INDEX

 ACKNOWLEDGEMENT
 DECLARATION
 ABBREVIATIONS
 INTRODUCTION TO HIL
 TECHNICAL SPECIFICATION
 SCADA
 INTELLIGENT LOAD MANAGEMENT SYSTEM
 SCADA’S FUNCTION
 SCADA AT RENUKOOT AND RENUSAGAR (AN OVERVIEW)
 HIGHLIGHT OF ILMS
 INPUT/ OUTPUT DETAILS
 OPERATIONAL DRIVERS FOR ILMS
 FUNCTIONALITIES OF ILMS
 LOAD SHEDDING SCENARIO
 LOAD SHEDDING (THE TYPES)
 WHY LOAD SHEDDING?
 BASIC POWER BALANCE CALCULATION FOR LOAD SHEDDING
 LOAD SHEDDING ALARMS
 GOVERNOR CONTROL
 IMPORTANT TERMS USED IN AGC CONTROL
 HINDALCO AGC CONTROL
 AUTOMATIC LOAD CONTROL
 AUTOMATIC VOLTAGE CONTROL
 OPERATION AT DIFFERENT MODES
 CONTROLLER AC 800M HARDWARE
 BASIC COMPONENTS IN CONTROL PANEL
 CONTROLLER AC 800M HARDWARE
 TYPICAL SINGLE LINE DIAGRAM
 SECURITY ISSUES

1
ABBREVIATIONS

HIL : Hindalco Industries Limited

SCADA : Supervisory Control And Data Acquisition system

ILMS : Intelligent Load Management System

AGC : Automatic Generation (active power) Control

AVC : Automatic Voltage (reactive power) Control

RTU : Remote Terminal Unit

IEMS : Industrial Energy Management System

AC800 : Advant Controller 800 series type

DI : Digital Input

AI : Analog Input

DO : Digital Output

AO : Analog Output

SOE : Sequence Of Events

I/O : Input /Output

OPGW : Optical Ground Wire

FDS : Function Design Specification

FAT : Factory Acceptance test

SAT : Site Acceptance Test

2
 INTRODUCTION TO

HINDALCO INDUSTRIES LIMITED

Hindalco Industries Limited is the largest integrated aluminium manufacturing plant in

India and is having its own coal based power generation facilities at Renusagar ( 35 km
from Renukoot ) to meet the bulk electrical power requirement for aluminium smelters at
Renukoot. In addition, there is a cogeneration plant at Renukoot to cater the electricity
requirement at colony and plant.

To evacuate electrical power from Renusagar power to Hindalco, Renukoot. There are 10
132kv transmission lines between Renusagar and Renukoot. Further, there is a wide spread
Electrical network for power distribution at 11kv, 6.6kv and 3.3kv at Renukoot. The
Hindalco power network is also connected with northern grid at 132kv sub-station of Rihand
Hydel Power Plant and UPPCL.

POWER PLANT AT RENUSAGAR

Coal based power plant is situated at Renusagar, 35km away from Renukoot. The power
plant consists of 10 no.s Turbo Generators over six control locations named as CL-1, CL-
2, CL-3, CL-4, CL-5 and CL-6.

PLANT OPERATION PHILOSOPHY AT RENUSAGAR

The plant started its operation in 1966-1967 with the commissioning of two units of 67.5MW
each. Since the Renupower goes subsequent expansion. The present capacity of plant is
760MW with 10 turbo- generators and 11 boilers (1 spare).

Renupower is well known in power section in India. It has a reputation of constantly

achieving around 90% Plant Load Factory (PLF) & Plant Availability Factor (PAF) of its
installed capacity of 760MW, in spite of odd like low grade coal and grid disturbance. Latest
techniques of quality control and safety like WCM, Quality Circle and OHSAS are
implemented for increasing production as well as productivity. Renusagar power division
achieved ISO 9001, ISO 14001 and OHSAS 18001 certificate were accorded to R.P.D. in
3
1998.

TECHNICAL TRAINING AND MANAGEMENT

DEVELOPMENT CENTRE (TTMDC)

The centre has developed learning culture in the organization. It is first training centre of its
kind recognized by “ Central Electrical Authority, Ministry of Energy and Govt. Of India”.
The centre is equipped with the latest training aid and facility for theoretical, practical and
on job training like lecture hall, model rooms, library, laboratory, workshops and well
trained faculties to provide technical and managerial training.

HOW ELECTRICITY IS GENERATED

In India, 71% of the total power generated comes from thermal power stations. In general
thermal power plants burn fuel and use the resultant heat to raise the steam temperature
which drives the turbo-generators.

