS system. The applications range from SG, TG controls and Station DCS for Industrial Co-generation CPP to geographically distributed Unified Plant Automation systems for Large Utilities upto 500 MW. BHEL is now well positioned with a Technical Collaboration Agreement with Metso Automation MAX Controlc USA for manufacture and supply of maxDNA DCS system for complete plant controls of Industrial CPP and Utility Power Plants. The automation actively controls the plant during the three main phases of operation. 1. Plant Startup. 2. Power generation in a stable or transient condition. 3. Plant Shutdown.

Operator Interface & Human Machine Interface systems

-------------------------------------------------------------------------------Major Supplies APSEB BSES DESU DVB GEB GIPCL HPCL HSEB IFFCO JTPCL KMCL KPCL

MSEB NTPC OPGCL PSEB RSEB TNEB WBPDCL

-------------------------------------------------------------------------------Hardware platforms currently in use are maxDNA system PROCONTROL P-13 system (Refer composite reference lists on these two platforms)

-------------------------------------------------------------------------------Benefits of Automation : The main benefit of plant automation are to increase the over all plant availability and efficiency coupled with safety of equipment and personnel. The increase of these two factors is achieved through the following features : Automated Plant Start-up Regulation and Shutdown. Optimisation of House Load consumption during Start-up and Shut-down. Co-ordination of house load to the generated power output. Ensure and maintain plant operation even in the case of disturbances using coordinated control of Boiler and Turbine operation. Bringing the processes in a safe stage of operation, where process components are protected against overstress. Superior control performance with minimal equipment life expenditure. Faster load response and tighter control of key process variables.

Effective feedwater firing rate ratio control. Effective fuel air ratio control. Generation to match load demand. D-E-B - Direct Energy Balance matches boiler energy supply to turbine energy demand. Bumpless transfer is assured, regardless of existing plant conditions Expert - level, best operating practices for start-up and shut-down. Real time calculation of allowable rate-of-change. On-line "health checks" of unit and digital control system performance. Process Structure : Drive Level. Function Group Level. Unit Level. Plant Level comprising many units for MIS. (Management Information System)

The Station C & I Control System is designed in such a way that no signal failure can cause to reduce the availability of the plant/signal except for that component. The operation and monitoring of the entire Power Plant is implemented in functional Distributed environment comprising the follows -Binary Controls / Open Loop Control System (OLCS) -Analog Controls / Closed Loop Control System (CLCS) -Signal acquisition / Measurement System (MS) The Open Loop Control System (OLCS) : The Open Loop Control System (OLCS) / Binary Controls systems performs the functions of sequential operation interlock and protection for various plant equipments like Boiler and Turbine auxiliaries, valves / dampers, drives etc.,. The sequence control comprises of number of steps and criteria. The steps shall be executed in a predetermined order fulfilling the necessary criteria. The waiting time between steps are monitored and feedbacks are intimated to operators for further actions as necessary. The

sequence control provides the safe and automatic startup - shutdown of plant item associated with a plant group or sub groups. The interlock and protection system ensures the safe operation of plant items at all the time and initiates automatic shutdown of plant items used in safe conditions. The sequence control system is envisaged in operated guided mode, semi automatic mode, and automatic mode and the functions are arranged in hierarchical control structure. The Closed Loop Control System (CLCS): The Closed Loop Control System (CLCS) / Analog Controls Systems continuously controls the valves, dampers, other mechanical devices and will include P, PI, PID and other control algorithms depending upon the process and functional requirements. The control strategy is designed to give stable control action in steady state condition and dynamic load change conditions. The CLCS controls includes D-E-B ( Direct Energy Balance) / State Variable based predictive control / Feed Forward Controls / Coordinated controls and its subset of boiler follow mode and turbine follow mode control concepts depending upon the overall system design. The typical open loop and closed loop controls are detailed below. Closed Loop Control System & Open Loop Control System. Co-ordinated Master Control. Direct Energy Balance. Drum Level Control. Furnace Draft Control. Mill Controls. Air flow Control. Fuel Control. Hotwell Level Control. Deaerator Level / Pressure Control. PA Header Pressure Control. HP / LP Heater Drain Level Control. Steam Temperature Control Sequence Controls for ID Fans, FD Fans, PA Fans, Air heaters. Boiler Feedpumps, Cooling Water Pumps, Condensate Feedpumps etc. and other non interlock drives.

Measurement Systems (MS): Measurement Systems (MS) All the signals that are coming into or going out of the DCS systems for control, monitoring and information purpose are caused by measurement systems. These are realized through input or output cards of the DCS systems which will perform a) Analog Signal Controlling and processing b) Binary Signal Controlling and processing Redundancy in measurement systems are build to match the process redundancy to achieve high availability. The measurement systems Inputs / Outputs are grouped , distributed suitably in different functional groups. Operator Interface & Human Machine Interface systems: This environment provides the following functions: Supervision of Plant Processes. Processing of Plant Information. Representation / Presentation of Plant Information. Analysis of Plant Events. Operator Dialogue. CRT / Keyboard based control of the plant ( Video Process Control/VPC). Long time storage of data for analysis of plant performance. Monitoring of plant performance by periodic calculations. Alarm management Sequence of events recording Historian Links to external systems for integration and DAS

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