3.4 GL For Monitoring Control Protection and Automation of SHP Stations

Version 2
STANDARDS/MANUALS/ GUIDELINES FOR SMALL HYDRO DEVELOPMENT
Electro-Mechanical Works Monitoring, Control, Protection and Automation of Small Hydropower Station
Sponsor: Ministry of New and Renewable Energy Govt. of India
Lead Organization: Alternate Hydro Energy Center Indian Institute of Technology Roorkee
May 2011
GUIDE LINES FOR MONITORING, CONTROL, PROTECTION AND AUTOMATION OF SMALL HYDROPOWER STATIONS CONTENTS
SECTION-I 1.0 INTRODUCTION .............................................................................................................. 3 1.1 OBJECTIVES ................................................................................................................. 3 1.2 GENERAL ...................................................................................................................... 3 1.3 REFERENCES AND CODES ........................................................................................ 3 SECTION-II 2.0 MONITORING OF SHP .................................................................................................... 5 2.1 SYSTEMS FOR MONITORING ................................................................................... 5 2.1.1 Water Conductor System ........................................................................................ 5 2.1.2 Hydro-mechanical Parameters ................................................................................ 5 2.1.3 Electro-mechanical Operating Parameters .............................................................. 6 2.2 REQUIREMENTS OF MONITORING SYSTEM ........................................................ 7 2.2.1 Instrument Transformers & Sensors ....................................................................... 7 2.2.2 Indicating Meters .................................................................................................... 7 2.2.3 Temperature Scanners ............................................................................................. 7 2.2.4 Indicating Lamps .................................................................................................... 7 2.2.5 Alarm & Annunciations .......................................................................................... 7 2.2.6 PLC Based System.................................................................................................. 8 2.3 LEVELS OF MONITORING ......................................................................................... 8 SECTION-III 3.0 CONTROL OF UNITS OF SMALL HYDROPOWER PLANT ....................................... 9 3.1 GENERAL ...................................................................................................................... 9 3.2 Technology ..................................................................................................................... 9 3.3 CONTROL FUNCTIONS .............................................................................................. 9 3.3.1 Turbine Control ..................................................................................................... 10 3.3.2 Generator Control ................................................................................................. 10 3.3.3 Plant Control ......................................................................................................... 11 3.4 Considerations for Selecting Control System ............................................................... 12 3.5 Categorization of Control System ................................................................................. 15 3.6 System Architecture, Communication and Databases ................................................. 17 3.7 Control Data Networks ................................................................................................. 17 3.8 Man-Machine Interface (MMI).................................................................................... 17 3.9 Hardware ...................................................................................................................... 18 3.10 Grounding ..................................................................................................................... 18 3.11 Static Control ............................................................................................................... 18 3.12 Information and Control Signals ................................................................................... 18
AHEC/MNRE/SHP Standards/E&M Works Guidelines for monitoring, control, protection and automation of SHP Oct. 2009
3.13 Communication Links................................................................................................... 19 3.14 Recommendations for control systems for various categories of MHP & SHPs ......... 21 3.14.1 Micro processor based control for micro hydro power plant (MHP up to 100 KW). 21 3.14.2 PC based Integrated Generation Controller (100KW to 1000KW) ........................... 21 3.14.3 Computer Based Control System for Powerhouses (1MW to 5 MW)....................... 22 3.14.4 Computer Based Control System for Power Plant above 5 MW .......................... 24 SECTION-IV 4.0 Protection of SHP generating units 26 4.1 General 26 4.2 Equipment trouble 27 4.3 Devices used in typical protection system 28 4.4 Criteria of selection of protection system ....................................................................... 333 4.4.1 Requirements of Protection of Turbine................................................................. 33 4.4.2 Requirements of Protection of Generator ............................................................. 33 4.5 Generator Protection System and Relay Selection ........................................................... 34 4.5.1 Categorisation .............................................................................................................. 34 4.5.2Transient overvoltage and surge protection .................................................................. 34 4.5.3 Protection for Micro hydel systems (up to 100 kVA).................................................. 34 4.5.4 Protection for Generating Units above 100 kVA and up to 5 MVA ........................... 35 4.5.5 Protection for generating Units above 5MVA and up to 25 MVA .............................. 41 4.6 GENERATOR CONNECTED IN PARALLEL TO GRID ............................................ 46 4.7 GENERATORS CONNECTED IN PARALLEL ON A COMMON BUS .................... 46 4.8 PROTECTION GROUPS ................................................................................................ 46 4.8.1 CONTROLLED ACTION SHUT DOWN ........................................................... 46 4.8.2 EMERGENCY SHUT DOWN ............................................................................. 47 4.8.3 IMMEDIATE ACTION SHUT DOWN....46 4.8.4 ELECTRICAL SHUT DOWN..46 ANNEXURE-I ............................................................................................................................. 49 COMPUTERISED AUTOMATION AND REMOTE CONTROL OF SMALL HYDRO POWER PLANT ........................................................................................................................... 49 ANNEXURE-II ........................................................................................................................... 85 LIST OF GENERATOR PANEL INDICATION AND RELAYS .............................................. 85 ANNEXURE-III .......................................................................................................................... 86 LIST OF PROTECTION ELEMENTS IN MICRO PROCESSOR BASED RELAYS .............. 86
GUIDE LINES FOR MONITORING, CONTROL, PROTECTION AND AUTOMATION OF SMALL HYDROPOWER STATIONS
SECTION-I 1.0 1.1 INTRODUCTION OBJECTIVES The purpose of this guide is to provide guidance for selection of monitoring,control and protection system for SHP up to 25 MW by developers, manufacturers, consultants, regulators and others. The guide includes selection of technology, extent of automation and monitoring system for different categories (micro up to100 KW, small up to 5 MW and above 5 MW to 25 MW) that is economical, easy to adopt and sustainable feasible and essential for safe operation. GENERAL The generating units of a small hydropower plant may have its shaft vertical, horizontal or inclined with the type of turbine selected to suit the sites physical conditions. Small hydro turbines may be selected as per site conditions, head and discharge available. Small hydro-generator are of the alternating current type and may be either synchronous or induction type. Usually small hydro units up to 5 MW are expected to require minimum amount of field assembly and installation work. While machine having capacity from 5 MW to 25 MW may have slow speed, large diameter and with split generator, stator that may require final winding assembly in the field. Mini & micro power stations are generally provided system suiting to these being run unattended or with few attendants while bigger machines up to 5 MW capacity have more elaborate arrangement of control monitoring and protection. Machine having capacity up to 25 MW and provision of parallel operation with other systems will have more comprehensive control, monitoring & protection system. This guide will serve as a reference document along with available national & international codes standards, guide & books. For the purpose of convenience this guide has been subdivided as follows: 1.3 Monitoring Control Protection
1.2
REFERENCES AND CODES IEEE guide for control of small hydro electric power plants IEEE guide for control of hydro electric power plants Guide for commissioning operation and maintenance of 3
IEEE Std 1020 IEEE Std 1010 IEEE Std 60545:1976
IEC 61116:1992 IEEE std 1046 IEEE std. 1249 IEEE std. C 37101 IEEE std. C 5012
IEEE std 4214 ANSI/ IEEE std 242:1996
ANSI/ IEEE std C 372-1987 ANSI/ IEEE std C 37.95 : 1974 ANSI/ IEEE std C 37.102:1987
Hydraulic Turbines Electro mechanical guide for small hydroelectric installations IEEE application guide for distributed digital control and monitoring for power plants IEEE guide for computerbased control for power plant automation IEEE guide for generator ground protection IEEE standard for salient pole 50 Hz and 60 Hz synchronous generator and generator / motors for hydraulic turbine application rated 5 MVA and above IEEE guide for preparation of excitation system specification IEEE recommended practice for protection and coordination of industrial and commercial power systems IEEE standard electrical power systems device function numbers (R1980) IEEE guide for protective relaying of utility IEEE guide for generator protection
The guidelines are based on the following: a) Technology recommended under UNDP-GEF Project for Himalayan range SHP project. These recommendations were made by AHEC (Alternate Hydro Energy Centre) as Indian consultant based on specific recommendations of M/s Mead and Hunt US consultant; M/s MHPG Group of European Consultants; World Literature review and local experience. a) UNDP/world bank recommendation for cost effective irrigation based Mini Hydro Schemes in India under Energy Sector Management Assistance programme (ESMAP) by standardization of designs and equipment. b) Economic Computer Controls for Low Head Hydro by R. Thapar and D.A. Perrault; WATERPOWER85, U.S.A. c) Thapar, Rakesh, et.al, Microprocessor Controller for a small Hydroelectric System, I.E.E. October, 1986. d) Microcomputer Based Control and Monitoring Systems; DIGITEK INC. 11807, North Creek Pkwy, So. Bothell, WA 98011 U.S.A. Technical Literature. e) Small Hydro-Electric Technology for Economic Development by O.D. Thapar, Presented in Eleventh National Convention of Electrical Engineers and Seminar on Environmental Friendly Electric Power Generation- Nov. 1995, Roorkee. f) Report on study and design and development of Model SHP based self sustained projects - E & M Equipment standardization and cost reduction Vol. III (a) prepared by Alternate Hydro energy Centre, IIT Roorkee for Power finance corporation Ltd. 2002. g) Design of al large number of SHP projects for different states and organization. h) Art & science of protective relaying 1956 by MASON, CR
SECTION-II 2.0 MONITORING OF SHP
Monitoring of operating parameters of the generating unit and their auxiliaries is very important for the life and optimum utilization of available discharge for generation. The efficient running of unit requires regular monitoring. The primary input data and generation output data are monitored periodically. The details of data required for monitoring performance of a generating station is as follows. 2.1 2.1.1 SYSTEMS FOR MONITORING Water Conductor System Storage level at dam / barrage / weir River discharge Headrace channel discharge Discharge at outlet of desilting basin Fore bay level Discharge of spillway Penstock pressure Tail water level
2.1.2 Hydro-mechanical Parameters Turbine and accessories o Pressure and levels in oil pressure system o Bearing temperatures (oil & pads) o Oil level in bearing sumps (if provided) o Cooling water pressure and temperatures o Clean water pressure for shaft gland o Vibration in shaft for large machines( optional) o Status of inlet and other valves. Generator and accessories o Stator winding temperature o DE/NDE end bearing temperatures o Cooling water and air temperatures Transformers o Winding temperature o Oil temperature o Oil level o Cooling water temperature and pressures
2.1.3 Electro-mechanical Operating Parameters Turbine & accessories o Speed o Guide vane opening & limits (precent) o Runner blade opening in Kaplan Turbine (percent) o Nozzle opening in impulse turbine (percent) Generator & auxiliaries o Governor actuator balance current (Amp) o Generated power (kW or MW) o Generated units (kWh) o Kilovolt ampere (kVA) o Kilovolt ampere reactive (kVAR) o Power factor (PF) o Frequency (Hz) o Excitation voltage (Volts) o Excitation current (Amp) o Recorder for kW, Hz, kWh etc Transformers o Tap position o HV/LV current o Primary/ secondary voltage Grid system & transmission line o Grid voltage o Grid frequency o Power export / import (kW) o Current (Amp) o Kilowatt hour (kWh) export / import Station auxiliaries o Voltage and current on LT AC system o Kilowatt hour (kWh) o Diesel generator running hour, kWh & other parameters o Drainage & dewatering system Running hours of pumps Water level in sump o Fire extinguisher periodical testing o Battery set- Regular monitoring as per manufacturers recommendations o Battery chargers & distribution boards voltage current etc. o Air compressors HP /LP pressures and running hours o OPU system Running hours of pumps Level in pressure accumulators Pressure of oil
2.2 2.2.1 i)
REQUIREMENTS OF MONITORING SYSTEM Instrument Transformers & Sensors CTs & VTs
Current and voltage transformers of rated voltage and appropriate ratio, class of accuracy are selected as per the requirement of the system. ii) Sensors
The sensors for temperatures, pressures, levels and speed are installed at the proper location. 2.2.2 Indicating Meters Analogue type of meters, separate for each parameter with selector switches etc were being used earlier installed on control panels. Now a days digital meters are being used for such parameters. Digital multifunction meters are now in use, only one meter provides several parameters on selection, as well as provides routine display. 2.2.3 Temperature Scanners
Digital temperature scanners indicating the temperatures of stator winding, bearing pads, oil coolers etc. are provided and installed on the generator control panels. These scanners get the signals from the sensor installed at specific locations preferably through screened cables. 2.2.4 Indicating Lamps
Indicating lamps of suitable colours as per code and practices should be provided on control panels for indication status of machine and various auxiliaries, pumps, electrical equipment like breaker, isolator, AC/DC supply system etc. Lists of such indication and relays are enclosed as Annexure-I&II. 2.2.5 Alarm & Annunciations
The protection system relays and auxiliary relays also provide signals to alarm and annunciation system. A set of annunciation windows are provided on control panels for each fault clearing relay with accept test and reset facility through push buttons. Alarm and trip annunciation indicate the fault and advise operating personnel of the changed operating conditions.
2.2.6 PLC Based System Recently control of machine and auxiliaries is done through PLC based control system automatically in addition to manual systems with local and remote facilities. The data is acquired through sensors and operation of machine is achieved on preset values through PC Monitors etc. The PLC will acquire data from generating units, transformers, switchgears and auxiliaries through transducers / sensors/ CTs / VTs. Wherever signals are weak, noise level is high shielded cables should be used for carrying data / signals. For sending output signals PLC will use relays for operating breakers etc and comparators for giving ON/OFF signal. 2.3 LEVELS OF MONITORING
Normally two levels of monitoring is provided in SHP as per recommendation of IEC 1116. The levels are: Alarm Tripping
In case of manned power plant alarm comes first so as to make the operator alert if no corrective action is possible then tripping command with indication / hooter and annunciation will be there. But in case of unattended power plant direct tripping command will be initiated and shut off the facility to avert possibility of any damage to the plant.
SECTION-III 3.0 3.1 CONTROL OF UNITS OF SMALL HYDROPOWER PLANT GENERAL
For small hydro installation simplicity of control system is advised, however, the sophistication of control should be based on the complexity and size of the installation, without compromising unit dependability and safety of personnel. Simplicity of control is desirable to keep total cost of installed equipment as well as cost of maintenance, repair and tests at economical level. Moreover a simpler system is more reliable as compared to complex one. 3.2 Technology
Up to 1980s, control of a hydro plants generating units was typically performed from governor panel or unit control switchboard. If the plant had multiple units, a centralized control board was provided. The unit control board and centralized control board using relay logic contained iron vane meters, hardwired control switches, and hundreds of auxiliary relays to perform the unit start/stop and other control operations. All the necessary sensors and controls required to operate the unit or units were hardwired to the unit control board and/ or centralized control board, allowing operator to control the entire station from one location. Data acquisition was manual. Modern systems still permit control of the entire plant from a single location. Modern control rooms utilize the far more cost-effective computer based automation which implies (IEEE: 1249 definition) use of computer component, such as logic controllers, sequence controllers, modulating controllers and microprocessors in order to bring plant equipment into operation, optimize operation in a steady state condition and shut down the equipment in the proper sequence under safe operating conditions. This includes programmable logic controllers (PLCs) for control system and PC monitor and hard disc for data display and data acquisition system and distributed computer control systems with graphic display screens to implement a vast array of control schemes. The SCADA (supervisory control and data acquisition) control scheme also provides flexibility in control, alarming, sequence of events recording, and remote communication that was not possible with the hardwired control systems. Data acquisition, storage and retrieval is provided by the computer. A detailed write up on computerized automation, remote control and SCADA is enclosed as Annexure I for reference. 3.3 CONTROL FUNCTIONS
There are many functions to be controlled in a small hydropower system. For example turbine governor controls the speed of turbine, plant automation covers operations as auto start, auto synchronization, remote control startup or water level control and data acquisition and
retrieval covers such operation as relaying plant operating status, instantaneous system efficiency or monthly plant factor. 3.3.1 Turbine Control
This is the speed / load control of turbine in which governor adjusts the flow of water through turbine to balance the input power with load. In case small plants in the category of micro hydel (100 kW unit size), load controllers are used, where excess load is diverted to dummy load to maintain constant speed. With an isolated system, the governor controls the frequency of the system. In interconnected system, the governor may be used to regulate unit load and may contribute to the system frequency control. Figure 1 shows the different types of control applicable to turbines.