Raw materials for the thermal power plant are coal, air, high speed diesel and water. The coal
is brought to power station by the trucks, from the coal mines to the Coal Handling Plant
(CHP). From CHP, the coal is being carried by conveyer belts to the coal bunkers where it is
fed to pulverizing mill, which grind it as fine as face powder. Finally, powdered coal mixed
with preheated air is then blown into furnace by primary air fan. The resulted ash is also fine
powder. Some of it bind together to form lumps, which fall into ash plants pits at bottom of
the furnace. Most of the ash, still in particle form, is carried out of boiler to the Electrostatic
Precipitator (ESP) as dust where it is trapped by electrodes charged with high velocity
electricity. The dust is conveyed by water to disposal area and while the clean gases pass
through ID fans to discharge up through the chimney.

Meanwhile, the heat released from the coal is absorbed by the water which gets converted
into steam. The steam in superheated is further passed through the turbines where it is
discharged through the nozzle on the turbine blades. Energy of steam striking these blades
makes the turbine to rotate. Coupled to end of turbine is the rotor of the generator, a large
cylindrical magnet, so when the turbine rotates, the rotor turns with it. The stator has heavy
coils of copper wire in slots. The electricity is produced by the rotating the rotating magnetic
field created by rotation of exciter motor. The

4
electricity produced by stator winding is transmitted to transformer which steps up the
voltage to 132kv so that it can be transmitted to long distance efficiently with low losses
over the power lines of grid. The steam which has given up its heat energy, is changed back
to water in condenser so that it is ready for recirculation. The boiler feed water must be
demineralised, an absolutely pure so as to avoid any damage to tube that feeds the turbine.

COAL HANDLING PLANT

Coal is supplied to 1200MT & 1500MT capacity bunkers at Jhingurdah loading station
by NCL conveyers. Coal is transported through mono-cable (300TPH) & bicable
(250TPH) ropeway to Renusagar through UP and MP forest areas.

At unloading station the coal is fed to 250TPH & 300 TPH capacity crushers. The crushed
coal travels trough conveyers. Vibrating screens are sent to different bunkers with the help
of tripper. The coal from bunker is fed to boiler mills/pulverisers through coal feeders. This
pulverised coal of size 74 microns is sent to the furnace through coal pipes and coal bunkers.
Primary air from PA fan aids to transport the coal into four corners of furnace at different
elevations.

BOILERS

There are total eleven boilers. These boilers are “ Top supported, Bi- drum, Radiant type,
Natural circulation, Tangential tilting firing system with pulverised coal firing.” Each
having capacity of 275- 320t/hr. Boilers are run with 83-85% efficiency.

STEAM TURBINE

Ten numbers impulse reaction type turbines with five extraction points with regenerative
feed water heating cycle and two pass surface type condensers are in each unit.

WATER AND STEAM CYCLE

Raw water is taken from Rihand lake and it is send to demineralisation plant. After
demineralisation process, water is fed to boilers for producing steam. The saturated steam in
upper drum is separated with help of drum internals and then superheated to 510deg Celsius
in superheaters.

5
The superheated steam is lead to rotor, which in turn transmits torque to generators and
power is generated. Extracted steam is sent into heaters where it exchanges heat. The drip
from the heaters flow into the condensers in a cascading process. The non soluble gases are
vented to the atmosphere through de-aerator.

ASH HANDLING PLANT

Ash handling system consists of bottom ash system, fly ash system and electrostatic
precipitator (ESP). Around 15-20% ash is taken out through bottom ash system and through
fly ash system. The whole system consists of pumps, hydro ejectors, hydro vectors, clinker
grinder etc. Apart from furnace bottom, the ash is removed from economiser, air pre-heater
and electronic precipitator hoppers. All the 11 boilers are provided with ESP. The
efficiency of ESP is about 99%.

6
3Typical diagram of a coal-fired thermal power station
1. Cooling tower 10. Steam Control valve 19. Superheater
2. Cooling water pump 11. High pressure steam turbine 20. Forced draught (draft) fan
3. transmission line (3-phase) 12. Deaerator 21. Reheater
4. Step-up transformer (3-phase) 13. Feedwater heater 22. Combustion air intake
5. Electrical generator (3-phase) 14. Coal conveyor 23. Economiser
6. Low pressure steam turbine 15. Coal hopper 24. Air preheater
7. Condensate pump 16. Coal pulverizer 25. Precipitator
8. Surface condenser 17. Boiler steam drum 26. Induced draught (draft) fan
9. Intermediate pressure steam
18. Bottom ash hopper 27. Flue gas stack
turbine

ELECTRICITY GENERATION

Steam turbine coupled generators run at 3000rpm and delivers 10.5kv (#3 to #10) and 13.8kv
(#1 & #2) at generator terminals. The power generated at 10.5kv and 13.8kv is stepped up to
132kv with the help of generator transformer and send to HINDALCO through 10
transmission lines for its pot lines. Approximately 10% of the generated power is used for
auxiliary equipments at Renusagar.

