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CCGT Operations Principles

Process Control
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Process Control Lesson Objectives
> Understand some of the parameters which need to be measured
in the power station environment
> Describe methods of measuring pressure, temperature, level and
flow
> Explain methods of transmitting information to the control system
> Describe the principle of a control system
> Examine examples of control configurations
> Explain the configurations of hardware used to implement control
systems
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Historical Instrumentation and Control

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A Boiler Operator! Photo Circa 1960s
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Carrington Boiler Control Panel Circa 1956
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Battersea Power Station Electrical Control
Room
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Battersea Power Station Engineer
Synchronising for the morning peak!
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Agecroft P.S. Unit Control Room Design Circa -1960s (photo probably 1980s)
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Drax Power Station CCR-1970s and 80s
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The Computer Age and DCS

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DCS ST Overview (Early Pembroke)
Note: simulated screen
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DCS ST Vibrations(EarlyPembroke)
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Field Instruments
> Pressure Measurement
> Level Measurement
> Flow Measurement
> Temperature Measurement
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Pressure Measurement - Definitions

Gauge
Absolute
Absolute
Gauge
Vacuum
Absolute Zero
Atmospheric Pressure
( Variable )
Differential
Pressure
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Manometers
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Manometer
H
h
h
(a)
Zero
Level
Applied
Pressure
Open to
Atmosphere
Gauge
(a)
Pressure
1
3
2
1
0
1
2
3
H
b)
(
Differential
Pressure
x
y
Scale
Liquid
Density
p2 p1
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Pressure due to a head of water =

DENSITY x GRAVITY x HEIGHT

= Kg/m x m/sec x M = N/M




Manometer Principle
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Bourdon Gauge

Bourdon Tube
Cross-Section
Pressure
Applied
No Pressure
Applied
"C" Shaped
Bourdon Tube
Threaded Pressure
Connection
Applied Pressure
Sealed End
Movement Of
Tube When
Pressure Applied

"C" Shaped
Bourdon Tube
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Bourdon Gauge - Movement

Applied Pressure

Bourdon Tube
End Piece
Adjusting Screw
( Angularity Adjustment)
Adjusting Screw
( Span Adjustment )
Block
Gauge Pointer
Pinion And
Pointer Shaft
Hair Spring
( Reduces Backlash )
( Zero Adjustment )
Quadrant ( Meshes With Pinion )



Pivot Pin
Threaded
Pressure
Connection
This measure principle can be adapted for remote reading
by connecting the measuring element to a transducer such
as an LVDT Linear Variable Differential Transformer
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Electronic Pressure Transmitters
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Differential Pressure Transmitter and
Transducer
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Capacitance Transducer
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Level Measurement

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Level Measurement Sight Glass



Scale
Drain Valve

Drain Valve


Isolators for easy removal of
gauge or to shut off if
glass breaks
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Level Measurement Differential Pressure
Open Tank

Datum
D.P. Cell
+
_
Vented
S.G. 1.0

Maximum
Level
3 Metres
Liquid
70 mm
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RFW Tank Level Measurement
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Level Measurement Differential Pressure -
Closed Tank

D.P. Cell
+
_

Datum
Liquid
Drain
Valve
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Closed Tank Measurement with Constant Head
Chamber e.g. condenser or boiler drum

Constant
Head
D.P. Cell
+
_
70mm

3 Metres
Datum
Vapour
Liquid
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Boiler Drum Measurement Constant Head
H L
Constant
Head
Steam
0 mm
Water
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Drum Level Measurement
> Accuracy due to density of fluid in wet legs (reference leg and
measured leg)
Caused by effects of drum pressure at different loads
Caused by difference in temperature between measuring device
and fluids in drum
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Drum Density Compensation - Graph

PRESSURE IN BARS
0
0.2
0.4
0.6
0.8
1
1.2
0 0 0
1
0 0 0 0 0 0

R
E
L
A
T
I
V
E

D
E
N
S
I
T
Y
WATER
STEAM
RELATIVE DENSITY GRAPH
0 20 40 60 80 100 120 140 160 180 200 220
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Drum Density Compensation Traditional UK
method Pressure Transmitter
Force on measuring
element is equal to height
difference
Drum Pressure
Transmitter
Constant Head
Chamber
Reference
Leg
Drum centre
line 0 mm
Drum level
Transmitter
Density is inferred from
pressure measurement and is
used to electronically correct
the level signal
Corrected signal
is used in three
element control
scheme
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Drum Density Compensation - Development -
Devices such as the IMV 31
shown here can process the
information from thermocouples
installed on the legs and
compensate for density
differences with on-board
processor
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Hydrastep - Components
D
E
T
E
C
T
O
R

A
N
D

L
O
G
I
C

U
N
I
T

DISPLAY
UNIT
Electrodes
Drum Steam
Connection
Drum Water
Connection
Hydrastep Vessel
Electrode
Tip
Ceramic
Insulator
Electrical
connection to
Detector
Hydrastep Vessel
Electrode
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Hydrastep - Installation