Fig. 1: Turbine Control 3.3.2 Generator Control
This is the excitation control of synchronous generator. The excitation is an integral part of synchronous generator which is used to regulate operation of generator. The main functions of excitation system of a synchronous generator are: Voltage control in case of isolated operation and synchronizing Reactive power or power factor controls in case of inter connected operation. The different generator controls are shown in fig. 2.
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Fig. 2: Generator Controls 3.3.3 Plant Control
Plant control deals with the operation of plant. It includes sequential operation like startup, excitation control, synchronization, loading unit under specified conditions, normal shutdown, emergency shutdown etc. The mode of control may be manual or automatic and may be controlled locally or from remote location. Plant control usually includes monitoring and display of plant conditions. Different plant controls are given in fig 3.
Fig. 3: Overview of Plant Automatic Control
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3.4
Considerations for Selecting Control System Governor and control systems for small hydro units especially in developing countries have to be selected keeping in view the following: i) Traditional mechanical flow control governor with mechanical hydraulic devices is complex demanding maintenance and high first cost. Further performance requirements of stability and sensitivity i.e. dead band, dead time and dashpot time especially for interconnected units may not be possible with mechanical governors. ii) The manpower as available for operation is unskilled and further adequate supervision is not feasible. iii) Load factors for stand-alone micro hydels are usually low which affects economic viability. iv) Cost of speed control and automation with electronic analaog flow control governors, unit control and plant control is high. These systems require attended operation and are mostly based on large capacity hydro units. This is making most of the units very costly and uneconomical to operate. Experience in successful operation of analog electronic control system in India for SHP is not good. v) Electronic digital flow control governors can take up plant control functions. vi) Flow control turbine governors are expensive and not recommended for small hydro units in micro hydel range. Electronic load control governing system with water cooled hot water tanks as ballast loads for unit size upto 100 kW be used. This will make a saving of about 40% on capital cost. If the thyristor control (ELC) is used then the alternator needs to be oversized upto 2% on kVA to cope with the higher circulating current included. Accordingly, in case of small units upto 100-150 kW size elimination of flow control governors by digital shunt load governor (electronic load controllers) will make these units economically viable and properly designed will eliminate continuous attendance requirement. vii) Data storage function can be added to the digital governors. viii) The dummy loads in the Shunt Load Governors (ELC) can be useful load system or can be used for supplying domestic energy needs. ix) Analog electronic governors and plant controllers are also used for small hydro auto synchronizing and for remote control and monitoring of system. x) Digital generation controllers were evolved to take care of speed control, unit control and automation, unit protection and generation scheduling and have been successfully in operation for over ten years.
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xi) PLC based system are reliable and suitable for harsh conditions. These have been in operation in India and abroad. xii) Dedicated PC based systems for complete generation control can be easily adopted for data acquisition and storage at low cost and can also be adapted to SCADA system. Customized software is used in these systems which inhibits wide spread use. Future systems using PC as controller and for SCADA with open architecture and use of commercially available software is recommended for economy and wide spread use.
Comparison of various options for control systems are given in table 1
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Table1. Comparison of various options for control system, including turbine governing supervisory control and data acquisition
S. No. Turbine Gov. and Controller Type Unit size kW Mode of operati on Suitability Turbine Gov. Unit Prot. Data storage and Retrieval SCADA Cost including Gov. control, protection, SCADA data Aq., Storage and Retrieval (see note-1) Capital 1. Mech. Flow control Gov. 50-100 Iso. Grid Iso. Grid Iso. Grid Do not available 100-500 Iso. Grid See note 3 Digital load control governor may be developed for SCADA Suitable At extra cost Low Low Not considered At high extra cost Very high O&M High without SCADA Not recommendation Recommendation Remarks
Unit control
100-500 & above 2. Load control governor 50-100
Suitable
Not feasible
3.
Analogue, Electronic Gov. & Plant Controller
50-100 Above 100
Iso. Grid Iso. Grid Iso. Grid Iso. Grid
At high extra cost
Very high cost High Moderate to high Moderate
Not recommended
4.
PLC integrated controller with SCADA by PC PLC digital governor with plant controller and SCADA with redundant PC Data Logger with PLC load controller PC based integrated system for governing; plant control protection and metering
SHP 100 kW to 5 MW Above 5 MW
Suitable
Low
Recommended
5.
Suitable See note 2
High
Moderate
Recommended for units above 5 MW
6. 7.
5 to 100 kW 100 kW to 2500 kW
Iso. Grid Iso.
Data not available Suitable Indigenous system not available
Low Low
Moderate Medium
Recommended Recommended with high speed PC suitable for harsh area
Grid
Notes:
1. 2. 3.
Cost normalized with main and backup SCADA system. Dedicated digital controller for Gov. and plant control with PC based SCADA backup. Recommended in conjunction with partial water flow control
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3.5 Categorization of Control System The control system can further be defined by identifying following three categories of control: Control category Location Subcategory Local Centralized Offsite Manual Automatic Remarks Control is local at the controlled equipment or within sight of the equipment Control is remote from the controlled equipment, but within the plant Control location is remote from the project Each operation needs a separate and discrete initiation; could be applicable to any of the three locations Several operations are precipitated by a single initiation; could be applicable to any of the three locations Operator is available at all times to initiate control action Operation staff is not normally available at the project site
Mode
Operation Attended (supervision) Unattended
Relationship of local centralized and off site control function as per IEC: (62270-2004) guide in fig. 4 & 5.
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TO REMOTE CONTROL CENTRALISED CONTROL
STATION OPTICAL FIBRE COMMUNICATION NETWORK (DUAL)
UNIT 1 LOCAL/MANUAL CONTROL PLC USER INTERFACE
INDIVIDUAL UNIT CONTROL SWITCHYARD CONTROL STATION SERVICE CONTROL & MONITORING PLANT REAL POWER CONTROL & MONITORING AUTOMATIC VOLTAGE CONTROL WATER & POWER OPTIMIZATION AUTOMATIC GENERTAION CONTROL SWITCHGEAR AND RELAY STATUS REPORT GENERATION DATA LOGGING/TRENDING HISTORICAL ARCHIVING
UNIT 2 LOCAL/MANUAL CONTROL PLC USER INTERFACE
SART/STOP SEQUENCING SYNCHRONIZING TRASHRACK CONTROL BLACK START CONTROL UNIT AUXILIARIES CONTROL GOVERNOR/EXCITATION CONTROL/STATUS UNIT LOAD CONTROL UNIT ANNUNCIATION UNIT METERING UNIT RELAY STATUS UNIT FLOW DATA CONDITION MONITORING
STATION SERVICE LOCAL CONTROL USER INTERFACE
SWITCHYARD CONTROL PLC USER INTERFACE
POWER HOUSE
Fig. 4
LOCAL CONTROL SYSTEM
PROTECTION SYSTEM
STATION COMMUNICATION LINK PROCESS (UNIT, SWITCHGEAR GATES, ETC.)
COMPUTER BASED CONTROL
PROCESS INTERFACE
LOCAL USER INTERFACE BACKUP CONTROL
Fig. 5
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3.6
System Architecture, Communication and Databases i. Open architecture system should be followed in accordance with IEEE-12491996. Interface or operating standards for the following should comply with ISO/IEC 12119/IEEE 802. Hardware interconnectivity Time stamping of data, Communications Operating system User Interface Data base Each of these elements should be capable of being replaced by or communicate with system elements provided by other vendors. iii. The scope of the bidder is not limited to the parts & components explicitly identified here in and shall have to provide any and all parts/components needed to meet the functional requirements laid down herein or are necessary for satisfactory operation of the plant. ii.
3.7
Control Data Networks Local area networks (LANs) should be configured to IEEE 802.3 (Ethernet) standard. Commercially available software should be used as far as possible.
3.8
Man-Machine Interface (MMI) The operators station of the station controller (SCADA system) should have an elaborate and friendly man-machine interface. A 19 or larger monitor should be provided for the display. Provision should be made for connecting a second colour monitor in parallel. The screen displays should be suitably designed to provide information in most appropriate forms such as text, tables, curves, bar charts, dynamic mimic diagrams, graphic symbols, all in colour. An event printer should be connected to PC of the SCADA system. Events should be printed out spontaneously as they arrive. Provision should be made to connect and use another printer simultaneously. Touch control screen, voice and other advanced modes of MMI are desired and should be preferred. The entire customization of software for MMI and report generation should be carried out. A window based operating system should be preferred.
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3.9
Hardware Input/output system should have following capabilities. i. ii. iii. iv. v. vi. Portability and the exchange of I/O cards from one I/O location to another. This can reduce spare parts requirements. Availability of I/O cards to be replaced under power. This avoids the need to shutdown an entire I/O location to change one card. Sequence-of-Events (SOE) time tagging at the I/O locations; accuracy and resolution. Availability of I/O signal types and levels that support the field device signals to be used. Support of redundant field devices, capability for redundant I/O from field device to the database and operator interface. I/O diagnostics available at the card, e.g., card failure indicating LEDs, or through software in the system.
3.10
Grounding Each equipment rack in which automation system components are located should be separately connected to the powerhouse ground mat by a large gauge wire. Shielded cables should be used for analog signals between the transducers and the automation system. Each shield should be tied to the signal common potential at the transducer end of the cable. If there are terminations or junction boxes between the transducers and automation system, each shield circuit should be maintained as a separate continuous circuit through such junction or termination boxes.
3.11
Static Control Equipment should be immune to static problems in the normal operating configuration. Anti-static carpet and proper grounding for all devices that an operator may contact should be provided.
3.12
Information and Control Signals Information and control signal for proper control and monitoring will be acquired from the following main and auxiliary/associated equipment and shall be provided as tentatively detailed along with the equipment as out lined in this paragraph. Deviation will be intimated in the bid 25% spare capacity for inputs and output shall be provided. The control system shall receive input signals from main equipment such as the turbine or the generator, and from various other accessory equipments, such as the governor, exciter, and automatic synchronizer. Status inputs shall be obtained from control switches, level and function switches indicative of pressure, position etc, throughout the
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plant. The proper combination of these inputs to the control system logic will provide outputs to the governor, the exciter, and other equipment to start or shutdown the unit. Any abnormalities in the inputs must prevent the units startup, or if already on-line, provide an alarm or initiate its shutdown. i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii. Generator Generator field excitation equipment Generator terminal equipment (Line and Neutral side) Unit generator breaker equipment Turbine Governor Generator cooling Service air Service water DC power supply AC auxiliary power supply Water level monitoring Fire protection
Following four types of signals are provided between control board and particular equipment
Analog inputs for variable signals from CTs, VTs, RTDs, pressure, flow, level, vibration etc. Digital inputs provides digitalized values of variable quantities from the equipment Digital outputs command signals from control boards to equipment Analog outputs transmit variable signals from control to equipment e.g. governor, voltage regulator etc.
3.13 Communication Links a. Communication links with remote control
Following methods are available for implementing control from a remote location: Hardwired communication circuits (telephone type line, optical cables etc.) Leased telephone lines Power line carries communication system Point to point radio Microwave radio Satellite
Metallic circuit in hardwired communication circuits and leased telephone lines, requires special protection for equipments and personals against ground potential rise (GPR) due to
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electric system fault, since the hydro-generator is source of fault current. GPR is also caused by lightning transmitted through power lines entering the power plant. As such suitable mitigation has to be provided. Power line carrier including insulated ground wire system can be used for communications purposes. This method couples a high frequency signal on the power line or insulated ground wire and is decoupled at an offsite point. Space radio can be used, utilizing power frequencies and micro wave radio can be practical if hydro plant owner has an existing microwave system. b. Communication with control boards
Data and control signals of following equipments will be required to be transmitted between control board & equipments.
Generator neutral and terminal equipment Head water and tail water level equipment Water passage shut off or bye pass valves gates etc. Turbine Unit transformer Circuits breaker and switches Generator Intake gates or main inlet valve and draft tube gates Turbine governing system Generator excitation system The communication link between control board and equipment should be reliable. Optical fiber cable, shielded cable and Ethernet are various options
c.
Communications with Auxiliaries
Data and control signals of following auxiliaries/ equipments will be required to be transmitted between control board and equipments.
Fire protection AC Power supply DC Power supply Service water Service air Water level monitoring Turbine flow monitoring
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3.14
Recommendations for control systems for various categories of MHP & SHP
3.14.1 Control for micro hydro power plant (5KW to 100 KW) Manual control and manual synchronization with ELC is recommended. However, data logger with PLC load controller may also be provided. Recommendations of Micro hydel Standard issued by AHEC, IIT, Roorkee are also to be reffered. 3.14.2 PC based Integrated Generation Controller (100KW to 1000KW) Integrated governor and plant control system are discussed in Guidelines for selection of turbine and governing system. PC based integrated generation controller capable of following function was developed by M/s Digitek of USA and M/s Predeep Digitek in India for SHP.
Governor speed control Automatic sequencing for start up and shutdown including synchronizing Automatic sequencing for emergency shutdown Data recording and reporting Alarm anunciation Full remote control and monitoring Control via terminal keyboard Water level control Flexible architecture Modular card system Ability to communicate with other microprocessor based equipment Alarm and status logging Data logging at user selected intervals Event recording Line protection- frequency and voltage Generator protection - voltage, current, reverse power, differential, loss of field
PC based system for unit control, governor control and other functions provided for Sobla SHP in Uttarakhand is attached as Fig.-6 is a cheaper alternative but lacks redundancy which can be provided by spare cards for each type. The scheme envisages installation of integrated generation controller, generator and line protection and metering was however provided by conventional meters and electromagnetic relays as shown in Fig.-6.
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Fig. 6 3.14.3 Computer Based Control System for Powerhouses (1MW to 5 MW) Most of the small powerhouses in the range have the control room at the same level as the machine hall. Accordingly the unit control and supervisory control functions can be provided in the control room.
i) PLC Based System One PLC integrated controller per unit may be provided for unit control, governor control, plant control, supervisory control and data acquisition and remote control provision AVR and measuring units and auxiliaries. Separate controllers may be provided for switchyard, common auxiliaries etc. Remote/Supervisory control and data acquisition all the unit may be provided by one PC. The recommended control system is shown in Fig. 7. Manual control facility is provided on PLC panel.
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See note-1
Fig. 7 -Typical Configuration for Computerized Hydro Station (proposed for SHP) Note-1 In case machine level and station level is same, manual/automatic control panel be combined with unit PLC panel ii) PLC integrated unit controller with PC for supervisory control data acquisition and remote control facilities for Triveni canal fall SHPs with provision for remote control of three nearby canal fall power plants have been shown in Fig.-8.