All the 11 boilers and 10 turbines are connected with common feed water header and steam
header. The advantage of connecting them with common feeder is that in case of failure of
any boiler. The particular turbine may be connected with other boiler and availability of the
unit is 100% assured.

STEP-UP TRANSMISSION SUBSTATION

A step-up transmission receives electric power from a nearby generating station and uses a
large power transformer to increase the voltage for transmission to different locations. A
transmission bus is used to distribute electric power to one or more transmission lines. There
can also be a tap on the incoming power feed from the generation plant to provide electric
power , to operate equipment and the generation plant.

Substations have circuit breakers that are used to switch generation and transmission circuits
in and out of service as needed or for emergencies requiring shut down of power to a circuit
or redirection of power.

7
The specific voltage leaving a step-up transmission substations are determined by the
customer needs of utility supplying power and to the requirement of any connection to the
regional grid.

8
TECHNICAL SPECIFICATION

TURBINE #1 &#2 #3 & #4 #5 #6 & #8 #9 & #10

#7
MAKE GE KWU/BH BERGM ABB GE SIEMENS
EL AN/BOR
SIG

NO. OF 17 (18+27) (6+18) 39 18 (15+29)

STAGES
NOMINAL 67.441 77 68 74 76.72 80
RATING
(MW)

RATED 3000 3000 3000 3000 3000 3000

SPEED
(RPM)

BOILER #1 &#2 #3 & #4 #5 #6 & #8 #9 & #10

#7
MAKE CE CE BHEL BHEL BHEL BHEL
TYPE BALANC BALANC BALANC BALAN BALANC BALANC
E E E CE E E
DRAFT, DRAFT, DRAFT, DRAFT DRAFT, DRAFT,
DRY DRY DRY , DRY DRY DRY
BOTTOM BOTTOM BOTTO BOTTO BOTTO BOTTO
, BI- , BI- M, BI- M, BI- M, BI- M, BI-
DRUM DRUM DRUM DRUM DRUM DRUM
BOILER BOILER BOILER BOILER BOILER BOILER

TYPE OF TANGEN TANGEN TANGEN TANGE TANGE TANGEN

FIRING TIAL TIAL TIAL NTIAL NTIAL TIAL
TILTING TILTING TILTING TILTING TILTING TILTING

STEAM 272 275 275 275 290 320

FLOW(TPH)
DESIGN 103.7 112.51 110 110 114 117
PRESSURE(K
g/cm2)

9
 SCADA
(Supervisory control and data Acquisition)

INTELLIGENT LOAD MANAGEMENT SYSTEM (ILMS)

SCADA is a technology that enables a user to collect data from one
Or more distant facilities and/or send limited control instruction to those facilities.

In other words we can say that SCADA is a centralized control system which is used to
those field processes which has multiple function.

When the dimension of process becomes very large hundreds or even thousands of
kilometers from one end to other’s one can appreciate the benefits of SCADA offers in terms
of reducing the cost of routine visits to monitor facility operation.

A SCADA system allows an operator to make set points changes on distant process
controllers to open or close values or switches to monitor alarms and to gather
measurement information from a location central to a widely distributed process such as
an oil or gas field , pipeline system or hydroelectric generating complex.

SCADA’S FUNCTION

Basically SCADA performs following given functions:

1. Monitoring and control of the entire electrical network

a. Single Line Diagrams (SLD’s)
b. Analog Measurements
c. Digital Indications/commands
d. Analog control
2. Generation of the time tagged Alarms/Events with high resolution to enable the
Sequence Of Events (SOE)
3. Maintain the power supply for the critical/essential loads continuously
4. Data Acquisition System
5. Graphical Trends
6. Historical data
a. Trends
b. Alarms/Events

10
Basic Overview of SCADA

Control Panel Field

HMI Process
AC800MController
with S800 I/O

Control Room

11
 Renukoot Network Configuration
Fast Network (VIP)

Opera SOE/Al Eng

Netw
tor arm g
ork
Statio Printer Stati
Print
n on
er

Redundant Plant
Network OPGW
Redundant
Servers from
Renusa
gar
Redundant Control
Network

CC
R
Co-
CR-1, Load Gen
C shedding
R-2&3,

12
 Renusagar Network Configuration
Fast Network (VIP)

Opera SOE/Al Engg Netw

tor arm Stati ork
Statio Printer on Printe
n r

Redundant Plant
Network OPG
Redundant W
Servers
To
Renuk
Redundant Control
Network oot

PQ GS/LS
Controller Controller

13
HIGHLIGHT OF INTELLIGENT LOAD MANAGEMENT SYSTEM

1. State of the Art Industrial IT platform comprising of 7 nos redundant AC 800

controllers with 2500 channels of S800 I/Os

2. Human Machine Interface based on Windows based Operate IT systems

3. 5 nos of Operator Stations at Renusagar

4. 2 nos of servers (redundant)