Boiler Drum
X
Y
X
Y
A B
Steam
Water
Detector
Unit
B
Detector
Unit
A
Odds
Evens
Odds
Evens
Hi/Lo Alarms
Logic
Unit
Power
Unit A
Power
Unit B
Drum Level
Control Room Level
Odd Even
Odd Even
Power
Supply
Source
Power
Supply
Source
Red
Lights
Green
Lights

Pressure Vessel A
Pressure Vessel B
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Level Measurement Ultra sound

1234
A
B
C

Liquid
Transceiver
Level
Display
Transducer
Path of Sound
Pulses
(Ultrasonic Wave)
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Flow Measurement

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Quantity Measurement

> There are two different types of quantity meter, inferential and
positive displacement meters
The principle of operation of a positive displacement quantity
meter is that a known volume is passed from the inlet to the
outlet of the meter
The principle of operation of an inferential quantity meter is that
the quantity is inferred by measuring the velocity

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Venturi Principles

> The principle of operation of an inferential quantity meter (1)is that
the quantity is inferred by measuring the velocity
> Therefore by measuring the difference in pressure across the
orifice plate, the rate of flow can be calculated
> Rate of flow is proportional to the square root of the differential
pressure (head)


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Venturi Principle
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Flow Measurement Differential Producers
Orifice Plate and Flow Nozzle


Flow
Pipe
Flange
Orifice
Identification
Tongue
Orifice Plate
Pipe


Flow
Nozzle
Upstream
Connection
Downstream
Connection
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Flow Measurement Pitot Tube
Fig.26 Pitot Tube Principle of Operation
P1
P2
Differential Pressure
Flow Indicator
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Flow Measurement - Electromagnetic
Principle of Operation
<>The operation of a magnetic flowmeter
or mag meter is based upon Faraday's Law,
which states that the voltage induced across
any conductor as it moves at right angles
through a magnetic field is proportional
to the velocity of that conductor.

Faraday's Formula:
E is proportional to V x B x D where:

E = The voltage generated in a conductor
V = The velocity of the conductor
B = The magnetic field strength
D = The length of the conductor


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Ultrasonic Flow Metering
Insertion
Technology
Clamp On
Technology
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Vortex Shedding Flow Metering (Water)
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Temperature Measurement

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Temperature Measurement Liquid Methods


Melting Point
Boiling Point

0 Deg. C
32 Deg. F
of Water
100 Deg.C 212 Deg.F
of Ice
Range
100 Deg.C
Range
180 Deg.F
Over Temperature
Bulb
Glass Stem
Cavity


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Temperature measurements based on the use of a
thermocouple rely on the basic principle that:


If two dissimilar metals are connected at one end to form a
measuring (hot) junction and are connected to a temperature
indicator at the other end to form a reference (cold) junction, a
voltage is produced at the measuring instrument which is
determined by the temperature difference between the two
junctions. (Thermoelectric effect)

Thermocouples
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Temperatutre Measurement - Thermocouples

Measuring ( Hot )
Junction
Reference ( Cold )
Junction

o
o
o
o
.
.
.
.
A
B
A
B
Junction
Connection
Head
0 Deg C Fridge or Oven
at Typically 50 Deg C
Compensating Cable
Copper Cable
Temperature
Indicator
Reference or Cold Junction
0 100
0 100
Deg C
Deg C
50
50
.
.
.
.
+
_
+
_
+
_
+
_
"X"
"Y"

Measuring
or Hot
Reference or
Cold Junction
Extension or
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Mineral Insulated Thermocouple
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The resistance of a metallic conductor will
increase with increase in temperature

This principle is utilised in resistance
thermometer detectors (RTD's).

Platinum is used for its resistance to corrosion
and its stability.

An accurately known value of platinum
resistance wire is wound on a suitable former to
make the RTD

Resistance Thermometer
Detectors (RTDs)
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The basic construction of an RTD consists of:

Platinum wire wound in a helix and encased in a ceramic insulator

Sealed with high temperature glass forming an impervious coating and
sealed in a metal sheath similar to a thermocouple.
Construction of RTDs
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DCS

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DCS

DATA STORAGE
PRINTER
CONTROL ROOM
COMPUTER
OPERATOR
STATION
DATA HIGHWAY "A"
DATA HIGHWAY "B"
PLANT MOUNTED CONTROLLERS / COMPUTERS
TX TX TX TX TX
CONTROL
VALVE
CONTROL
VALVE
POWER
CYLINDER

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DCS

DATA STORAGE
PRINTER
CONTROL ROOM
COMPUTER
OPERATOR
STATION
DATA HIGHWAY "A"
DATA HIGHWAY "B"
TX TX TX TX TX
CONTROL
VALVE
CONTROL
VALVE
POWER
CYLINDER

