Automatic Turbine Run Up System

AUTOMATIC TURBINE RUN
UP SYSTEM
(ATRS)
9/23/15
Gyanendra Sharma - NPTI Delhi
Presentation outline
Overview of Plant Controls
Functions of ATRS
Structure of ATRS
Program Structure of ATRS and
Turbine protection
9/23/15
MAN-MACHINE-INTERFACE
OPERATOR
INSTRUMENTATION & CONTROL
PLANT
9/23/15
3
POWER PLANT
PLANT CONTROL
CONTROL
POWER
UNIT CONTROL
BOILER
TURBINE
9/23/15
GENERATOR
4
INSTRUMENTATION
AND
CONTROL
MONITORING
MEASUREMENT
CLOSE-LOOP
CONTROL
OPEN-LOOP
CONTROL
PROTECTION
9/23/15
5
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.
9/23/15
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
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7
HIERARCHY OF CONTROL
UNIT
CONTROL
GROUP CONTROL
(WHEN, HOW MANY,WHICH)
SUB-GROUP CONTRL-1
SUB-GROUP CONTRL-2
CONTROL INTERFACE
SWITCH GEAR (MCC)

9/23/15
CONCEPT OF C&I IN THERMAL POWER

STATION
CRT /MMI DISPLAY UNIT IN
OWS
OPERATOR
ANALOG AND
BINARY
LOGS
CONTROL
ROOM
SIGNALS
UNIT CONTROL
AUTOMATION
CLOSED
LOOP
CONTROL
SIGNAL
CONDITIONING
ALALOG, BINARY
FUNCTIONAL
GROUP
CONTROL
PROTIVE
LOGICS
DATA PROCESSING, ALARM

ANNUNCIATION
CONTROL INTERFACE
9/23/15
PLANT INTERFACE
EQUIPMENT
MOTOR CONTROL CENTRE

SWITCH GEAR
SIGNAL TRANSMITTER
EQUIPMENT
PLANT (FIELD)
DRIVES
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
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10
ATRS STRUCTURE
OIL SYSTEM, VACUUM SYSTEM, TURBINE etc.
GC
SGC
SLC
CI9/23/15
SLC
CI
SGC
SGC
SLC
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
9/23/15
12
ADVANTAGES OF ATRS
ELIMINATES HUMAN ERROR

PROVIDES MAXIMUM PROTECTION AGAINST
MALFUNCTIONS
OPERATORS 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
9/23/15
13
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
9/23/15
14
MONITOR &
STEP 01
BLOCKING TIME
START DRIVE A
DRIVE A ON
&
MONITOR &
STEP 02
BLOCKING TIME
9/23/15
OPEN DMPR A
15

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.
9/23/15
16

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.
9/23/15
17
PROGRAM STEP OF A SUBGROUP

CONTROL
STEP CRITERIA FOR STEP -2
FROM STEP 1
&
BYPASS CRITERION
EXAMPLE
1
&
02
&
PROGRAM LOOP
WAIT
50s
MO TIME
20s
COMMAND
1
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.
9/23/15
18
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.
9/23/15
19
ATRS CONTROLS:
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.
9/23/15
20

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

issues commands to the drive control level.
SLC logic is also realised in the processor module.
9/23/15
SGC and
21

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.
9/23/15
22

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.
9/23/15
23

ATRS STRUCTURAL SYSTEM:
ATRS IS ORGANISED IN THREE SGCs :
1.
SGC-TURBINE :
SGC Turbine acts directly on the following systems :
9/23/15
Sub-loop Control (SLC) Drains.

Warm up Controller.
Starting Device of turbine governing
system.
Speed & Load Setpoint devices of turbine
governing
system.
Auto-synchroniser.
24

2.
SGC-OIL SUPPLY :
SGC oil supply directly acts on the following system :
9/23/15
Sub-loop control (SLC) turning gear.

SLC auxiliary oil pump 1.
SLC auxiliary oil pump 2.
SLC emergency oil pump.
SLC jacking oil pump.
25

3.
SGC-CONDENSATE & EVACUATION :
SGC- Condensate & Evacuation directly acts on the following

systems :
Sub-loop
Control
(SLC)
extraction pumps.
Starting ejector, if provided.
Main ejectors / vacuum
applicable).
Vacuum breaker.
9/23/15
condensate
pumps
(as
26

3.
SGC-HPCF :
SGC- HPCF acts on the foll :
9/23/15
Sub-loop Control (SLC) HPCF

SLC HPCF pumps
HPCF pumps
HPCF re-circulation pumps
LPCF temp control valve
27

3.
9/23/15
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.
Gyanendra
Sharma - NPTI Delhi
28
TURBINE START-UP / SHUT-DOWN CONTROL,