5. 7 nos of Operator Stations at Renukoot

6. 2 nos of Engineering Stations

7. 48 Rittal make standard Cubicles

8. Systems at Renukoot and Renusagar interconnected using OPGW Link.

INPUT/OUTPUT DETAILS

1. The SCADA Input/Output envisaged for Generating Units/Potlines

& substations are:-

2. Digital Inputs for Pot lines (Tap position, L/R position, Protection...

3. Digital Inputs for all Loads CB (Breaker ON/OFF status)

4. Digital outputs for Pot lines, Auxiliary & Alumina Loads

5. Ex: Breaker Trip command, Pot line lower, OLTC/Transductor Raise/Lower

6. Analog Outputs for Pot line Control

7. Digital Inputs for all Generators (AVR excitation, Turbine control,

Protection)

8. Digital Inputs for all Generator CB (Breaker ON/OFF status, Lock out)

9. Digital outputs for all Generator

a. Ex: Breaker Trip command, Gov lower, AVR Raise/Lower

10. Analog inputs through different transducers.

14
OPERATIONAL DRIVERS FOR ILMS

Critical loads
Limited plant generation Load
} Load/Generator
Shedding

throw

Several generators/pot lines

Power-sharing with other plants
} AGC/AVC/ALC

Field Data Access

Monitoring/control of Field devices

} DAS

FUNCTIONALITIES OF ILMS

1. Load Shedding
2. Active Power Control (Frequency control)
3. Reactive Power Control (Voltage Control)
4. Import Control
5. Export Control
6. Generator Control
7. Pot line Control
8. MD Control
9. Supervision, Control and Data Acquisition (SCADA)
10. Circuit breaker Control
11. On Load Tap Changer (OLTC) Control
12. Overloading – Transmission line, Tie line & Bus bar

15
 LOAD SHEDDING SCENARIO

1. Import high limit (Capacity of grid lines) violated

2. Network islanded
3. Generator tripped
4. Bus coupler tripped (contingency change)
5. Under frequency relay operated
6. Maximum demand violated

LOAD SHEDDING: THE TYPES

1. Fast Load Shedding on Binary status

2. Load Shedding on loss of Generation
3. Load Shedding on Frequency Drop
4. Slow Load Shedding on Overload
5. Slow Load Shedding on Demand control

WHY LOAD SHEDDING?

1. To protect electrical system from total/partial black-out

2. To Maintain system frequency within the permissible limits
3. To keep reliability of the system
4. To keep grid limits under control
5. To maintain power flow in Transmission/Tie line
6. Maximum Demand violation Control

16
BASIC POWER BALANCE CALCULATION FOR LOAD SHEDDING

1. PToBeShed = PGeneration + PSpinningReserve – PLoad – PInhibited > 0

2. The components in the calculation have the following meaning:
3. PGeneration is the actual generated power.
4. PSpinningReserve is the spinning reserve.
5. PLoad is the total load in the contingency priority/load table.
6. PInhibited is the total of the loads inhibited by the operator
7. Upon a trigger from FLS, the outcome of this calculation is compared to zero.
It will be used to find the priority to be shed from the priority/load table, when
the outcome is negative.

LOAD SHEDDING ALARMS

1. Network islanded
2. Generator tripped
3. Bus coupler tripped (contingency change)
4. Import high limit violated
5. Import high limit for fast action violated
6. Load shedding blocked
7. Error in priority entry

17
Operator Input Loadbusbar Priority/Load Table

Priority definition for Loads Loadbusbar A

Priority 1: 10 MW

Inhibiting of loads in Fast

Priority 20 : 45 MW
Generated/Available power : 64 MW
Inhibited load : 5 MW
Mismatch : 0.5 MW
Load Data  Load encoding
 loadbusbar Priority/
Active power measurement Load table building
 Available power
calculation
Circuitbreaker status  Mismatch
calculation
I/O error detection

Generation Data
Maximization of  Contingency
Active power measurement & determination
Generated power
Maximum Power  Contingency
on Turbine max.
Priority/Load Table
Circuitbreaker status building
 Power Balance
Calculation
I/O error detection  Calculate shed
priority
Fast LS  Data presentation
Detection of CB Trigger for FLS
change

Operator Input Underfrequency LS

Priority setting for Underfreq. LS
 Detection of ULS shed commands Command Trip Commands
Underfrequency generation
 Generate shed
Frequency relay commands
Frequency Stage All items not in a dashed
AUTOMATIC line box are part of Main LS

18
GOVERNOR CONTROL

1. This is also called as active power control

2. The main objectives of this control are
a. Maintain grid export with in the limit
b. Maintain frequency of the system with in the permissible limits if
HINDALCO system gets islanded
c. Maintain active power of individual generator within the capability limits of
generators
d. Transmission line /Busbar overloading control