GT
Controller
ST
Controller
HRSG
Controller
BOP
Controller
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DCS System (Part) Plant Controllers
HMI
Turbine Process Station
Input/Output
Module
GT Controller ST Controller
Open Loop Control
Sequence Programmer
Closed Loop Control
Protection
Digital Inputs
Digital outputs
Analogue Inputs
Analogue Outputs
Human Machine
Interface
Data Highway
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HMI Human Machine Interface
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DCS System (Part) Plant Controllers
HMI
Turbine Process Station
Input/Output
Module
GT Controller ST Controller
Open Loop Control
Sequence Programmer
Closed Loop Control
Protection
Digital Inputs
Digital outputs
Analogue Inputs
Analogue Outputs
Human Machine
Interface
Data Highway
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DCS System (Part) Plant Controller
Systems
HMI
Turbine Process Station
Input/Output
Module
GT Controller ST Controller
Open Loop Control
Sequence Programmer
Closed Loop Control
Protection
Digital Inputs
Digital outputs
Analogue Inputs
Analogue Outputs
Human Machine
Interface
Data Highway
Egatrol and GT
Control System
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Egatrol and GT Control System
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DCS System (Part) Plant Controller
Systems
HMI
Turbine Process Station
Input/Output
Module
GT Controller ST Controller
Open Loop Control
Sequence Programmer
Closed Loop Control
Protection
Digital Inputs
Digital outputs
Analogue Inputs
Analogue Outputs
Human Machine
Interface
Data Highway
Egatrol and GT
Control System
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What are Open Loop Control Functions
> Used for final control elements such as pumps, valves and
breakers and for drive groups of relevant process areas
> Includes logic for manual and automatic commands, supervision of
protection signals and interlocks
> Not to be confused with the definition of open loop control within
modulating or auto control circles!
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Starting Lubricating Oil System - Generic
1
2
Lub Oil Tank Level? Consider: Interlocks, Releases, Permissives
Tank Lub Oil Temperature? Open Loop Control starts each item of sequence!
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DCS System (Part) Plant Controller
Systems
HMI
Turbine Process Station
Input/Output
Module
GT Controller ST Controller
Open Loop Control
Sequence Programmer
Closed Loop Control
Protection
Digital Inputs
Digital outputs
Analogue Inputs
Analogue Outputs
Human Machine
Interface
Data Highway
Egatrol and GT
Control System
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Sequence Programmer
> Interfaces with other relevant systems to complete specific tasks
e.g. start oil systems, place GT on turning gear
> Capable of starting open and closed loop items to ensure
satisfactory progress
> High level Automation Function sequencer capable of complete
plant start up
> Example of GT Start Up Sequence for Staythorpe
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DCS System (Part) Plant Controller
Systems
HMI
Turbine Process Station
Input/Output
Module
GT Controller ST Controller
Open Loop Control
Sequence Programmer
Closed Loop Control
Protection
Digital Inputs
Digital outputs
Analogue Inputs
Analogue Outputs
Human Machine
Interface
Data Highway
Egatrol GT
Control System
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Closed Loop Control Functions
> Closed loop control is used for final control elements such as
control valves, guide vanes and for level, temperature, pressure,
flow control of the process together with the necessary interlocks
and protections
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Closed Loop Control System
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DCS System (Part) Plant Controller
Systems
HMI
Turbine Process Station
Input/Output
Module
GT Controller ST Controller
Open Loop Control
Sequence Programmer
Closed Loop Control
Protection
Digital Inputs
Digital outputs
Analogue Inputs
Analogue Outputs
Human Machine
Interface
Data Highway
Egatrol GT
Control System
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Protection Functions
> Three Channels each channel connected to triple redundant,
dual redundant or single measuring loops
> evaluated in 2 o o 3 logic, 1o o 2 logic and 1 o o 1 logic according
to the redundancy of measuring loops
> The measurement redundancy minimises the number of spurious
trips
> Protection channels fed via redundant power supply modules
> Supervision of the three channels monitors discrepancies between
sensors and/or sensor disturbances
> Trip circuit is failsafe de-energised to trip
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Triple Redundant Measurements
1oo2
1oo2
1oo2
1oo1
1oo1
1oo1
&
&
&
CHANNEL 1
CHANNEL 2
CHANNEL 3
Outputs to
2 o o 3
Tripping
Device
High Speed
Link HSL
SENSOR 1
SENSOR 2
SENSOR 3
DE-ENERGISED TO TRIP
DE-ENERGISED TO TRIP
LIMIT VALUE
CONNECTION TO OTHER
1oo2 & 1oo1 voting
2 o o 3
2 o o 3
2 o o 3
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Example of 2 o o 3 Tripping Philosophy
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DCS System (Part) Plant Controller
Systems
HMI
Turbine Process Station
Input/Output
Module
GT Controller ST Controller
Open Loop Control
Sequence Programmer
Closed Loop Control
Protection
Digital Inputs
Digital outputs
Analogue Inputs
Analogue Outputs
Human Machine
Interface
Data Highway
Egatrol GT
Control System
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Analogue and Digital Signals?

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Typical Sources of Analogue and Digital Information

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Some More Photographs!
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Staythorpe B Panel
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Manual Synch Staythorpe C circa 2010
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Manual Synch Battersea circa 1952
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And One Who Failed His Desk Authorisation!
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End of Session