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Fig.8 System Configuration Triveni SHP project (Punjab) (Canal based) (Provided by M/s ALSTHOM) 3.14.4 Computer Based Control System for Power Plant above 5 MW 3.14.4.1 Functional Capabilities
Functional capabilities summarised below may be provided to the extent economically feasible. i. ii. iii. Computer based automation system should permit operation of power plant, switchyard, outlet works, Inlet valves etc. from a single control point. Manual/Local control should be provided by equipment located near the generating unit. The local unit computer (PLC) should be part of the equipment. Automatic unit start/stop control sequencing should be part of computer based automation. Automation system should include capability to provide diagnostic information so as to isolate the problem and get the unit on line as fast as possible. Auto synchronising should be computer based. There is no objection to provide synchronising function as internal to the automation system. Check synchronising relay should be provided for security. The computer system shall optimise individual unit turbine operation to enhance unit operation in respect of following: 24
iv.
v.
a) b) c) d) e)
Efficiency maximization - gate position, flow, unit kW output, unit reactive power output. Minimization unit vibration or rouges running zone - gate position, unit vibration. Minimization of cavitation: Gate position, flow, Hydraulic head, turbine manufacturers cavitation curve. Black start control - this may including starting emergency generator. Centralised Control Individual units, switchyard, station service control, plant voltage/Var control, water and power optimization; Forebay level control.
vi. vii. viii. ix. x. xi. xii. xiii.
Data acquisition capabilities Alarm processing and diagnostics Report generation Maintenance and management interface Data archival and retrieval Data access Operator simulation training Provision of frequency relay for operation in stand alone or in an isolated or islanded mode, should be made.
A typical block diagram of computer based control system for 2 x 10 MVA Mukerian StageII power house with offsite control is shown in FIG.9. A provision for a programming station with back up for operation is also included as redundant system.
Fig. 9 Redundant computer based control system for 2 x 10 MW Mukerian Stage II with remote control for stage (proposed by M/s BHEL)
25
SECTION-IV 4.0 4.1 PROTECTION OF SHP GENERATING UNITS GENERAL
Small hydro turbine-generators should be protected against mechanical, electrical, hydraulic and thermal damage that may occur as a result of abnormal conditions in the plant or in the utility system to which the plant is electrically connected. The abnormal operating conditions that may arise should be detected automatically and corrective action taken in a timely fashion to minimize the impact. Relays (utilizing electrical quantities), temperature sensors, pressure or liquid level sensors, and mechanical contacts operated by centrifugal force, etc., may be utilized in the detection of abnormal conditions. These devices in turn operate other electrical and mechanical devices to isolate the equipment from the system. Where programmable controllers are provided for unit control, they can also perform some of the desired protective functions. Operating problems with the turbine, generator, or associated auxiliary equipment require an orderly shutdown of the affected unit while the remaining generating units (if more than one is in the plant) continue to operate. Alarm indicators could be used to advise operating personnel of the changed operating conditions. Loss of individual items of auxiliary equipment may or may not be critical to the overall operation of the small plant, depending upon the extent of redundancy provided in the auxiliary systems. Many auxiliary equipment problems may necessitate loss of generation until the abnormal conditions has been determined and corrected by operating or maintenance staff. The type and extent of the protection provided will depend upon many considerations, some of which are: (1) The capacity, number, and type of units in the plant; (2) The type of power system; (3) Interconnecting utility requirements; (4) The owners dependence on the plant for power; (5) Manufacturers recommendations; (6) Equipment capabilities; and (7) Control location and extent of monitoring. Overall, though, the design of the protective systems and equipment is intended to detect abnormal conditions quickly and isolate the affected equipment as rapidly as possible, so as to minimize the extent of damage and yet retain the maximum amount of equipment in service. Small hydroelectric power plants generally contain less complex systems than large stations, and therefore tend to require less protective equipment. On the other hand, the very small stations should be typically unattended and under automatic control, and frequently have
26
little control and data monitoring at an off-site location. This greater isolation tends to increase the protection demands of the smaller plants. An inherent part of the power plant protection is the design of the automatic controls to recognize and act on abnormal conditions or control failures during startup. Close coordination of the unit controls and other protection is essential. 4.2 EQUIPMENT TROUBLE 4.2.1 Plant Mechanical Equipment Troubles 4.2.1.1 Turbines (a) (b) (c) (d) (e) (f) Excessive vibration Bearing problems Over speed Insufficient water flow Shear pin failure Grease system failure
4.2.1.2 Hydraulic Control System (a) Low accumulator oil level (b) Low accumulator pressure (c) Electrical, electronic or hydraulic malfunctions within the governing or gate positioning system 4.2.1.3 Water Passage Equipment (a) (b) (c) (d) Failure of head gate or inlet valve Head gate inoperative Trash rack blockage Water level control malfunction
4.2.2 Plant Electrical Equipment Troubles 4.2.2.1 Generator (a) (b) (c) (d) (e) (f) (g) (h) (i) Abnormal electrical conditions Stator winding high temperature Low frequency Bearing problems Motoring Fire Excessive vibration Cooling failure Over speed
27
4.2.2.2 Main Transformer (a) (b) (c) (d) Insulation failure High temperature Abnormal oil level Fire
4.2.2.3 Generator Switchgear and Bus (a) Electrical fault (b) Mechanical failure (c) Loss of control power 4.2.3 General Plant Troubles 4.2.3.1 Station Service (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) 4.2.4 Transformer failure Unbalanced current DC System Trouble Station Air System Trouble Service Water System Trouble Flooding Fire Unauthorized Entry Protection or Control Logic System Malfunction Water level Monitoring System Malfunction Utility System Troubles
Utility line faults and other abnormal utility system conditions should be detected and the plant be disconnected from the utility system. Abnormal utility system conditions include the following situations: a. b. c. d. Ground or phase faults Single phasing Abnormal voltage System separation (islanding)
Coordination with the utility is needed in selecting specific protective equipment, particularly for line fault detection. 4.3 DEVICES USED IN A TYPICAL PROTECTION SYSTEM
There are numerous ways of providing the functional protective requirements of the plant. While standard devices are generally available that can provide the protective functions
28
required, however each station should have specific design suitable for protection requirements of the power plant equipment as well as the interconnection. The following section describes components of a typical protection system that might be applied to a small hydro plant. Discussions and diagrams are included to illustrate location and arrangement of relays. 4.3.1 Protective Devices 4.3.1.1 Temperature A temperature device, possibly incorporating display and contacts for alarm, annunciation and tripping to monitor bearing, stator and transformer winding temperatures. Resistance temperature devices operating relays can also be used to detect generator stator overheating. 4.3.1.2 Pressure and Level Pressure and level switches installed in the turbine air and oil systems, to alarm, block startup, or trip, as necessary. 4.3.1.3 Over and under speed Direct-connected or electrically driven speed switches for alarm, control, and tripping. 4.3.1.4 Vibration Vibration detectors monitoring turbine or generator shaft sections, with alarm and trip contacts. 4.3.1.5 Water level A measuring system incorporating level sensors and monitoring equipment, to alarm, trip, or control turbine output on limiting values of headwater or tail water level, or head. 4.3.1.6 Fire Sensors located in areas where fire can occur and connected to a central fire monitor for alarm. Small generators usually do not have fire sensors or suppression equipment, since they are not usually enclosed. 4.3.1.7 Miscellaneous mechanical Sensing devices are integral to the protected systems, such as automatic greasing system, wicket gate shear pins, transformer cooling and station sump drainage system.
29
4.3.2 Protective Relay and Protection System 4.3.2.1 Features of relays The protective relays stand watch and in the event of failures short circuits or abnormal operating conditions help de-energize the unhealthy section of power system and restrain interference with rest of it and limit damage to equipment and ensure safety of personnel. The protective relays should possess following features:
Reliability To ensure correct action even after long period of inactivity and also to offer repeated operation under sever condition. Selectivity To ensure that only the unhealthy part of system is disconnected Sensitivity Detection of short circuit or abnormal operating condition. Speed To prevent and minimize damage and risk to instability of rotating plant. Stability The ability to operate only under those conditions that calls for its operation and to remain either passive or biased against operation under all other conditions.
4.3.2.2 Protective Relay Technology Protective relay technology has changed significantly in recent years. Induction disk relays for each individual protective function were normally used. Individual solid state static relays for protective function were introduced in the decade 1980-1990 and IS 3231-1965 was accordingly revised in 1987. The old conventional electromagnetic relays were replaced with static relays which are much faster and maintenance free. These relays are more reliable and sensitive. These days microprocessor based multifunction relays are available which have different protections elements and therefore, a separate relay for each protection is not required. 4.3.2.2.1Microprocessor based Multifunction Relays: Microprocessor based multi function relays are now being used. Advantages of these relays are as follows: i) Self-monitoring of operating status on continuing basis and to alarm when to function. ii) Multiple protective functions in one relay reduce panel space and wiring end. iii) Self calibration by software programming iv) Programmable set point by software programming v) Interfacing with SCADA will be easy Microprocessor relaying has gained widespread acceptance among both utilities and consumers. The relay functions are the same as those in electromechanical and solid-state electronic relaying, but microprocessor relays have features that provide added benefits. Microprocessor relays may have some disadvantages, however, so that there are additional considerations when these are applied for protection in SHP. 4.3.2.2.2Benefits of Microprocessor Relays:
30
The benefits of microprocessor relays include the ability to combine relay functions into economical unit. Where an electromechanical over current relay may be only a single phase device, a microprocessor relay will often include three phases and a neutral. It could also include reclosing, directional elements, over/under voltage, and over/under frequency. A microprocessor generator relay could include differential, over current, negative sequence, frequency, voltage, stator ground, and other protective functions. Similarly, a microprocessor transformer relay might combine differential an overcurrent protection. A transmission line relay could combine multiple zone phase and ground distance elements, over current fault-detectors, pilot scheme logic, and reclosing. An electromechanical scheme will normally consist of individual relays for each zone of phase and ground protection, separate fault-detectors, and additional relaying for pilot scheme logic. These same devices can include non-relaying functions such as metering, event recording and oscillography. All of these functions are contained in an enclosure that requires less space than the combination of relays and other devices they duplicate. A microprocessor relay has self-monitoring diagnostic that provide continuous status of relay availability and reduces the need for periodic maintenance. If a relay fails, it is typically replaced rather than repaired. Because these relays have multiple features, functions, increased setting ranges, and increased flexibility, it permits stocking of fewer spares. Microprocessor relay also have communication capability that allows for remote interrogation of meter and event data and fault oscillography. This also permits relay setting from a remote location. The relays have low power consumption and low CT and VT burdens. They also increase the flexibility of CT connections. For instance, microprocessor transformer differential relays can compensate internally for ratio mismatch and the phase shift associated with delta-wye connections. All of these features have economic benefits in addition to the lower initial costs and potentially reduced maintenance costs that microprocessor relays have when compared to individual relays. 4.3.2.2.4 Disadvantages: The operating energy for most electromechanical relays is obtained from the measured currents and/or voltages, but most microprocessor relays require a source of control power. Another disadvantage is that the multifunction feature can result in a loss of redundancy. For instance, the failure of a single-phase over current relay is backed up by the remaining phase and neutral relays. In a microprocessor scheme, the phase and neutral elements are frequently combined in one package and a single failure can disable the protection. Similarly, a microprocessor generator/transformer package that has both differential and over current relaying provided less redundancy than a scheme comprising separate relays. The selfdiagnostics ability of the microprocessor relay, and its ability to communicate failure alarms, mitigates some of the loss of redundancy. It may also be economical to use multiple microprocessor relay. Microprocessor relays require more engineering in the application and setting of the relay though less work in the panel design and wiring. The increased relay setting flexibility is accompanied by an increase in setting complexity that requires diligence to avoid setting errors.
31
Also, some relays have experienced numerous software upgrades in a short period of time. Microprocessor relays have relatively shorter product life cycles because of the rapid advance in technology. As a result, a specific microprocessor relay model may only be available for a relatively short period of time. As a failure may require replacement rather than repair, it may not be possible to use an exact replacement, which may require more engineering and installation work. Although less frequent testing may be required, but for testing it requires a higher level of training for the technician and more test equipment than is normally used with electromechanical relays in order to obtain the full benefit of all the features of the microprocessor relay. The selfmonitoring capability of these relays is only effective if the alarm output can be communicated to a manned location such as a control center. Also, the remote communication ability assumes there is a communication channel available to the relay. Following annexure are enclosed for ready reference
Annexure-II - List of SHP Generator panel indications & relays Annexure-III - List of protection elements in Microprocessor based relays
4.3.2.2.5 Protection relays for SHP i) The application of relays must be coordinated with the partitioning of the electrical system by circuit breakers, so that least amount of equipment is removed from operation following a fault, preserving the integrity of the balance of the plants electrical system. Generally, the power transmitting agency protection engineer will coordinate with the utility protection engineer to recommend the functional requirements of the overlapping zones of protection for the main transformers and high voltage bus and lines. The utility protection engineer will determine the protection required for the station service generators and transformers, main unit generators, main transformers, and powerhouse bus. Electromechanical protective relays, individual solid state protective relays, multifunction protective relays, or some combination of these may be used as appropriate for the requirements. Individual solid state protective relays and/or multifunction protective relays offer a single solution for many applications plus continuous self diagnostics to alarm when unable to function as required. Multi-function protective relays may be costcompetitive for generator and line protection where many individual relays would be required. When multi-function relays are selected, limited additional backup relays should be considered based upon safety, cost of equipment lost or damaged, repairs and the energy lost during the outage or repairs. When redundancy is required, a backup protective relay with a different design and algorithm should be provided for reliability and security. Generators, main transformers, and the high voltage bus bar are normally protected with independent differential relays (above 1000 kW unit size).
ii)
iii)
iv)
v)
vi) vii)
32
4.4
Criteria of selection of protection system
The designer must balance the expense of applying a particular relay against the consequences of losing a generator. The total loss of generator may not be catastrophic if it represents a small percentage of the investment in an installation. However, the impact on service reliability and upset to loads supplied must be considered. Damage to equipment and loss of product in continuous processes can be dominating concern rather than generating unit. Accordingly there is no standard solution based on MW-rating. However, it is rather expected that a 100 kW, 415 V hydro machines will have less protection as compared to 25 MW base load hydro electric machine. With increasing complications in power system, utility regulation, stress on cost reduction and trends towards automation, generating unit protection has become a high focus area. State of the art, micro processor based protection schemes offer a range of economical, efficient and reliable solution to address the basic protection and control requirements depending upon the size and specific requirement of the plant. 4.4.1 Requirements of Protection of Turbine Two level protections are recommended as per IEC 1116. Elements to be considered are: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Speed rotation Oil levels in bearing Circulation of lubricants Oil level of the governing system Oil level of speed increaser (if provided) Bearing temperatures Oil temperature of governing system Oil temperatures of speed increasers Oil pressure of governing system Pressure of cooling water
Immediate tripping is required for a, c, i, and j. While for item b, d, e, f, g and h only alarm and annunciation is required to alert the operator and take corrective action, but in case corrective action is not taken, tripping will eventually follow. Applying brakes at a particular speed (30% of full speed) is done to reduce time to achieve stand still position of machine. It is recommended two independent devices must be provided for over speed shut down on larger machines. One for alarm mostly at 110% and other for tripping at 140%, specially for machines which are not designed for continuous run away speed. 4.4.2 Requirements of Protection of Generator Elements to be considered normally are a. Stator temperature
33
b. c. d. e. f. g. h. i.