IMPORTANT TERMS USED IN AGC CONTROL

1. Capability curve

Capability curve defines operating region (boundaries) of a generator

considering its characteristics

2. The various modes and data related to the generators are presented on the MMI in
the form of capability curves. Limits, such as the rotor and stator heating, minimum
and maximum excitation etc. are considered while preparing this diagram.
3. The calculation of the various control margins for MW and MVAr are based
upon this capability diagram.
4. Participation factor

Ratio of participation of a generator to total generation

19
HINDALCO AGC CONTROL

1. System connected to grid

a. HINDALCO has to maintain an export which shall not greater than
operator settable limit(60Mw)
b. When total generation exceeds this limit ,the deference in set point (grid limit)
and grid mw is calculated
c. Identifies available generator in the network
d. Difference is distributed among the generators in that network by
considering its participation factor
e. calculated automatic set points send to individual generators control which
in turn generates lower pulses.
f. AGC action automatically stops when export become within the grid
limit(60Mw)

2. HINDALCO Network isolated from grid

a. Selects busbar frequency setpoint for control action

b. Selects busbar frequency measurement by checking healthiness of the

measurement

c. Calculates the difference between frequency setpoint and measured frequency

d. The calculated difference in frequency is within the predefined

deadband,There is no action performed by AGC

e. If the calculated frequency is greater than dead band then the difference will
be distributed among the available generator by considering its participation
factor

20
 3. Transmission line/Busbar overloading control

a. Calculates the bus bar overloading value by Mw direction and summing

current at particular section (in coming generator,busbar breaker,
transmission line)

b. Compare with operator entered limit

c. Difference in current is converted to Mw

d. Group the generator by considering bus coupler Mw direction

e. Distribute the calculated MW difference among grouped generators

AUTOMATIC LOAD CONTROL

Main Objectives are

1. To keep grid import with in the limit

2. To keep system frequency under specified limits when HINDALCO
system gets islanded
3. Individual Potline setpoint control
4. Transmission line/Busbar overloading control

To limit grid import with in the limit

1. HINDALCO has to maintain an import which shall not greater than operator
settable limit(40Mw instantaneous)
2. When total load exceeds this limit ,the deference in set point (grid limit)
and grid mw is calculated
3. Identifies available loads in the network
4. Difference is distributed among the loads in that network by considering its
participation factor

21
 5. calculated automatic set points send to individual Potline control which in
turn generates lower pulses or lower setpoint.
6. AGC action automatically stops when import become within the grid
limit(40Mw)

HINDALCO Network isolated from grid-UF

1. Selects busbar frequency setpoint for control action

2. If the system frequency is less than operator settable limit
3. Selects busbar frequency measurement by checking healthiness of the
measurement
4. Calculates the difference between frequency setpoint and measured frequency
5. The calculated difference in frequency is within the predefined
deadband,There is no action performed by ALC
6. If the calculated difference is greater than dead band then the difference will
be distributed among the available Potline by considering its participation
factor

Individual pot line Interlocks

a. Potlines breaker open

b. Potlines reaches minimum tap position
i. this shall further block pot line reduction
c. Potlines reaches Maximum tap position
i. This shall further blocks potline raising
d. Measurement error
i. Blocks entire potline operation (Auto Mode)
e. OLTC tap failed
i. Blocks auto mode operation
f. Voltage Limit Exceeds maximum limit
i. While voltage limit exceeds then Auto Mode raising shall be blocked
but lowering shall be available for control (Manual/Auto) and
generates alarms

Load and generation control (AGC/ALC) common control

1. It consists of three modes

2. Normal Mode
3. Potline loading shall be inhibited
22
 4. Normal mode is active as soon as HINDALCO network gets islanded. In this
mode frequency is maintains between 50.0-50.5Hz(50.25+0.25)
5. If system frequency is less than 50.0Hz Potline load reduction shall
take place
6. If system frequency is greater than 50.5Hz generation reduction shall
take place
7. Loading mode
8. When this mode Potline selected rising shall be enabled
9. Synch Mode
10. This mode can be used for synchronizing HINDALCO network with
grid

AUTOMATIC VOLTAGE CONTROL

Objectives are

a. Maintain system power factor within the limits when grid connected
b. Maintain system voltage(132kV) when HINDALCO electrical
network gets islanded
c. Perform the control operation within the capability of generators and
shift the operation to OLTC for maintaining voltage/pf

AVR control when HINDALCO Network grid connected

HINDALCO has to maintain pf between 0.93 when exporting and 0.97 while importing.
control action performed by AVR is as follows

1. Calculates power factor from Act. Power and Rea.Power measurements

2. Converts entered power factor set point to reactive power value
3. Calculates the difference between reactive power set point (calculated) and
measured value
4. The calculated difference in reactive power is within the predefined dead band,
There is no action performed by AVR
5. If the calculated reactive power is greater than dead band then the difference will be
distributed among the available generator by considering its participation factor