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

CRITERIA
CRITERIA
SEAL
STEAM
CONTROL(SSC)
ELECTROMECHANICAL
HYDRAULIC
HYDRAULIC
CONTROL(EHC) CONTROL(MHC)
MANUAL
ON/OFF
TURBINE
TRIP
SYSTEM(TTS)
AUTO
ON/OFF
TURBINE
STRESS
EVALUATOR
LP WATER
INJECTION
SUBLOOP
LP-WATER
INJECTION
AUTOMATIC
SYNCHRONIZER
MANUAL
OPEN/CLOSE
GENERATOR
MAIN CKT.
BREAKER
SUBLOOP
DRAIN
VALVE
AUTO
ON/OFF
MANUAL
ON/OFF
THYRISTOR
VOLTAGE
REGULATOR(TVR)
9/23/15
AUTOON/OFF
DRAIN
VALVES
29
SGC-DISPLAY
4
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
9/23/15
30
SLC-DISPLAY
2
1
1. PUSHBUTTON MANUAL ON/OFF
2.LAMP SLC OFF
3.LAMP FAULT
4.LAMP SLC ON
9/23/15
31
DRIVE INTERFACE-DISPLAY
3
1. PUSHBUTTON OFF (CLOSE)

2. PUSHBUTTON ON (OPEN)
3. LAMP OFF (CLOSE)
4. LAMP FAULT
5. LAMP ON (OPEN)
9/23/15
32
EXPLANATION OF KWU IDENTIFICATION SYSTEM (KKS)
ORDINAL SECTION
GENERAL
NAAANN
EXAMPLE
1MAJ15
AANNN
AP001
AANN
XB01
SIGNAL IDENTIFICATION
CONSECUTIVE NO. OF EQUIPMENT

TYPE OF EQUIPMENT
NO. OF SUBGROUP
PLANT GROUP (FUNCTIONAL GROUP)
NO. OF UNIT
9/23/15
33
PROTECTION SYSTEM
FOR
STEAM TURBINE
9/23/15
34
TURBINE PROTECTION SYSTEM
TASK PERFORMED :
PROTECTS TURBOSET FROM INADMISSIBLE

OPERATING CONDITIONS
PREVENTS DAMAGE IN CASE OF PLANT FAILURE
FAILURE OCCURRENCE REDUCED TO MINIMUM
9/23/15
35
ADVANTAGES :
DETECTION OF UNIT IRREGULARITIES
PREVENTION OF UNIT OVERSTRESSING DUE TO TRIPS
RELIEF OF OPERATING PERSONNEL FROM QUICK AND

CORRECT DECISION TAKING
9/23/15
36
HYDRAULIC
TRIP SYSTEM
- OVER SPEED
TRIP DEVICE
1/2
- VACUUM TRIP
DEVICE
- HAND TRIP
LEVER(LOCAL)
1/2
9/23/15
ELECTRICAL
TRIP SYSTEM
- MANUAL
REMOTE TRIP
( UCB)
- LOW VACUUM
TRIP
- LOW LUBE OIL
- FIRE PROT.
TRIP
-BRG METAL
TEMP
-AXIAL SHIFT
-HP/IP TOP/BOT
DIFF TEMP HI
EXTENDED
TURBINE PROT.
- LP EXH. STM.
TEMP. > MAX
PROT. CRITERIA
FROM OTHER AREA
-GENERATOR
PROTECTION
- MASTER FUEL
TRIP RELAY
ENERGISED
- BOILER
PROTECTION
OPTD.
37

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.
9/23/15
38

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.
9/23/15
39

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.
9/23/15
40
9/23/15
41

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-outof-3logic.
9/23/15
42

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.
9/23/15
43

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.
9/23/15
44

TRIPPING CRITERIA :
5. TURBINE TRIP SWITCH OPERATED :
The protection acts when the turbine trip

control room is operated manually.
switch
in unit
6. TRIP COMMAND INITIATED FROM ATRS :
The protection acts when the trip command signal

initiated from the Automatic Turbine Run-up System .
9/23/15
is
45

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.
9/23/15
46
THANK YOU
9/23/15
47

Automatic Turbine Run Up System

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AUTOMATIC TURBINE RUN

Gyanendra Sharma - NPTI Delhi

Gyanendra Sharma - NPTI Delhi

INSTRUMENTATION & CONTROL

OPERATING PERSONNEL FREED FROM ROUTINE

Gyanendra Sharma - NPTI Delhi

TURBINE C&I PACKAGE CONSISTS OF THE FOLLOWING SYSTEMS:

MONITORING & MEASUREMENT SYSTEM

SWITCH GEAR (MCC)

Gyanendra Sharma - NPTI Delhi

CONCEPT OF C&I IN THERMAL POWER

DATA PROCESSING, ALARM

MOTOR CONTROL CENTRE