Over current (stator and rotor) Earth fault with current limits (stators & rotor) Maximum and minimum voltage Power reversal Over/ under frequency Oil level in bearing sumps Pad & oil temperature of bearings Cooling air temperature
Immediate tripping is required for items b, c, d, e & f while for items a, g, h and i first alarm and annunciation is required for taking correcting measure and then tripping if correcting measure is not taken within permissible time. It is advisable to provide heating arrangement to prevent condensation in generator. 4.5 4.5.1 Generator Protection System and Relay Selection Categorisation
In view of the economy and plant requirements generator protection for small hydropower stations is categorized a follows:
Generator size less than 100 kVA Generator size 100 kVA to 5000 kVA i) Generator size 100 kVA to 1000 kVA ii) Generator size 1 MVA to 5 MVA Generator size above 5 MVA
4.5.2 Transient overvoltage and surge protection Transient over-voltages and lightning surges are controlled by lightning arrestors. Surge capacitors are provided to restrict rate of rise of surge voltages and their magnitudes. Every generator is provided with a set of lightning arrestors / surge diverter of appropriate rating and generated voltage. 4.5.3 Protection for Micro hydel systems (up to 100 kVA) Monitoring and Protection as recommend in micro hydel standards be provided. Micro hydel (100 kVA) may be provided with series over current and short circuit protection (MCCB), residual current breakers for earth fault protection and surge protection equipment. A typical 50 kW micro hydel single line diagram showing protection is attached as Fig. 10. MCCB could be provided with shunt trip coil for providing over voltage; over current and unbalance load trip as a part of shunt load governor if possible.
34
62 Grid 27 81 L 81 H R esidu al C u rren t Op erated C ircuit B reaker As A MC C B W ith Shu n t Trip C oil MC C B As A Feed er-1
LEGEND
81L-Freq Relay (Low) 81H-Freq Relay (High) 27-Under Voltage Relay 62-Timing Relay A- Ammeter F-Frequency Meter V-Voltmeter 32-Reverse Power Relay LA-Lightning Arrestor kWh-Kilo Watt Hour Meter MCCB-Moulded Case Circuit Breaker MCB-Miniature Circuit Breaker
V Vs F
kW h A
kW h 32 As A
or MC B LA Su rg e Protectio n
Controller Module
Triacs
H eater Mod u le
G 50 kW 415 V
Fig.-10. 4.5.4 Protection for Generating Units above 100 kVA and up to 5 MVA Monitoring and protection with two levels of protection and recommended as follows in SHP as per IEC-1116. 4.5.4.1 Turbine In principle, two levels of protection can be specified: alarm and tripping. Elements to be considered are: (a) speed of rotation; (b) oil level in the bearings; (c) circulation of lubricant;
35
(d) (e) (f) (g) (h) (i) (j)
oil level of the governor system; oil level of the speed increasers; bearing temperature; oil temperature of the governor system; oil temperature of speed increasers; oil pressure of the governor system; circulation of cooling water
Immediate tripping is required for items a), c), i) and j). Items b), d), e), f), g) and h) may have an alarm annunciated first if the station is manned allowing corrective action to be taken, but in any case, in the absence of corrective action, tripping will eventually follow. In some cases, braking is used to reduce the time to standstill. It is recommended that two independent over speed shut-down devices be used on larger units which might not be designed for continuous runaway. 4.5.4.2 Generator The following are normally specified. (a) (b) (c) (d) (e) (f) (g) (h) (i) Stator temperature; Over current (stator and rotor); Earth fault with current limits (stator and rotor); Maximum and minimum voltage; Power reversal) Over/under frequency; Oil level in the bearing sump; Bearing temperature; Cooling air temperature.
Immediate tripping is required for items (b), (c), (d), (e) and (f). Items (a), (g), (h) and (i) may have an alarm annunciated if the station is manned allowing corrective action to be taken, but in any case, in the absence of corrective action, tripping will eventually follow. Depending on the individual case, heating equipment to prevent condensation may be required. It is advisable to consider differential protection when the size of the generator and/or its environment justifies it. The instruments and devices generally recommended for monitoring and protection are as follows: voltmeter, ammeter, wattmeter, energy meter, power factor meter, tachometer, hours of operation counter, synchronizer, water-level and/or pressure indicator, turbine opening indicator, emergency stop device, short-circuit current protection, over current protection, reverse power relay, frequency monitor, voltage monitor, bearing monitor.
36
Monitoring and control and data acquisition system (SCADA system) can be a part of the P.C. based digital governor and generation control equipment. Provision of data storage of one month with 16 MB of Ram memory and a 540 to 850 MB Hard Drive as part of the PC based governing and control system should be provided. This data could be retrieved on a floppy drive after one month for examination. As the communication links develop the data can also be transmitted via a Modem to a remote point for examination and supervisory control. Typical single line diagram for synchronous and asynchronous generators are attached as figure 11 and figure 12 respectively. Typical single line diagram for 22.5 MW SHP developed by M/S ANDREZ HYDRO is shown in FIG. 13 for reference
37
Fig.-11
38
Fig. -12
39
FIG.13-A typical single line diagram for 22.5 MW SHP( Source ANDREZ Hydro)
40
4.5.5 Protection for generating Units above 5MW and up to 25 MW The following protection may be provided by using integrated numerical generator protection relay on generator, generator transformers and feeders. Back up electromagnetic relays with instrument transformers may be provided as mentioned below:
4.5.5.1 Generator 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Generator Differential Protection (87G) Negative Phase Sequence (46) (Phase Unbalance) Generator Reverse Power Protection (32) Voltage Restrained Over Current Protection (51V) Stator Earth Fault Protection (64 G) Loss Of Excitation Protection (40) Over /Speed (electrical) Protection (12G) Rotor Earths Fault Protection (64R) Over Voltage Protection (59) Fuse failure Protection (97) on PTS Under voltage (27) Check synchronizing
Following additional back up electromagnetic relays from different set of CTs and PTs be also provided. 1. 2. Voltage restraint over current relay Stator earth fault
Following Mechanical Protections are proposed 1. 2. 3. 4. Embedded Temperature detector (PT-100) in stator core and in bearing for indication, alarm, recording and shut down of the unit. Governor oil pressure low. Over speed mechanical for normal and emergency shut down. For large generators, fire protections system will use CO2 as the quenching medium which will operate automatically. Hot spot/ smoke detectors are provided all around the periphery of generator winding. Bank of CO2 cylinders with control panel etc. are provided common for all the generators. The individual pipes let the CO2 enter in the faulty generator and quench the fire. Generator is isolator from the bus bar and machine stopped. The system is more effective in closed cycle cooling systems of generators.
41
4.5.5.2 Power Transformer 1. 2. 3. 4. 5. 6. Generator transformer differential protection ( 87 GT) Over current and earth fault protection with high set Inst. Element (50/51,64) Stand by earth fault protection (64GT) on 33 kV side. T/ F Winding Temperature High Alarm/ Trip (49T) T/ F Oil Temperature High Alarm/ Trip (38T) Buchholtz relay
4.5.5.3 Station Transformer Protection 1. 2. Fuse set on 33 kV side. Digital over current and earth fault relay with high set unit on B.T. side. (50/51, 64).
A typical single line diagram of metering and relaying is shown as figure 13 and figure 14.
42
TO 33 kV SUBSTATION
TO 33 kV SUBSTATION
NOMENCLATURE
40 -------- LOSS OF EXCITATION RELAY 41G -------- EXCITATION BREAKER
L.A. L.A.
//
/
P.T.
//
/
PS CLASS FOR BUS DIFFERENTIAL CT CORE-1, 5P10 CT CORE-2, METERING ACC.CLASS 1-0
P.T.
PS CLASS FOR BUS DIFFERENTIAL CT CORE-1, 5P10 CT CORE-2, METERING ACC.CLASS 1-0
45G -------- FIELD SURGE PROTECTION 51 -------- OVER CURRENT RELAY 51V -------- OVER CURRENT VOLTAGE RESTRAINT RELAY 51D -------- DIRECTIONAL OVER CURRENT RELAY E/F -------- EARTH FAULT RELAY 59 -------- OVER VOLTAGE RELAY 63 -------- BUCHHOLZ RELAY 64F -------- ROTOR EARTH FAULT RELAY 64G -------- STATOR EARTH FAULT RELAY 64T -------- BACKUP POWER SYSTEM E/F RELAY 87G -------- GENERATOR EARTH FAULT RELAY 87GT -------- GEN. TRANSFORMER E/F RELAY 25 -------- CHECK SYNCHRONISING 46 -------- NEGATIVE SEQUENCE RELAY
52-3
52-5
LEGEND 331661132 kV BUS

52-6
ISOLATING SWITCH HV CIRCUIT BREAKER LINK

CT CT
TRANSFORMER
41G
52-1 52-2
EXCITATION BREAKER WITH DISCHARGE RESISTOR CURRENT TRANSFORMER
CT 5P10 GENERATOR TRANSFORMER-1 64T

51
CT 87GT GENERATOR TRANSFORMER-2 64T SATTAION AUX. T/F

51
POTENTIAL TRANSFORMER
LIGHTNING ARRESTOR FUSE EARTH

87GT
87GT
11 KV BREAKER
DG SET 11 KV CIRCUIT BREAKER 11 KV CIRCUIT BREAKER
11-1
11-2
CT
TO P.T.
CT
TO P.T.
P.T. CT
EXCITATION CONTROL
RECTIFIER BRIDGE
P.T. CT
EXCITATION CONTROL
RECTIFIER BRIDGE
P.T. 41G GENERATOR-
P.T. 41G GENERATOR-2
G1
PS CT CT CT
G2
45G PS 5P10 PS CT CT CT
5P10 PS
FIG. 2.3.1 TYPICAL SINGLE LINE DIAGRAM
DISTRIBUTION TRANSFORMER
43
Figure 13
33 K.V. BUS
NOMENCLATURE
GENERATORS
CT
NOTES
1.THE SCHEME MAY BE MODIFIED TO SUIT ACTUAL EQUIPMENT ORDERED 2.COMMON TRIPPING RELAYS FOR SIMILAR FUNCTIONS WILL BE PROVIDED WITH LOCK OUT FACILITIES, SIGNAL TYPE CURRENT RELAYS FOR DISCRIMINATION OF FAULTS ARE PROPOSED TO BE PROVIDED IN THE INDIVIDUAL CIRCUITS OF COMMON TRIPPING RELAYS . 63T 3.TRIPPING BLOCK DIAGRAM DOES NOT INCLUDE FIRST STAGE ALARMS 4.DETAILS OF R.T.D. (RESISTANCE TEMPERATURE DETECTORS) ARE AS UNDER : (A) GENERATOR STATOR WINDINGS - 12 NO. (B) GENERATOR THRUST BEARING - 2 NO. (C) TURBINE GUIDE BEARING - 2 NO. 5. UNIT-2 IS SAME AS UNIT-1
52-1
BREAKER
87T 64T 5P10 CT 38T 87 GT GEN.TRANSFORMER 50/51 CT PS LINK C.T. 5P10 TO 86 EB 11-1 87 GT RECTIFIER TRANSFORMER 25 TO P.T. THYRISTOR BRIGES STATIC EXCITATION VOLTAGE REGULATOR AND CONTROL 59 SYNCH. 51 EX 11 KV GENERATOR BREAKER 250 kVA 11/.415 kV
CENTRIFUGAL SPEED SWITCH ELECTRICAL OVERSPEEDC RELAY CHECK SYNCHRONISING RELAY AIR COOLER (OUTLET/INLET) AIR TEMPERATURE 26G TEMPERATURE DETECTORS FOR FIRE PROTECTION SYSTEM 26GS STATOR WINDING TEMPERATURE 32 REVERSE POWER RELAY 33AB AIR BRAKE POSITION INDICATION 33CW/80CW COOLING WATER VALVE POSITION/FL 38 BEARING TEMPERATURE DEVICE 38-2 38GT GUIDE BEARING TEMPERATURE 38QB BEARING OIL TEMPERATURE 38THT THRUST BEARING TEMPERATURE 40 45F 46 47 48 50/51 T 51V 60 63 63FG 63QTH 63 T 63 TX 64G 64F 65SN 65SL 71QBH/L 86 EA 86 EB 86 MA 86 MB 87G 87T
31 41G 51 EX 59 64F 86 EX LCD OER PAR COMP
12 12G 25 26AU/AI
51/64
C.T.
47
S.S. FROM EXCITOR 2
. .. .. . .
S.S. S.S. S.S. 63FG 41G 64F
TO 86 EB VAR.COMP
FIELD FAILURE RELAY FIELD SURGE PROTECTION NEGATIVE PHASE SEQUENCE RELAY PHASE SEQUENCE CHECK RELAY (FOR SYNCHRONIZING) INCOMPLETE SEQUENCE RELAY TARNSFORMER OVERCURRENT RELAY INSTANTANEOUS OVERCURRENT WITH VOLTAGE RESTRAINT RELAY VOLTAGE BALANCE RELAY GOVERNOR LOW OIL PRESSURE SWITC FIRE EXTIGUISHING SYSTEM OPERATIO THRUST BEARING HIGH PRESSURE OIL SYSTEM START INTERLOCK/FAILURE A MAIN TANK OVER PRESURE SWITCH AUXILIARY RELAY GROUND VOLTAGE RELAY - STATOR ROTOR EARTH FAULT RELAY SOLENOID SPEED NO LOAD SOLENOID SHUT DOWN BEARING OIL LEVEL(HIGH/LOW) LOCKOUT RELAY ELECT. GROUP "A" LOCKOUT RELAY ELECT. GROUP "B" LOCKOUT RELAY MECH. GROUP "A" LOCKOUT RELAY MECH. GROUP "B" GENERATOR DIFFERENTIAL RELAY TRANSFORMER DIFFERENTIAL RELAY
SYNCHRONISING SOCKET PT L L
EXCITERS
27 V EXCITATION RELAY GENERATOR FIELD BREAKER INSTANTANEOUS TIME OVER CURRENTRELAY OVER VOLTAGE RELAY GROUND VOLTAGE RELAY - FIELD LOCKOUT RELAY LINE DROP COMPENSATION OVER EXCITATION RELAY PARALLEL COMPENSATION
FROM BATTERY
PT
EQUIPMENT
31
FIELD FLASHING
LDC
EX. CONTROL
V RUN KWH F
V INC F
METERING
SYN KVAR MANNUAL SYN. PANEL A FM RECT SUPV. TZ V VARM VS WHM WM AMMETER FREQUENCY METER TEMPERATURE MEASURING AND RECORDINGINSTRUMENT SUPERVISORY TRANSDUCER VOLT METER VAR METER VOLT METER SWITCH WATT HOUR METER WATT METER
60 38THT THERMOSTAT R.T.D. 71QBH/L GENERATOR GUIDE & THRUST BEARING 12 33AB 63 QTH 39V RECT 38QB BLOCKS 50/51V & 40 ON LOSS OF RELAY POTENTIAL V SURGE ARRESTOR FM
VS
KW 63T PF 63TX
26G
FIRST STAGE ALARM
G
12G 26AO/AI 26GS
66 K.V. SYSTEM
CT A3 38 63 48 MISC TRIP 52-1, & 41G TURBINE SHUT DOWN 27L 30 50/51DN 51 H 62 62L 64T 81H 81L 86H 87GT 94 52-1 UNDERVOLTAGE RELAY ANNUNCIATOR RELAY DIRECTIONAL OVERCURRENT AND GROUND FAULT RELAY INSTANTANEOUS TIME OVERCURRENT PHASE RELAY TIMING RELAY -DOH.V. SYSTEM STAND BY GROUND FAULT HIGH FREQUENCY RELAY LOW FREQUENCY RELAY LOCKOUT RELAY GENERATOR TRANSFORMER DIFFERENTIAL RELAY GENERATOR TRIP RELAY 66 K.V. BREAKER
59
51V 46 40 32
OER
33CW/80CW 38TG TO 86 EB 38QB
TURBINE GUIDE BEARING R.T.D.