HINDALCO Network get isolated from Grid

1. Control action performed by AVR as follows

2. Selects Busbar voltage setpoint(132kV) for control action
3. Selects busbar voltage measurement by checking healthiness of the measurement
23
 4. Calculates the difference between voltage setpoint and measured busbar
voltage
5. The calculated difference in voltage is within the predefined deadband,There is
no action performed by ALC
6. If the calculated difference is greater than dead band then the difference will be
distributed among the available generator by considering its participation factor

OLTC shifting operation for pf and V control

During following conditions automatic shifting of generator control to OLTC take places

a. Generator reactive power reaches its maximum (reactive margin A=0) then
operation shifted to GT OLTC and performs OLTC TAP lower.
b. Generator reactive power reaches its minimum (reactive margin B=0) then
operation shifted to GT OLTC and performs OLTC TAP Raise.

Individual AVR control for generator

Individual generator are facilitated with lower and raise button for controlling reactive
power

-To operate AVR from faceplate

a. Click on generator object from graphics display

b. Select AVR control panel
c. Select droop mode
d. Click on raise/lower buttons
e. There are two raise and lower buttons are available ,one set is useful for slow (fine)
control and other set for fast (coarse) control
OPERATION AT DIFFERENT MODES

 TWO CONDITIONS OF OPERATION

o IMPORT MODE
o EXPORT MODE
 TWO MODE OF OPERATION
o GRID CONNECTED
o
ISLANDED
1. GRID CONNECTED WITH IMPORT MODE & THEN ISLANDING
OCCURS
a. If freq. < 49Hz
Load shedding command to pot lines as per priority, immediately.

24
 Margin between priorities – 0MW
b. If freq. > 49Hz & Import < 30MW
Only ALC slow action (Pot line load regulation)
c. Freq. > 49Hz & Import >30MW
Load shedding command to pot lines as per priority. Margin between
priorities – 15MW

2. GRID CONNECTED WITH EXPORT MODE & THEN ISLANDING

OCCURRED

GOVERNOR MARGIN OF INDIVIDUAL MACHINE= 15% OF RATED

GENERATION (MAX. LIMIT)

ACTUAL GOVERNOR MARGIN OF INDIVIDUAL MACHINE= Pact - Pmin

Pact = Actual power generation Pmin = 0.85 *

P (rated)

TOTAL ACTUAL GOVERNOR MARGIN OF ALL RUNNING MACHINE is

sum of difference of individual machine between Pact & Pmin i.e. ∑ (Pact
- Pmin)
a. IF EXCESS GENERATION IS GREATER THAN GOVERNOR
MARGIN AND LESS THAN PRIORITY 1st
Only AGC slow action (Generator Load Reduction)
b. IF EXCESS GENERATION IS GREATER THAN GOVERNOR
MARGIN AND ALSO GREATER THAN PRIORITY 1st Priority 1
(P1) Generator tripped.
c. IF EXCESS GENERATION IS LESS THAN GOVERNOR
MARGIN & GREATER THAN P1
Only AGC slow action (Generator Load Reduction)

OLTC OPERATION

If voltage reach Min. in all units or Max. in all units then OLTC operate command
is enabled.

Qmax max

Qmin min

7MVARH
Qmin is 5MVARH in all units (except #5) & still surplus reactive power is going to grid then

25
SCADA generate an alarm to trip capacitor bank at HIL, Renukoot.

EXPORT MODE Cosᶲ 0.90+0.02

IMPORT MODE Cosᶲ 0.90+0.01

Export mode 65MW set point + 1MW dead band.

ISLANDING CONDITION

NORMAL MODE NM: f=50.25 + 0.25 Hz

To charge a tripped pot line, HIL will generate request to R.P.D. and
R.P.D. will give permission to change the same. LOADING
MODE LM: f=50.5 + 0.5 Hz
In loading mode pot line can be changed at >50.7 Hz and at less than 50 Hz SCADA will
block the loading signal.

SYNCHRONIZING MODE SM FOR GRID SYNCHRONIZATION:

-Can keep required frequency.

-Press soft key at the time of synchronization before closing Renukoot end breaker and
after closing of Rihand end breaker the soft key is depressed.

GRID CONNECTED MODE: (EXPORT WITH ONE FEEDERS)

65MW –

At > 80MW shedding

GRID CONNECTED MODE: (EXPORT WITH TWO FEEDERS)

65MW – 140MW only

From > 140MW – 160MW as per

priority

At >160MW generate shedding

GRID CONNECTED MODE: (IMPORT WITH ONE FEEDERS)

40MW –

At > 80MW priority 15MW

132KV TRANSMISSION LINE

26
If transmission voltage is less than 110kv & difference of any two phase is greater than

132KV TRANS. LINE O/L (GRID CONNECTED MODE)

MIN.

TRANS. LINE Amp.

AGC action, If import violation then, ALC action

MAX.

TRANS. LINE 1 to Amp.

generator shedding or load shedding as per situation with a 4 sec timer

During switching/ charging operation O/L calculation will start after 3 sec timer.

ISLANDING MODE
MIN.

<50.0Hz ALC in service

>50.5Hz

MAX.

TRANS. LINE Amp.

Generator shedding or load shedding as per situation with a 4 sec timer.

BUS BAR OVERLOAD (GRID CONNECTED MODE)

MAX. LIMIT

Bus Bar #1 1740 Amp.

Bus Bar #1 870 Amp.

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Bus Bar #2 895 Amp.

Bus Bar #3 895 Amp.

Bus Bar #4 1790 Amp.

Bus Bar #5 2000 Amp. Bus Bar

2000 Amp.

AGC action, if import violation then, ALC action.

3. IN ISLANDING CONDITION
a. If frequency < 49Hz (1st stage)
Load shedding command to Pot line tripping for priority st
1 .
b. If frequency < 48.5Hz (2nd stage)
Load shedding command to Pot line tripping for priority nd
2 .
If generator tripping occurred and frequency greater than 49Hz with power
deficit of less than 30MW Only ALC slow action
c. If generator tripping occurred and frequency more than 49Hz with
power deficit of more than 30MW.
Load shedding command for pot line tripping up to required priority
to maintain power balance margin between priorities 15MW.
d. If generator tripping occurred and frequency less than 49Hz

Load shedding command for pot line tripping up to required priority

to maintain power balance margin between priorities 0MW.

e. Load through less than governor margin

Only ALC slow action
f. Load through greater than governor margin and greater than priority
P1(Gen.)
Generator tripping as per priority.
Never trip generator if load through less than generation of particular
generator.

GENERATOR TERMINAL VOLTAGE

If generator terminal voltage VT is less than 9kv & difference of any two phase is greater

TERMINAL VOLTAGE

UNIT #1 & 2 (Min.) 14.0KV – 14.7KV (Max.)

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UNIT #3,4&5 (Min.) 10.4KV – 11.0KV (Max.)

UNIT #6 to 10 (Min.) 10.3KV – 10.5KV (Max.)

NOT IN SERVICE. AVC operating range.

Starting-point for Load Shedding

15MW 20MW 30MW

 Secure electrical power to
G1 G2 critical loads
 Minimal disturba nce to
plant operation
 No sp urious operation
M1 M2 M3 M4 M5 M6 M7

9MW 6MW 1MW 20MW 10MW 7MW 12MW

(5) (3) (3) (1) (2) (4) (5)

Active and Reactive Power Control

 Active Power Sharing:

 Automatic Generation Control
 Automatic Load control
 Import/Export control of MW

 Reactive Power Sharing:

 Automatic Voltage Control P

 OLTC Control
 Import/Export control
of Mvar/PF

Q-Lead Q-Lag

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 CENTRALIZED COMPUTER SYSTEM CONCEPT

Input P
Peripherals R
O
CPU C
E
S
Memory S
I
/
Output O
Peripherals
© Copyright yearABB - 3 -

All input, output and control functions are done through the
ONE redundant central computer.

CONTROLLER AC 800M HARDWARE

AC 800M

a. Three CPU variants

i. PM856, 8 MByte
ii. PM860, 8 MByte
iii. PM861, 16 Mbyte RAM, single & redundant
iv. PM864, 32 Mbyte RAM, single & redundant

30
 b. Local and remote I/O possibilities
c. Built in redundant Ethernet
d. Built in RS232
e. Integrated ABB drives on optical ModuleBus possibility
f. Hot swap of I/O modules
g. Optional communication modules
i. PROFIBUS-DP & DP/V1(line redundant)
ii. Foundation Fieldbus – H1
iii. RS232C
iv. MaserBus 300
v. Support INSUM
vi. Support S100 I/O
h. Marine certified

BASIC COMPONENTS IN CONTROL PANEL

I/O
CPU
CI 861

1. PM 864 RTU
2. S800 IO
Modules 3. TB 840

31
 4. TB 825
5. CI 861
6. Communication Cables
a. OFC
b. TCP/IP
7. Networking Switches
8. Transducers
9. BPS – Bulk Power Supply
10. DOU – Diode Oring Unit
11. Thermostat & Space Heater
12. Cubical Fluorescent Lamp

CONTROLLER AC 800M HARDWARE

AC800M Hardware Configuration

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 The hardware units that form the AC 800M Controller are:

1. Processor units (including base plate)

(PM856/PM860/PM861/PM864)
2. Communication interfaces for different protocols (including base plates)
3. (CI851/852/853/854/855/856/857)
4. Power supply units, providing various power output levels (SD821/822/823)