86 MA
AND ALARM
86 MB 71QBH/L 87G
TRIP 52-1 & 41 G TURBINE SHUTDOWN , PENSTOCK GATE CLOSURE AND ALARM
PS
5P 10
CT CT CT
38-2 12 12G MISC
86 EB
TRIP 52-1 & 41 G TURBINE SPEED NO LOAD AND ALARM
LINK
86 EA TRIP 52-1 & 41 G RELEASE CO2, TURBINE SHUT DOWN WITH ALARM 64G
1 2
RESISTOR RATED 15 SEC.
FIG. 2.3.2 TYPICAL UNIT METERING SINGLE LINE DIAGRAM
44
Figure 14
45
4.6
GENERATOR CONNECTED IN PARALLEL TO GRID
Whenever generators are running parallel to grid, a comprehensive auto synchronizing & Grid islanding scheme will be required. This scheme will help in synchronizing the generator to the bus and opening the incomer breaker of the plant whenever there is a severe grid disturbance, thus protecting the generator from ill effects of disturbed grid.
Grid disturbances Under-voltage / Over-voltages Under-frequency/Over-frequency Rapid fall/ rise of frequency (df / dt), Grid failure or other faults
Generator may not be able to operate below a certain power-factor. At low power-factor, reverse reactive power flow may damage the generator.
Grid fault detection Over current and directional earth fault, Rapid fall/ rise of frequency (df/dt), Vector surge relay, GENERATORS CONNECTED IN PARALLEL ON A COMMON BUS
4.7
Whenever more than one generator is operating in parallel, it is necessary to see that the plant load is equally shared by the generators in parallel. If there is unequal sharing, there would be sever hunting amongst the generators and eventually this will lead to cascaded tripping of all generators, causing a total black out. Specific load sharing relays are available in the market which provides the most effective, online load sharing system for generators in parallel. 4.8 PROTECTION GROUPS
The protective relays and devices of generator and turbine are proposed to be grouped into following four categories for an orderly shutdown of the affected unit with the remaining generating units and auxiliaries continue to operate. 4.8.1 CONTROLLED ACTION SHUT DOWN Controlled action shutdown will be initiated by any of the following conditions Generator thrust bearing pads temperature very high Generator guide bearing pads temperature very high Turbine guide bearing pads temperature very high Governor OPU oil level low stage-II 46
Governor OPU oil pressure low stage-II
4.8.2 EMERGENCY SHUT DOWN Emergency shutdown will be initiated by any of the following conditions. Sped 115% and deflector/ guide vanes/ runner blades apparatus not moved to closing Deflector etc. fails to close in preset time Unit over speed (electrical) > 140% Unit over speed (mechanical)>150% Stop push button on control panel in control room is pressed Emergency shutdown system will perform following functions:
Trip generator breaker Stop turbine by governor action Trip generator field circuit breaker Operate trip alarm in control room Energizes emergency solenoid valve in governor cubicle to stop the turbine by bypassing governor Close main inlet valve
4.8.3 IMMEDIATE ACTION SHUT DOWN Immediate action shut down will be initiated by any of the following conditions
Generator differential protection operates Generator stator earth fault protection operates Generator field failure protection operates Generator transformer stand by earth fault protection operates Over current in stator Over current instantaneous protection in the excitation circuit The immediate action shut down perform following function
Trip generator breaker Trip field breaker Initiates controlled action shut down stop turbine by governor action Trip annunciation in control room 4.8.4 ELECTRICAL SHUT DOWN Electrical shutdown system will be initiated by any of the following conditions
Over current in the excitation circuit 47
Generator back up protection operates Generator over voltage protection operates Excitation failure protection operates Reverse power protection operates Generator T/F IDMT over current, over current instantaneous & earth fault protection operates Electrical shut down system will perform following functions
Trip generator breaker Trip field breaker Governor brings the unit to spin at no load
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ANNEXURE-I COMPUTERISED AUTOMATION AND REMOTE CONTROL OF SMALL HYDRO POWER PLANT
Er. S. K. Tyagi, Consultant, AHEC, IIT, Roorkee
1.0 1.1
INTRODUCTION Purpose This Guide is intended to assist in preparation of technical specification for finalizing automation scheme for control, monitoring and data acquisition of a small hydro power plant. The guide includes different type of control, control locations, automation schemes, system architecture, system protocols, network protocols, type of networks, PLC based, computer based SCADA system, user and plant interfaces, remote control & power source etc. References & Codes Latest edition of following standards & codes are applicable: IEEE Guide for Control of Small Hydroelectric Plants ANSI / IEEE standard 1020:1990. IEEE Guide for Control of Hydroelectric Power Plants ANSI / IEEE standard 1010:1991. Communication Protocol IEEE Tutorial course 95-TP-103 IEEE Press, NY 1995. Hydro Plant electrical Systems by David M Clemen. IEC: 62270-2004-Hydro-electric power plant automation-Guide for computer based control. IEEE-1048-Guide for distributed digital control and monitoring for power plants (ANS). AUTOMATION AND REMOTE CONTROL OF SHP In a modern hydroelectric power station almost all apparatus are connected with the plant control system to perform all operations in either manual or automatic mode. Most of the major apparatus (e.g. generator, turbine and spillway gates) are equipped with electrically actuated control elements allowing to operate automatically. Many power stations are controlled from remote locations and these automatic control systems facilitate unattended plant operation. Manual Operation Control In manual control it is the responsibility of operator to manually perform control and data acquisition tasks. The quality of data acquisition has been subject to the limitation of available staff and human error.
1.2
2.0
2.1
49
The manual control can be local (control located on panel nearest to the equipment or on equipment) or/and centralized (with in plant at some other place). This system is not found sometimes to be as efficient, accurate, safe and consistent as required by the system. 2.2 Semi Automatic Control For many years, relay logic type automatic control systems were provided. These systems were limited to unit control sequencing (start/stop) and were not easily changed, once installed. Plant operators were responsible for manually performing control and data acquisition tasks. The quality of data acquisition has been subject to the limitations of the available staff and human error. PLC, Computerised Automatic Control Automation of hydroelectric power plant operations has made it possible to accomplish data acquisition and control activities like unit startup& shut down sequence, which were previously performed by relay logic. Computer based control and data acquisition systems have made it possible to acquire and process more data than in past, so generated reports can keep Plant Engineer apprised of total plant condition. Computer based automation system also permit operation of power plant, switchyard and outlet works (spillway gates, bypass gates, valves, fish ways, fish ladders etc.) from a single control point that can be local, centralized or remote. The single control point system has many advantages, including reduction of staff, consistent operating procedures and capability to have all control and data available for reference during normal and abnormal conditions. 2.4 Control Locations 2.4.1 Local Controls are located on the equipment or with in the sight of equipment for all auxiliary equipment. For generating unit control is located on unit control system interface governor control panel. Local control is synonymous to most basic control. 2.4.2 Centralized In this system controls for all units are brought to a centralized control room located in the plant itself on control panels. Control of all important auxiliary equipments are also brought to the control panels installed in the control room. All protection, metering, synchronizing panel and outgoing lines control panels are located in this centralize control room.
2.3
2.4.3
Off site (remote) An off site control location is one that is external to plant. It could be located at switchyard, another place or at some other remote location. The type of control is characterized by a greater degree of sophistication in the control them selves. The off site 50
control of hydro power stations is inter connected via communication link in lieu of hard wired point to point control. Relationship between all these three control location is shown in Figure-I.
3.0 3.1
AUTOMATION OF HYDROPOWER PLANT Control Requirements Basic control requirements are as follows: Gathering process information Controlling the process Protecting and supervising the process Monitoring the process Gathering process information: Process information can be gathered continuously or periodically and consists of control parameter statics information or feed back signal. Presentation can be visual, recorded, audible or combination of all, strips charts recorders, analog / digital indication instruments, video display unit (VDU), lamp indicators and liquid crystal display are some visual information formats. Audible presentation may be in the form of bell, gong or tone alerting the operator to an alarm condition / information. Process consists of turbine, generator, common auxiliaries unit auxiliaries, D.C. distribution system, low voltage power, medium voltage power, switchyard, intake bye pass and draft tube gates etc.
3.1.1
3.1.2
Controlling the process: Process information gathered serves two purposes: 51
i) It is used by automatic control system to perform appropriate control actions ii) It allows the operator to operate the plant in safe reliable, secure and economical manner. The operator should however, be properly trained to start, stop, load, unload and monitor the generating units and to control the plants auxiliaries including switchyards, water control system and other ancillary features associated with the project. 3.1.3 Protecting and supervising the process The protection system is divided in two subcategories: (a) Electrical protection system covering major plant electrical apparatus and essential electrical auxiliary systems (e.g. generator, step up transformers, station service electrical system). Protective systems have progressed from specific purpose electromagnetic relays to specific purpose electronic analog relays to contemporary multipurpose digital relays. (b) Mechanical protection is confined to generating units hydraulic turbine, generator and major plant mechanical systems (e.g. turbine, draft tube, air depression system). Protection of Non electrical apparatus and systems in the plant are normally assigned to the plant control system. The control system generally provides tripping signal required for input to the plant protection system in case any of the mechanical systems or apparatus require removal from service. The supervisory process involves comparing plant and equipment operating values against designed /set limits. This involves monitoring equipment status as well as limits. For example on or off, open or closed position may be incorporated into the supervisory process with consequential control action. 3.1.4 Monitoring the process Operating and control parameters can be monitored using display devices at their respective control board (e.g. turbine, governor mechanical cabinet board). Analog and digital instruments, VDUs and other devices as mentioned above are used as monitoring equipment. Some display units also permit manual control via touch screens. AUTOMATION SYSTEM ARCHITECTURE System Architecture System architecture defines the structures and relation-ships among the components of hydroelectric power plant automation system, including its interface with operational environment. Architecture includes hardware components, software components networks, performance, reliability concepts and maintainability of the automation system. System architecture for hydroelectric power plant also consider such factors as number, size, types of turbines and generators in the plant, the plant auxiliary system. A wide range of hardware components, networks software, component and database alternative are available to configure cost effective architectures to meet the automation systems design goals. Open system architecture offers the advantages in case of expansion, ability to accommodate changing technologies and immunity to premature obsolescence.
4.0 4.1
52
While in proprietary system architecture, taken as part of turnkey automation from some vendor, flexibility as explained above is not available. 4.2 System classification: Advances in computer technology provide users with the choice of variety of system architecture for configuring hydroelectric automation systems. This guide focuses on systems currently employed or envisioned to find future use in hydroelectric plant automation applications. There are two general classification of system architecture used in hydroelectric plant automation systems: (i) This class uses proprietary hard wares and software and makes little or no provision for interoperations with other hardware and software. These are called as closed systems also. The other system class is an integrated system, with all plant control and monitoring components having a common data communication hardware & software structures. These are the open systems which relates to its ability to replace hardware, modify software and expand system capability without a wholesale reconfiguration of the control system. Attributes of open systems are interconnectivity of hardware and software, possibility of software and interoperability of application and system. From practical point of view neither fully closed nor truly open system exists, rather a combination of systems exist with some ability to communicate or function with other systems. Examples of applications and majors components of above two general system classes along with traditional supervisory control system are as under: Traditional supervisory control system These are hardwired supervisory control systems. Major components are: Master station Non programmable remote terminal unit. Closed system There are stand alone systems (proprietary, single function controllers) Major components are: Proprietary controllers Proprietary operators console Open System: The application examples are: Hydroelectric plant controllers (systems) Large scale energy management systems, SCADA systems (Microprocessor based) Major components are: Programmable logic controllers Networked PCs or work station
(ii)
(i)
(ii)
(iii)
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5.0 5.1
End user programmable remote terminal units SOFTWARE CONFIGURATION: Customized software (Proprietary) In the customized software there are several options which are as follows: (a) Dedicated The software changes are closed to the end user (b) Configurable The software has features that can be changed by the users software maintenance personnels. These changes are normally of the form of turning on or off a feature that is already in the software through a software key or password. (c) Programmable The software has features that can be changed or added by the users software maintenance personnel.
These software are normally available as part of turnkey automation system and as such sometimes are called proprietary softwares.
5.2
Commercially available (open sources) softwares These softwares can be purchased as a part of turnkey automation system or directly from open source by plant owner. In later case the owner will have to make provisions for the installation and configuration of the software. Spread sheets, data base managers, operators interface software packages are some examples of such softwares being used as part of the power plant automation system. These softwares provide flexibility and has many options. In such case owner may have support from original vendor, other users or possibly other vendors. The most common options are as follows: (a) User configurable: The user has all the documents necessary to change the software operation or to add new code that is linkable to the rest of the software. The user has the ability to add features or change options, but can not change features in the original code with out the help of original vendor. (b) User programmable: The user has the source code as well as the documentation for the software and can modify it as needed or implement his own software to be added to the system. (c) Full graphic: The user has the ability to generate pixels and / or vector graphic image on the displays in any form. The software has sophisticated art work generation and real time display of these images under system control. Often full graphics are implemented in a window operating environment. (d) On line configurable: The features mentioned can be done by authorized person sitting in front of the online and running system. That is authorized person can change the configuration of the running system as they wish.
6.0 6.1
NETWORKS Control level data networks Control data network are communication structures that conveys data through out the system. These networks are used for transmitting time tagged measurements and status input signals to update live databases. The application program outputs, consists typically of control commands and alarms are then transmitted in turn, over the network
54
to other data stations that interface directly with the process or that display or report information to the plant operators. The control data communication network is also used for transmitting sequence of event data with specified time resolution. The data is recorded or displayed for trend and plant diagnostic analysis. The automation hierarchy, the intra plant network services the unit and functional group levels. Subnetworks and field buses service the instrumentation and local control levels. The control data network should be able to support transfer of long messages (e.g. file transfer) as well as short messages for data acquisition, reporting and control commands. The network should be able to reduce operators, technicians burden to operate and maintain the over all control and monitoring system. Hot and cold system initialization should be achieved automatically or manual command from the control console. Power plant Engineer should be able to assess the current status of network, to locate bottlenecks and other problems and to plan action accordingly. The network should also be able to transmit specific diagnostic and maintenance trouble shooting data for status display.
6.2
Device level Data Network Device is an operating element such as relay contactor, circuit breakers, switch or valve used to perform a given function in the operation of electric equipment logic. Field wiring for contact interrogation or control devices Hard wired Fiber optic cables Hard wired system should be protected against ground potential rise (GPR), for which proper shielding of cables is to provided while for fibre optic cables such protection is not required. Field wiring however, should be protected such that a fault on these cables does not cause loss of more than a minimum tolerable functionality of the system. With the advent of programmable logic controllers (PLC) number of wires needed for connection is reduced by 80% which improved the reliability and availability of functionality of the system.