Redundant CPUs– Hot Standby

Control IT

 The PrimaryCPU is always updating

the Backup CPU Communication
Bus (CEX) Upper CPU
 A write toa memorycell is duplicated, which means that TK850 PM 861/864
the status of Primary is equal to Backup
 Redundancy transparent to application and
operating system

 Select late in your project, ifyou needredundancy

andnot.
Lower CPU
 Thecommunicationbusisshared PM861/864
 If one CPUfails, the CPUdon’t need toswitch
communicationinterface, just the CPUis switched
 Switch-over at HW failure
© Copyright year ABB - 18 -

 No interruption of sequential operation

 No loss of data
 Norepetition of incremental outputs RCU Link Cable
TK851

33
 How does it look in real life?

CPU 1 - Upper

CEX Link

Redundancy Link
RCU Cable
© Copyright year ABB - 26 -

CPU 2 - Lower

ControlIT AC 800M Redundancy topology

CEX Extension Cable

PROFIBUS-DP/V1 Cable

Redundancy Link
Cable
© Copyright year ABB - 30 -

Optical ModuleBus Cables

34
 Control IT
I/O systems
Redundant Connection of I/O via Module bus (Local I/O)

Control IT

Optical
Modulebus
© Copyright year ABB - 7 -

Optical Modem (12 modules)

TB840

Control
S800 I/OIT
I/O systems
Overview Redundancy

 Features
 Redundant FCI

 Redundant ModuleBus

 Redundant optical expansion

 Bumpless switch-over

 Redundancy principles
 Bumpless switch-over at lowest possible system level

 The ModuleBus is redundant all over

© Copyright year ABB - 6 -

35
Typical Single Line Diagram:

36
SECURITY ISSUES

The move from proprietary technologies to more standardized and open solutions together
with the increased no. of connections between SCADA systems and office networks and the
internet has made them more vulnerable to attacks. Consequently, the security of SCADA
based systems has come into question as they are increasingly seen as extremely vulnerable
to cyber-warfare/cyber- terrorism attacks.

In particular, security researchers are concerned about:

 The lack of concern about security and authentication in the design, deployment and
operation of existing SCADA networks
 The mistaken belief that SCADA systems have the benefit of security through
obscurity through the use of specialised protocols and proprietary interfaces
 The mistaken belief that SCADA networks are secure because they are
purportedly physically secured
 The mistaken belief that SCADA networks are secure because they are supposedly
disconnected from the internet.

SCADA systems are used to control and monitor physical processes, examples of which are
transmission of electricity, transportation of gas and oil in pipelines, water distribution,
traffic lights, and other systems used as the basis of modern society. The security of these
SCADA systems is important because compromise or destruction of these systems would
impact multiple areas of society far removed from the original compromise. For example, a
blackout caused by a compromised electrical SCADA system would cause financial losses
to all the customers that received electricity from that source. How security will affect
legacy SCADA and new deployments remains to be seen.

There are two distinct threats to a modern SCADA system. First is the threat of unauthorised
access to the control software, whether it be human access or changes induced intentionally
or accidentally by virus infections and other software threats residing on the control host
machine. Second is the threat of packet access to the network segments hosting SCADA
devices. In many cases, there is rudimentary or no security on the actual packet control
protocol, so anyone who can send packets to the SCADA device can control it. In many cases
SCADA users assume that a VPN is sufficient protection and are unaware that physical
access to SCADA related network jacks and switches provides the ability to totally bypass all
security on the control those SCADA networks. These kinds of physical access attacks bypass
firewall and VPN security and are best addressed by
endpoint-to-endpoint authentication and authorization such as are commonly provided in the
non-SCADA world by in-device SSL or other cryptographic techniques.

37
Many vendors of SCADA and control products have begun to address these risks in a basic
sense by developing lines of specialised industrial firewall and VPN solutions for TCP/IP
based SCADA networks. Additionally, application white listing solutions are being
implemented because of their ability to prevent malware and unauthorized application
changes without the performance impacts of traditional antivirus scans. Also, the ISA
Security Compliance Institute (ISCI) is emerging to formalise SCADA security testing
starting as soon as 2009. ISCI is conceptually similar to private testing and certification that
has been performed by vendors since 2007.
Eventually, standards being defined by ISA99 WG4 will supersede the initial industry consortia
efforts, but probably not before 2011.
The increased interest in SCADA vulnerabilities has resulted in vulnerability researchers
discovering vulnerabilities in commercial SCADA software and more general offensive
SCADA techniques presented to the general security community. In electric and gas utility
SCADA systems, the vulnerability of the large installed base of wired and wireless serial
communication links is addressed in some cases by applying bump-in-the-wire devices that
employ authentication and Advanced Encryption Standard encryption rather than replacing
all existing nodes.

38