6.3
Network Protocol The protocol implies the methods for packing messages data in the form of bit, bytes, blocks & packets to communicate between the devices. Just sharing bits & bytes will not allow devices to communicate successfully. Some situations may require
55
multiple protocols to be run on the same physical media. This is a common situation with plant LAN. IEDs (Intelligent electronic device) know what data values are in the message and where they are placed in data stream. This is part of protocol specification that is performed by the software that assembles and dissembles the message stream. 6.3.1 Proprietary and standard based protocols and networks: A proprietary network consists IED connected via some media (standard or proprietary) using a vendor specific proprietary protocol that will only interoperate with similar IEDs running the same protocol, proprietary protocols are intended to be stand alone. There may be no need for IEDs on these networks to inter operate with IEDs on other networks. A gateway IED is required to connect proprietary network to other portion of the plant network, should such a connection is needed. IEDs can typically communicate on a standard serial communication bus by virtue of sharing a common messaging protocol such as Modbus, Modbus plus and DNP3. There are few other protocols that have been implemented by some users with the help of specific suppliers. These IEDs may be compatible but may not inter operate. Often one IED in the network can interoperate with all IEDs and serves as a gateway.
IEDs that support Ethernet can be connected in the same Ethernet network even when different protocols are used. This is different from standard serial or proprietary networks where all IEDs on the same network use the same protocol. IEC 61850 is usually considered a protocol that runs on Ethernet networks.
Local area networks (LANs) should be configured to IEEE 802.3 (Ethernet) standard. Commercially available software should be used as far as possible.
6.4
Network topology Network topology is either logical or physical. A logical topology is a way that data passes over a network from one IED to the next without regard to physical IED interconnection. The physical topology of network maps the IEDs of the network and the connections between them. There are two major groups of topologies: i) Point to point: Point to point connection only connects two IEDs together. ii) Point to multipoint: These networks have several major network topologies for communications. Bus Topology A bus topology has each IED connected to the same physical media as shown in Figure below:
56
IED
IED
IED
IED
FIG. 2 :
BUS TOPOLOGY
Star Topology In a star topology such as Ethernet, each IED is connected to special node at the centre that can be passive, providing a path for message to traverse or active regenerating electrical signals. Hub simply repeat and message on all ports. More intelligent hubs are switches which route the message to the port where target IED is connected. The arrangement is shown in figure below: IED IED IED IED
HUB OR SWITCH
FIG. 3: STAR TOPOLOGY
Ring Topology: In ring each IED is connected to next with entire network forming a closed circle. Each IED is isolated from all but two IEDs. Ring networks are less efficient because data travels through more IEDs before reaching the destination.
6.5
Type of Networks Network permit passing messages between end points over a wide range of distances and provides a messaging service that is independent of message content. Any number of different media supports network messaging, network design should be such that it retains critical function in case of a network failure.
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6.5.1
Wide Area Network (WAN) A wan provides long-distance transmission of data, voice, image and video information over a large geographical area. A WAN can be owned by utility or WAN services can be leased from telecommunication providers. WAN permits enterprise access to all modes on the WAN. Normally connections to a WAN are made through router, bridge or firewall to control access to distant nodes such as power plants, substation etc. Local Area Network (LAN) A LAN is normally designed for limited geographical area such as power plant, utility substation or an office area. A LAN is considered to be part of facility and is owned by utility owners. It is capable of transmitting data, voice, image or video information. On a plant there may be one or more LANs to logically group devices and functions as well as control loading and security. It is passive, similar to slave in master slave communication It waits requests from clients Upon receipt of requests, it process them and then sends a response. The characteristics of a client are as follows: It is active, similar to the master in master slave communication It sends requests to servers It waits for and receivers server replies Master slave and client server communications are similar. The biggest difference is that generally there is one master, where as there can be multiple clients.
6.5.2
7.0 7.1
Communication relationship models: Master slave Master slave communication is when the master controls all of the traffic on the channel. There are two different types dedicated master and token passing masters. Dedicated: Polling scheme involve no network contention because access medium is granted in orderly fashion with energy device taking its turn. With centralized polling all IEDs are addressable and the master IED will send out messages only addressed to single slave. Each device has different address as defined in the protocol being used. The master communicates to each IED one at a time so as to prevent communication collisions.
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MASTER IED
IED-1
IED-2
IED-3
FIG. 4: CENTRALISED POLLING
Token Passing Each IED acts as repeater of message called a token and each IED can be both a master (requesting data from other) and a slave (sending requested data to other IED). The token may contain some data that is copied by the receiver. If token contain no data, then an IED can use it and fill in its information in the token. PLC communication and some other control system use token passing scheme to give command to IEDs along the bus.
7.2
Client-server model This is the most popular model for network application. Each IED on the network is either client and / or server. The characteristic of server are as follows:
7.3
Peer to Peer Model There is growing trend in IED communications to support peer to peer messaging. Here each IED has equal access to the physical media and can message any other IED. Thus each IED is both client and server. This is substantially different than master slave communications even when multiple masters are supported. A peer to peer network to provide a means to prevent message collisions or to detect them and mitigate the collision. On this configuration each IED can communicate to each other in an unsolicited manner. SCHEMES OF AUTOMATION Following schemes are normally considered for automation of small hydro plants. Conventional control system Computerized conventional control system Programmable logistic controller (PLC) system
8.0
59
- Single PLC with manual backup - Redundant PLC PC with PLC based control system Computer based SCADA system (Microprocessor controller with SCADA)
Regard less of degree of automation desired, control sequence can be divided in to following parts: Pre-start checks Auxiliary start Unit run, synchronize and load Running control Unit shutdown Emergency shutdown in abnormal conditions Recommendations: A. 5 KW to 100 KW Data logger with PLC load controller B. 100 KW to 5000 KW (i) 100 KW to1000 KW (ii)1000KW to 5000 KW C. 5000KW and above 8.1
PC based integrated system for governing and plant control PLC integrated controller and SCADA with PC PLC digital governor with plant controller and SCADA with redundant PC
Conventional Control The hardware need to perform above functions in a conventional centralized hardwired control system which is generally similar to that used for individual local unit control. This consists of equipment such as control panels with discrete control alarm and indication devices, dedicated data logging, load and voltage control equipment and anunciators. This equipment interfaces to the units in parallel to the local unit control or through the local unit control board. Control circuits are with appropriate inter locks. Computerised conventional control system This type of control systems are used for control of hydroelectric units because of the speed and flexibility needed to run the real time control algorithms and to manage the associated data. The computer system interfaces to the plant and to the conventional control system via input / output (I/O) interface equipment suitable for operation in the harsh power plant environment. This interface may be parallel to the hardwired control system and may operate conventional hard wired control circuits. It may be desirable to furnish a programming and training console that permits software development and operator training while providing back up hardware for alternate use when the normal operator interface is out of service. Inter locking may be provided to permit only one console to be in control at time.
8.2
60
Special consideration must be given to the design of the computer system power supply, grounding and shielding in view of harsh power plant environment and generally sensitive nature of computer equipment. Protection from electro magnetic and radio frequency interference should be provided. Computer equipment may be located in controlled environments such as control rooms. However they may be located in plant where extreme of temperature, humidity and moisture is absent. Batteries of uninterrupted power supply (UPS) are commonly used to provide reliable power for control system. The capacity and duration requirements are dependant on the shutdown and operation procedures and critical nature of the unit. Software development and purchase must be considered easily in the design so that the hardware will be compatible, software will perform desired control and the human requirement IEEE Std. 1249 may be referred for greater details on the subject of computer based control. 8.3 Programmable logistic controllers (PLC) based control system As a result of fast progress in technology, many complex operation tasks have been solved by connecting PLC and control computer besides connection with instruments like operating panels, motors, sensors, switches valves and such possibilities for communication among instruments are so great that they allow high level of exploitation and process coordination, as well as greater flexibility in realizing a process control system. In automated system PLC controller is usually a central part of a processor control system. With execution of program stored in program memory, PLC continuously monitors status of the system through signals from input devices. Based on the logic implemented in the program, PLC determines which action needs to be executed with output instrument. To run more complex process it is possible to connect more PLCs to a central computer. 8.3.2 Control Panels In conventional control relay logic is utilized and these were connected using wires inside control panels. The disadvantages of such panels are as follows: Too much work in connecting wires Difficulty in making changes or replacements Difficulty in locating error requiring skillful workforce. When problem occur hold up time is indefinite, usually quite long. With intervention of Programmable Logic Controllers, much has changed in how a process control system is designed. Advantages of PLC based control panels are as follows: Compared to conventional process control system, number of wires needed for connections is reduced by 80%. Power consumption is greatly reduced because a PLC consumes less than a bunch of relays. Diagnostic functions of a PLC controller allow for fast and easy error detection 61
8.3.1 PLC

8.3.3
Change in operating sequence or application of a PLC controller to a different operating process can easily be accomplished by replacing program through a console or using PC software (not requiring changes in wiring, unless addition of some input output device is required) Needs fewer spare parts It is much cheaper compared to conventional system, especially where large number of I/O instruments are needed and when operational functions are complex Reliability of PLC is greater than that of an electro-magnetic or static analog relay.
Process Control System Function of process control system is watched by input devices (switches sensors) that gives signal to PLC controller. In response to this, PLC controller and signals to output devices (viz. solenoids, electro magnetic valves, relays, magnetic starters, as well as light and sound signalisers) that actually control how system functions in assigned manner. Program for sequence of operation is also entered in PLC memory. Automation schemes The two control schemes utilized for small and medium hydro stations are: (i) A single PLC with provision of manual operation as back up system (ii) A redundant PLC for back up system and other PLC for main control There are various modification of these two basic schemes which depend on the individual plant requirement and owners preference. The singe PLC system offers the advantage of low cost and simplicity and is typically backed up by hard wired system. With redundant PLC system back-up control and memory are provided by second PLC. The advantages and disadvantages of both systems are given in following table.
S. No. 1. Single PLC with manually operated backup In manually operated backup system for control the unit output is set at operators discretion. An operator usually keep safety margin of approximately 10% in headwater or discharge level to avoid problem such as drawing air into the system. As a result maximum generation (KWH) for the machine is not realized in manual operation. Less expensive as compared to redundant PLC Non-uniform spare parts, spare parts would have to be arranged for both PLC system as well as manually operated system. But manual system being simpler in construction few spare parts would be required Operators familiarity with trouble shooting hardwired relay system Redundant PLC 10% Backup for CPU. The CPU includes the processor, system memory and system power supply. Head water level and discharge control is taken care of by redundant PLC whenever the PLC is disabled. With this system maximum expected generation can be achieved. The cost of second PLC exceeds the cost of manual system. Uniform spare parts. Only on set of I/O cards need to be maintained. Items such as spare relays and control switches associated with hard wired system are not required. Trouble shooting is complex for SHP operator may not be trained for PLC system trouble shooting (some of the complexity is offset by the PLC and 1/0 card self diagnostics now available)
8.3.4
2. 3.
4.
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5.
Less chance of common mode failure because the hardwired system is less prone to surge induced failure and more tolerant to inadequate grounds
Some time instantaneous surges may causes failure of both PLC simultaneously owners must insist for good surge protection system and effective grounding. More over if software is non-standard, software problems will be common to both.
In control system all unit protective relays should be independent from programmable controllers. The independence will allow protective relay system to function even if PLC fails ensuring the safety of unit & personnel. For a single PLC scheme with a manual operated back up system it is usually preferable to have and independent RTD (Resistance temperature detector) monitor and annunciation panel functionally operative during manual operation of the unit. It is also recommended in single PLC scheme, it may have redundancy for power supply in the same PLC. Redundant PLC for supervisory control only can also be considered in case it meets the requirement of the system. 8.4 PC with PLC based Control System Modern control systems utilize PCs in conjunction with PLC control. The PCs are utilized with man-machine interface (MMI) software for control display graphics historical data and trend displays, computerized maintenance management systems (CMMS) and remote communication & control. PLC programming software usually reside on the PC eliminating need of separate programming terminal to implement or change the PLC software coding. PC can also be used for graphical displays of plant data greatly enhancing operational control. Standard Microsoft based graphical display software packages are available for installation at standard PC. These displays include control display with select before use logic informational displays for plant RTD temperatures or historical trending plots of headwater, tail water and flow data. Modems with both dial out and dial in capabilities can be located in either PC or PLC or both to provide offsite access to plant information. These modems may be utilized to control the plant operation from a remote location. For plants having capacity up to 1000 KW PLC having integrated governor and plant control system with a PC is recommended while for plants having capacity more than 1000 KW unit control PLC with SCADA is recommended. 8.5 Computer based SCADA System (Microprocessor controller with SCADA): The complex operating system at bigger power stations require a computer based SCADA system computer in place of PLC. Some elements of this complexity are multiple units, complex reservoir or run-off-river water level algorithms and operation of number of intake gates, inlet valve, spillway gates, sluice gates and draft tube gates in conjunction with unit start/ stop sequence for flood conditions. The DCS (Distributed Computer System) is appropriate for this type of operation because it has ability to handle
63
large quantities of inputs and outputs quickly, providing operator with real-time information. 8.5.1 System: Computer based SCADA system use microprocessor based control technology physically distributed through out the power house. The separate microprocessor units are linked together by a number of digital communication paths to form a completely integrated control system. The distributed system offers several advantages over a centralized main frame computer type system: Improved system performance, as the various distributed microprocessors perform dedicated software functions or tasks at the same time (parallel processing) Reduced software complexity, with each microprocessor performing its own dedicated task. Modular elements, make the system easily expandable and simplifying component replacement Increased system reliability because of reduced complexity and modular structure which allows most of system to function through the failure of one or more components. Supervisory control and data acquisition (SCADA) is system operating with coded signals over communication channels so as to provide control of remote equipment and to acquire information about the status of remote equipment for display or for recording functions. 8.5.2 Control Parameters: SCADA system should be complete with primary sensors, cables analysers/ transmitters, monitors, system hardware/ software and peripherals etc. to monitor/ control the following parameters. Generator stator and rotor winding temperatures Generator and turbine bearing temperature Lubrication oil temperatures Status of generator cooling system Governor control monitoring of turbine speed Generator terminal voltage current KW, KVAR, KVA, KWH, Hz, PF, field voltage and field current. Annunciation for violation of permissible limits of above parameter Turbine guide bearing temperature detector Generator guide & thrust bearing temperature detector Guide and thrust bearing oil level indicator Generator winding temperature detector Turbine speed Generator speed Governor oil pumps, oil pressure indicator and low pressure indicator and low pressure switch Cooling water pumps, section and discharge pressure switch / gauge. Inlet pressure gauge at inlet of turbine 64
Level indicator for level in fore bay
8.5.3 Requirements of SCADA System SCADA should provide monitoring of parameters listed above. The list may have additional parameters as per requirement of individual plant. It should be able to control in grid mode or isolated mode as the case may be. In case of off site control it should be able to provide remote monitoring and control. It should have following features. Reliable safe control of unit with very high availability Automatic start up, on load control and shut down of units by the control system Control of auxiliary equipment Remote monitoring of all plant status and alarm information Remote normal startup on load control and shut down of machines by control system as well as by operator.
8.5.4
Specifying response time The processing speed of the computer or computers used in control system determines the over all response time which is very important especially during emergency situations therefore, when specifying a control system, the plant owner should take care to define response time speed of control system clearly. Some of the times related to the response time of computer system are: Time duration required to update a graphical display from the instant a field contact changes state Time duration from the instant a control is activated at the operator station until the command is implemented at the field device; and Over all time duration to process and log an alarm once it is received at the computer. The specification should define the acceptable time durations for each of the above events in both normal leading and high activity loading scenario. Penalty should be included in specification if vendor can not meet the response time defined. The computer system response times should be verified at the factory acceptance test to confirm the system will operate as required by specifications.
8.5.5
SCADA should have following controllers: Unit controller Common plant controller/ supervisory control Remote supervisory control
8.5.5.1 Unit Controller: It is microprocessor based / PLC based and is required to perform all functions as below. It is required to have capability to implement closed loop PID function for governing and to perform all monitoring, control, protection and recording functions that a power plant required independently. (a) It should monitor and control items
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Turbine wicket gate Turbine/ Generator RPM Generator power out put Generator excitation Generator breakers (b) Automatic unit control modes should include following: Unit automatic start sequence Unit automatic shutdown sequence Unit automatic synchronizing Unit wicket gate set point control Unit load set point control Unit flow control (c) The unit should include digital governor with proportional, integral and derivative gains. The governor be with in a position loop controlled by speed loop and capable of 0-10% droop. A manual position control should be provided. Following governing functions should be provided. Speed evaluator Speed control Speed set point adjustment Gate limiter Start up and shutdown control of turbine Position controller for guide vanes with power amplifier for control of servo valve. (d) Unit Auto synchronization The controller should be capable of synchronizing the generator to the bus by reading the slip frequency (generator-bus) and adjusting the governor speed set point until the correct slip frequency is obtained while sending voltage raise/lower pulses to the voltage regulator to match generator voltage to bus voltage. When the slip frequency is obtained and the generator and bus voltage are equal, the controller should send a close breaker command when the generator voltage and the bus are in phase. An additional external sync check relay should also be provided to supervise the controller close breaker command and the manual close breaker command. The controller should follow synchronization limits in terms of breaker closing angle and voltage matching condition specified by generator manufacturer.
(e) Shutdown sequence The shutdown sequence provided by controller should be such that the turbine generator set from any moving state to a complete standstill with all auxiliaries correctly shutdown. The unit controller should automatically shut down if the control system detects turbine mechanical system faults; generator electrical faults or specific shut down conditions are generated with in system. Following three types of shutdown to be performed on the turbine/generator set should be provided by the controller. (i) Normal shutdown 66
A normal shutdown should be initiated by a shutdown command that has been issued by an operator either from the panel mosaic or the supervisory system locally or remotely. This sequence should allow the plant to be shutdown in a standard orderly manner. After the plant has completely shutdown it should return to a state in which it can be restarted again on the issuing of a startup command.
(ii)
Emergency shutdown An emergency shutdown should be initiated if a failure occurs in a critical item of plant, which is likely to cause unsafe operation of plant such as an electrical trip. The plant should quickly and safely shutdown with lockout to avoid damage to plant or injury to personnel. The plant should be blocked from restarting again until the fault is rectified and acknowledged by the operator from either the panel mosaic or the supervisory system. Rapid shutdown A rapid shutdown is initiated if a safety trip occurs on the plant. The plant is rapidly shutdown taking care not to cause unfavorable effects such as pulsations, backwater surges and suction waves. The plant is blocked from restarting until the fault is rectified and acknowledged by the operator. Unit start-up sequencing The controller should allow the unit to be started manually (if all permissive are met) and bring generating unit speed to synchronous speed. Alternately if automatic start up mode is selected either locally or remotely then unit should automatically start provided all the start up permissive are met. The unit controller should allow parameters of the start-up sequence to be configured to match the turbine generator. Lockout The controller should include a generator lockout function. Whenever the lockout function is on it should inhibit the generator from starting. Any alarm should be configurable as a lockout alarm. The lockout should be reset with a command entered on the keyboard. When the lockout is on, it should be displayed on the screen annunciator. Auto restart The controller should be capable of automatically restarting the turbine after certain shutdowns if so enabled and if the lockout is not set. The time to wait for a restart and the enabling of the restart function should be configurable. Automatic power control modes
(iii)
(iv)
(v)
(vi)
(vii)
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The unit controller when the unit is not under plant control mode should be capable of several forms of automatic power control. The operator should be able to select automatic power control modes at any time and enter a new set point at any time. .The available power control modes should meet the requirements of system. Gate position should be automatically controlled to match the wicket gate to a position set point. Gate position should be controlled to match the kW output of the generator to a kW set point. Regardless of the kW set point, the generator output should be limited by a maximum kVA limit specified during configuration. Gate position should be controlled to match a flow set point that is calculated by the controller from a flow versus gate position curve for the operating head which is entered during the configuration process. (viii) Override control The controller should provide at least two override controls that when enabled will take over turbine control from the Automatic Power Control mode when certain set point limits are reached. When these interim conditions return to normal, the controller should automatically revert to the primary automatic power control mode. The controller should modulate the turbine output so that the measured generator stator temperature (hottest of the three phases) does not exceed the Temperature Control set point. (ix) Reactive power control The controller should have four reactive control modes, one manual and three automatic. The generator capability curve should be entered into the controller during configuring. All automatic reactive power control modes should be limited by the generator capability curves. If an operator enters a set point, that will take the generator outside its capability curves, the reactive power control program should control reactive power to get as close to the set point as possible, but remain within the generator's capability. Manual: The controller should provide operator capability, using "raise/lower" keys on the VDT keyboard and the "raise/lower" switch on the manual control panel to control voltage and reactive power. Automatic VAR control: The controller should automatically control the generator output to that VAR set point set by operator. The generators voltage limit and capability curve should not be exceeded regardless of the VAR set point. Automatic PF Control: The operator should enter power factor set point from the keyboard and The controller should automatically control the generator output to that power factor (leading or lagging) set point set by operator. The generator 68
voltage limit and capability curve should note be exceeded regardless of the power factor set point. Automatic voltage control: The controller should automatically control the generator output to match that voltage set point set by operator. The generator's voltage limit and capability curve should not be exceeded regardless of the voltage set point. Alarm Annunciation There should be two types of alarms used by the controller. One type should be the external alarms from contacts fed into the digital inputs of the controller and the second, the internal alarms generated by the controller. All alarms, whether internal or external, should be capable of being configured to cause different sequences.
(x)
(xi)
Unit controller should be capable of providing audible and visual alarms in the event of faults occurring in the power plants. The instant the fault occurs the relevant fault indicator is activated. All faults have to be acknowledged by the operators and can only be reset when the fault has been resolved. On the occurrence of following faults audible warning should be activated to attract the attention of the plant operators. Manual control panel The unit controller should have a manual control panel that bypasses the processor and allows the generator to be operated manually. The manual control panel should include start relay circuitry that is station battery powered. Manual switches to trip and close the breaker, turn the field on and off, start and stop the turbine and raise and lower the voltage should also be included. The gate should be capable of manual operation by a potentiometer that is located on a manual control panel and should be calibrated to position within 0.1 percent. Unit Protection The protection system should be based on the use of discrete microprocessor based relays with the following features: Continuous self monitoring Online display of actual values Should be capable to communicate with supervisory system through unit controller. The tenderer may also quote for multifunctional numerical relay.
8.5.5.2 Supervisory Controller It should monitor and control the status of power plant, provide automatic unmanned operation, log data, display the process through a mimics, supervise water levels of reservoir, startup and shutdown of units, control manually control auxiliary and alarm monitoring. All such control should subject to password-bases security system. Depending on the station requirements, the operator should be able to enter set points for power output, voltage and power factor. It should also have online documentation and expert diagnostics, efficiency management and plant management. (i) Operating Regimes:
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(ii)
The plant should be controlled either manually or automatically under different operating regimes. Following operating regimes may be provided. Plant efficiency control mode: In this mode of operation, the automatic control system should maximize the plant's energy production for a given headwater level and river flow. To achieve this, the system should automatically select the optimum number of units to run in combination with the most efficient unit loading point to dispatch all available water for a particular gross operating head. The operator should be able to specify the order in which units are to be started and stopped by the control system. Plant load sharing mode: In this mode of operation, the control system should automatically adjust the output of each unit by an equal percentage of rated power output in response to fluctuations in reservoir level. Load sharing should be the default mode used in conjunction with automatic reservoir level control. Reactive power control mode: In this mode of operation, the control system should automatically adjust the excitation field current to maintain the output power factor or VARs within a defined range (i.e., leading or lagging). The operator should be capable of entering a set range that the power factor or VARS must fall within for each unit. The control system should maintain the unit's output power factor or VARs within this set range unless limited by the generator capability curve or the exciter output current capability. The system should verify that the VAR set point is an identical percentage of rated output for all units when used in conjunction with automatic load sharing control. Operator Interface Requirements: The controller should use a video display terminal or PC as the main operator console. It should have powerful graphical user interface to the operators. The operator should be able to completely operate the plant by typing commands/function key on the keyboard or by push button on control panel. All information required to operate the plant should be shown .on the screen. A printer should be used to print out plant information. Symbols and colours specified in the international standard IEC 204 should be used for display. Screen display: The screen display should include all metering, indication and annunciator information normally displayed on a typical power plant control panel. This should include all metered data such as three phase generator volts and amps, generator watts, VARS, power factor, speed and frequency. This display should also show generator stator and bearing temperatures, breaker status, line volts, line frequency, and kilowatt-hours. The time and date should also be displayed with time to the minute. Screen data should be updated promptly whenever actual data changes. Alarm and status information should be updated within one second of actual changes. Analog data should be updated within two seconds of a change. Calculated value such as
(iii)
(iv)
(v)
(vi)
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temperature, watts, VARS, and power factor should be updated within five seconds of an actual change. All DC analog readings on the screen display should have configurable scale factors. All except speed should have configurable labeling on the screen. The AC scaling should be configurable by specifying WYE or DELTA and maximum AC voltage and current. Data shown on the display should have the following minimum accuracies. AC Voltage 1% of full scale AC Current 1% of full scale Frequency 0.005 HZ DC Inputs 25% of full scale KW, KVAR, PF 25% of full scale Temperatures + 5 degrees C (vii) Annunciator display: A portion of the screen should be dedicated for an annunciator. Alarms should be displayed in order of occurrence with the oldest alarm at the top of the screen. The sequence of alarms should be distinguishable if alarms are more than 1/60 th of a second apart. The display should include space for a least 23 alarms. When an alarm clears, the alarm below it should move up to fill in the blank space keeping the sequence. No alarms should be lost. Any alarms that do not fit on the screen should be save until these is room. Alarms should flash until the acknowledge key on the keyboard is presses. If the alarm is still on after it is acknowledged, it should stop flashing but remain on the screen. If the alarm has cleared, it should disappear from the screen when the acknowledge key is pressed.
The annunciator should display both alarms that are internally generated by the controller and alarms that are sensed external to the controller. The controller should be capable of generating a contact closure (option) on selected alarms for use with a horn or telephone dialer. (viii) Control status display: The display should include an indication of the status of the turbine i.e., starting, stopped, synchronizing, etc... (ix) Automatic control status display: The display should show the current automatic control mode, its set point, turbine gate limit, and any overriding control modes. (x) DT Keyboard: The keyboard should be a standard keyboard with upper and lower cases, ten key numeric pad and at least ten function keys. The function keys should be assigned important functions. The operator should be able to start and stop the turbine from the keyboard using simple commands. The operator should be able to enter set points via keyboard,
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(xi)
select any one of automatic power control modes and select any one of reactive power control modes External Interface Supervisory Controller should have a number of protocol modules which should provide connectivity to other devices including remote terminal units and programmable logic controllers. Event Recording and Data Logging Data logging Their should be a provision for a data logging printer at the plant to provide data logging at adjustable intervals, trouble logs and operator comments entered manually at the keyboard. The data logging interval for each printers should be adjustable by the operator in increments of one minute. Alarm and status logging All alarms annunciated on the screen should be recorded on the data log, timetagged to 1/60 of a second resolution. Plant status or operational changes should also be recorder on the data log, time-tagged to 1/60 of a second resolution. The operator should be able to enter comments on the log manually through the keyboard.
(xii) (a)
(b)
(c)
kWH logging Plant watt-hours should be accumulated and recorded on the data log at both daily and monthly intervals. The integrated power generation controller should have the capability to accumulate these data by one of two methods: internally, by a calculation method based on direct monitoring of generator CT and PT inputs, or externally, by receiving and totalizing counts from pulse initiator output from an external watt-hour meter.
8.5.5.3 Remote Supervisory Controller In case of off site (remote) control, identical desk top computer based supervisory controller should be installed at offsite station. This controller should provide identical set of screens to that of station itself. The same information is displayed at this controller almost simultaneously with it appearing on the Supervisory Controller at the power station. The same level of control is also provided on this remote controller. Using the detailed screens for the startup and shutdown sequences, remote operator should monitor exactly what is happening in the power station. A big screen should also be installed at some sutable wall of the remote control center displaying on line data. In case some generating facility is to be added at later date it should be ensured that there is no problem in protocol matching. The controller should have following features from safety and security point of view: It should ignore all unsafe commands. Only one operator is able to control the unit at any point of time. Multiple authorization levels allow different operators access to different levels of control.
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(i)
Communication Link To interface Remote Supervisory Controller located at offsite location to plant Supervisory Controller at centralized control of plant proper communication system should be installed and commissioned. The equipment to be supplied should have the facility of transmission of speech and data simultaneously. Data transmission speed should be 9600 bps.
(ii)
Software Requirements The operating system: The software should run in a priority interrupt driven, multitasking operating system. The system should provide each task with dedicated random access memory to allow preemptive scheduling of tasks without loss of information. Programming language The controlling programs should be written in a high level compiled language whenever possible for ease in maintenance, with the exception of time critical tasks which should be written in assembly language. The code should be reentrant and employ mutual exclusion techniques to prevent deadlock of resources. Standardization The software should reside in non-volatile EPROM memory, which should not require reloading for routine power interruptions to the controller. Configurability Configuring of the control software should be accomplished via a menu driven user-friendly program that will be run on an IBC PC or compatible computer. The configuring should be able to be accomplished at an area remote from the controller and should not prevent operation of the controller during configuring except during the transfer of the configuring information to the controller. (vi) Functions The software should allow the operator to examine and modify those parameters of the control software that will specify the operating conditions and restrictions of a particular plant. These features should include but are not limited to: - Timings - Decision paths - Set points - Equation coefficients - Enabling functions - Plant description information The software should also allow for specifying particular contact inputs, analog inputs and analog outputs. The software should allow user designation and titling of contact inputs. Analog scale factors should be set via the configuring program.
(iii)
(iv)
(v)
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(vii)
Communications The configuring information should be communicable with the controller via standard RS-232C communications protocol. The communication should have the ability to be via voice grade telephone communication as well as a direct connection with the controller. Security The configuring software should provide a means of preventing unauthorized access to the configuring information. Further it should provide a means of differentiating three or more security levels of configuring information to create three or more depths of configuring accessibility. Human interface The configuring program should be "user-friendly" in that it should be menu driven and should be operable by non-technical personnel.
(viii)
(ix)
8.6
Physical and Environmental (i) Physical The equipment should be constructed on a modular basis, using plug-in connection. The controller should be suitable for mounting in a standard 19-inch wide rack, with a minimum depth of 24 inches. Input/output termination cabinets should be internally labeled, to permit ready identification of the incoming and outgoing wiring. The equipment should be of self protecting against surges that may be generated on power supply bus by contact operation, circuit resonance, etc. External connections should utilize modular screw terminal blocks which should be should be suitably mounted and readily accessible. Each terminal device shall suitably identify all conductors. All wiring should be clearly marked and so designated on the drawing to permit identification for maintenance. Wire not colour coded should be identified by a wire number marker on each end. All cables and jacketing material should be oil, moisture, and heat resistance thermosetting compounds under operating conditions. Controller AC power connection should be a standard NEMA PI5-5 plug configuration. Environmental The controller and video display should be capable of withstanding the environmental conditions of the site of plant during air condition failure. Power Requirements The controller should use standard wall outlet AC power, however an inverter should be supplied that is powered from the station battery to provide AC power. The controller including VDT, DTC, printer, and modem other peripheral equipment should operate from a 250 VA inverter.
(ii)
(iii)
9.0
USER AND PLANT INTERFACES

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9.1
User interfaces The most critical interface for a power plant automation system is the User Interface (UI). The plant interfaces discussed later in this clause are important to the automation system in order to perform effective monitoring, annunciation, control, etc., but the UI is crucial to the success of the system. If the operator is not able to use the system easily and conveniently, the system will never be used properly or cost effectively. The operator's needs are critical to the successful operation and use of a power plant automation project. UIs offering the look and feel of a personal computer may be desirable to reduce special training. In order to make the system acceptable to the operations personnel, care must be taken in the selection of the hardware and software used. The hardware options are numerous for input and output devices as well as the workstations to be used.
9.1.1
Input devices Input devices are not mutually exclusive and may be combined to incorporate desired features. Typical devices include the following: a) Trackballs. Pointing devices for menu driven software. Trackballs are normally used in conjunction with a standard ASCII keyboard and/or numeric keypad and occupy very little desktop space. b) Mice. Similar to track balls, they are normally used in conjunction with an ASCII keyboard arid/or numeric keypad. A mouse requires more desktop space than a trackball since the mouse must be moved in order to move the cursor on the screen. c) Light pens. A pointing device for menu-driven software. Light pens normally use an ASCII keyboard and/or a numeric keypad for data entry and require no desktop space. d) Keyboards. Normally installed on all workstations for data input and system control. Desirable features for keyboards and numeric keypads include standard key layouts and tactile feedback. They need to be well constructed to withstand continuous use. They should be waterproof and dustproof. Keyboards using layouts similar to the familiar PC will minimize the chance for confusion arising from the use of a nonstandard keyboard. e) Touch screens. Useful for cursor positioning but not well suited for data entry. f) Speech recognition. This input technique is a leading edge technology. It has many disadvantages at present such as speaker dependency, large error or misinterpretation rates, large memory needs, and extensive processing time.
9.1.2 Output devices As with input devices, various output devices may be combined to incorporate desired features. Some typical devices are as follows: a) Printers. These devices range from dot matrix units to letter-quality line printers in both black and black-plus-color models. They are used for hard copy output of the computer data for reports or historical records.
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b)
c) d)
CRT screens. These output devices are on most UI systems and are the primary output device for the computer. They range from small monochrome units to large color units with millions of color combinations. Speech synthesis. Provides the operator with a phonetically-based audible message output. Mimic boards. Graphical displays or map boards used to represent the configuration and data of the plant or system. Mature technology units range from manual displays with movable parts to fixed displays with lights to indicate equipment status. New technology units include displays of system data in graphical form and large projection screens with computer generated displays.
9.2
Plant Interfaces The plant to computer-based control system interfaces are important to the success of the automated hydroelectric power plant's control system. There are many types of hardware interfaces, each with specific requirements that must be addressed as the system is designed, installed, and tested.
9.2.1
Types Examples of plant interfaces include analog transducer signals, dry contacts (i.e., contacts without sensing voltages) and digital data. This clause covers several generic types, however, installations may have special application requirements to meet unique concerns. This discussion addresses the analysis process for any plant interface.
9.2.1.1 Digital, contact, and pulse inputs Digital or contact inputs should meet minimum criteria for operations at the voltages and current loads anticipated. The current required to drive the input circuitry should be adequate to ensure false indication changes do not occur due to noise. The current should be as low as possible to conserve power and reduce heat generation. Wetting voltages (e.g., those voltages required to sense the status of dry contacts) may be provided by the control system or the field device. Contact bounce in the input signal can cause erroneous data in the system. Digital inputs should have filters to detect only sustained input signals. These filters may be in the hardware or the software. Filters must be selected in accordance with time tag accuracy. Simple low-pass filters can introduce undesirable delays. Voltage levels for logic detection should be sufficient to prevent erroneous readings. Digital inputs may also serve the functions of pulse accumulators or counters. This function is normally in software or firmware at the I/O. Accuracy, counting, and pulse accumulation rates should be sufficient for the intended use. Another variety of digital inputs comes in the form of a parallel (e.g., binary coded decimal) data. The quantity of wire conductors, noise immunity, and hand shaking requirements should be considered when making accommodations for these inputs.
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Serial digital inputs (e.g., EIA RS232, RS422) are frequently used as an interface to newer transducers. Digital input status indicators, often LEDs, may be provided. These indicators ease I/O and control circuit troubleshooting. 9.2.1.2 Digital and contact outputs Digital or Contact outputs provide data and control contacts for external circuits. These contacts must have sufficient current and voltage rating for the external load. These ratings must often be considered in total for a given card or group of I/O as well as for individual circuits. Wetting voltage is typically provided by the external circuit. The ability of the solid-state devices in the output circuitry of the I/O to absorb the required current (without thermal instability of the devices) is a function of temperature (heat generation). Where higher current ratings are required, interposing relays are typically installed. The current ratings are then those of the interposing relays. Digital outputs may be latched, momentary, or maintained. These functions may be implemented in software or in the output relay. Digital output status indicators usually LEDs may be provided, similar to those on input I/Os. The failure state of digital outputs should be defined and specified. Digital output failure may be critical in some applications. 9.2.1.3 Analog inputs Analog inputs may be low-level (e.g., 0-1 mA dc, 4-20 mA dc, 1-5 V dc, etc.) current or voltage, resistance, or thermocouple signals. Resistance or millivolt (thermocouple) inputs may be scaled to engineering units by the I/O processor, or a separate RTD or thermocouple to current or voltage converter located with the I/O. The I/O is often capable of providing the loop power supply for analog inputs. Voltage, tolerance, stability, and loading should be considered. Scaling accuracy, resolution, deadband, and thermal stability should all be specified to meet the needs of the applications. Thermocouple and RTD replications should meet the standard accuracy for these devices. Open thermocouple detection is often desirable. Common and differential mode rejection ratios should also be specified. When multiplexing technology is used, the multiplexing hardware should be solid-state and not electromechanical. Multiplexing schemes must be fast enough to ensure that the most recent values are available when required for all control loops. 9.2.1.4 Analog outputs
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Analog outputs are typically low-level voltage or current. Accuracy, resolution, deadband, and thermal stability should all be specified. Similar to digital outputs, the condition or value of analog outputs upon failure may be critical in some applications. 9.2.1.5 Analog-to-digital/digital-to-analog conversion The accuracy of any analog input or output depends on the conversion between the computer's digital data system and the analog information. The conversion is typically performed by multi-bit A/D converters. Conversion accuracy and resolution are a function of the number of A/D converter bits and I/O amplifier design. Further, the accuracy is affected by temperature-induced drift. Thus, A/D resolution, input accuracy, and temperature stability should all be specified. 9.2.1.6 Field devices and field bus standards Another major source of interface signals are those originating from intelligent electronic devices (IED) and intelligent field devices (e.g., a field device capable of measuring more than one parameter and transmitting the measured parameters over one pair of wires. 9.2.2 Sources The sources of information to be interfaced to control systems are numerous and not all are covered in this clause. The most common ones are highlighted, as follows: a) Digital Input Signal Monitoring. Usually accomplished by sensing the state of relay contacts using the station battery or a voltage supply to detect the opened or closed status of the contact. The output devices are normally solid-state or electromechanical relays that are energized or de-energized by the control system. b) Analog Input Devices. Normally transducers that convert potential transformer (PT) and current transformer (CT) signals to quantities such as megawatts or megavars. In existing plants, control system analog outputs may drive display panels or strip chart recorders for operator observation. c) Parallel Input Devices. Usually shaft encoders or digital panel meters. The output devices are digital panel meters or process controller modules. These interface sources are in many cases bidirectional, i.e., they are both input and output devices. d) Serial Sources. Normally bidirectional devices with built-in intelligence, providing both input and output capability. The devices consist of smart watthour meters, shaft encoders, temperature transducers, etc.
9.2.3 Input/output protection All inputs and outputs should be specified to withstand the Surge Withstand Capability (SWC) test, -as described in IEEE C37.90.1-1989, without any false operations. The SWC test has proven to be a reliable means to identify noise problems similar to those found in a hydroelectric powerhouse.
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9.2.4 Collection process The data collection process involves all of the aspects discussed above as well as some considerations that are internal to the control system as opposed to the interface itself. 9.2.4.1 Scan rate The scan rate deals with the rate at which the data is moved from the interface to the data base or from the database to the interface. 9.2.4.2 Archival rate The archival rate of the control system is normally the rate at which data is stored for long-term, historical purposes. This rate varies dependent on data type, in order to save storage space, retrieval time, and analysis efforts. For example, the archival rate for temperature data does not need to be as often as that for electrical data. 10.0 REMOTE CONTROL OFF SITE CONTROL Remote control of hydroelectric plant means controlling activities of a plant from off site control centers. Personnel at such control centers are responsible of operating several power plants and substations. Some of the control functions performed from such control centers are: Periodic MW & MVARs adjustments to maintain power system operation in accordance with grid requirements as per guide lines of system control. Maintain generation reserves to assure power system stability as per guidelines of system control. Energy interchange scheduling Automatic generation control, including time error control and frequency control (in coordinative with area system control centre). Hourly load forecast Transmission line loading (system power flow) Power export control adjustments. Remote control can be automatic or manual with duplication of local controls at remote location for desired operation at that site control logic system can be provided by hardwired relay logic programmable logic controllers, microprocessor based system or a combination of these. Interlocks are required at the local site to prevent improper remote manual operation. Remote control and indications may be established by the use of supervisory control equipment, using one of the modern communication means totally automatic start & slop initiation is possible from remote location. However unattended operation requires that special attention be given to fail safe characteristic of control system. 10.1 Control requirement: Initiation and control functions are listed below. The items installed will vary according to size of plant, method of system operation and economics. Start and stop sequence initiation Breaker operation open/ close 79
10.2
Motorized excitation or voltage regulator setting rheostat to allow remote setting of field current and generator terminal voltage. Governor control and flow control device position (guide vanes, blade angle or nozzle or valve) - speed no load - Best efficiency - Position (guide vanes, blade angle, nozzles or valve) - Unit auxiliary system Instrumentation requirements: KW output per generator KVAR output per generator KWH output per generator field voltage and current synchronoscope indication Generator voltage, current and frequency System voltage Head water level Tail water level, when required Turbine flow control devices (guide vanes, blade angle, nozzle or valve) Status of bye pass, sluice or spillway gates Transducer or signal transmitters are provided either at the control board or at the equipment. Status / Alarms requirement: Ready to start Breaker position (No alarm if manual operation only) Intrusion alarm Fire alarm Emergency station alarm (immediate response) General station alarm (can be differed for some time) Trash rack differential pressure alarm Unit stop when not required Unit turning when not required High bearing temperature Loss of lubrication or cooling or both Low hydraulic system oil pressure High or low water levels Incomplete start or stop sequence loss of power Communication Links: Following communication methods are used for implementing control from Remote site: Hardwired communication - Telephone type lines - Fiber optical cables Leased telephone lines 80
10.3
10.4
Power line carrier communication system (PLCC) Point to point radio at approved frequency Microwave system Satellite
For items of 1 & 2 arrangements of special protection for equipment and personnel against ground potential rise & lightening surges are essential. It is seen that optical fiber cable, PLCC, Satellite communication links are the most preferred options as these are more reliable. 11.0 SITE INTEGRATION FOR AUTOMATION OF EXISTING PLANT Before taking up automation of existing plant it is necessary to study site conditions and ensure that interfaces and other circumstances are compatible with proper operation of the automation system some features requiring study for automation are as under: Existing contact output: Most automation systems include large numbers of contact status point inputs. These contact can be found in: - Protective relays - Manually operated control switches - Level switches - Position switches - Other devices. The contacts should be used directly as inputs to automation system. It is advisable to avoid input through auxiliary relays. Sometimes contacts in protective relays are connected in parallel with annunciation equipment. In such case care should be taken to avoid any sort of interference between automation system and annunciation equipment. In case one side contacts is connected to power source from station battery, the automation system should provide electrical isolation between the inputs to prevent sneak paths between inputs when either side of the battery is disconnected from one of them. 11.2 Existing Transducers: An automation system can be configured to adapt to any electrical signal as input but it is preferable to have standardized inputs. The accuracy of existing transducers should be studied to ascertain that they most system accuracy requirements. The most commonly used transducers provide O - + port) signal as an output but transducers providing 4-20 mA signal are also used by manufacture different transducer outputs require different input circuits on the automation system. It is therefore, preferable to have minimum transducer outputs to have less complexity in automation system. It will make it easier to add or reconfigure the inputs after the equipment. Existing control output points: The functions of output points are: 81
11.1
11.3
Close /trip Raise / lower Start / slop
The characteristic of each output point supervised should be determined. The old break trip circuits, speed level motors require high level inductive current to be switched as such output circuits must be capable of reliably switching this current through out the life of automotive system alternatively interposing auxiliary machine tool type relays can be used on such outputs. 11.4 Grounding Each equipment rack of automation systems is required to be separately connected to the power house ground mat. During power system fault conditions, a large potential rise can occur between different locations with in power house due to large current flowing through ground. This potential rise will appear between different components of equipment communication circuit connecting different components must with stand this potential rise as such with stand value of maximum potential rise for links must be specified. The use of optical fiber cable as communication link between equipment is one way of solving this problem. Shield ties on transducer end are used on communication cables between transducers and automation system. 11.5 Power Source 11.5.1 Battery set with charger Normally a battery set with automatic float rectifier type battery charger powered by station AC is provided to feed critical load such as protection and control circuits and devices as D.C. source is more reliable. An evaluation (as described in IEEE Std 485-1983) should be performed to ensure that station battery is having enough capacity to operate automation system along with all other D.C. loads for specified time periods (half an hour is considered adequate in case of station AC failure). The chargers must be capable of supplying D.C. system load while charging up the battery. If the evaluation shows that larger batteries or chargers are required, consideration should be given to it for improving automation system efficiency. Reducing other D.C. load is other option. Some components of automation system operate on AC power since AC power source available at power house is not considered very reliable providing inverter to convert power from D.C. station battery to A.C. power is considered reliable option. Some automation features like sequence of event recording operating on A.C. are vital and can not be afforded to be missed as such provision of inverter become inescapable. Inverter, however, should include a bump less static switch with automatic transfer of power source for the automation system to the station A.C. power source in the event of inverter failure. Also the inverter should be designed to produce an A.C. output with wave form deviation and wave form characteristics consistent with the requirement of
82
supplied load. Appropriate failure detection and alarming should be specified in the investor. In case of large power stations two sets of batteries of full required capacity are required to make availability of D.C. more reliable. UPS of proper capacity are preferred for SHP as these require less maintenance and are considered more reliable. 11.5.2 Uninterruptible Power Supply System (UPS) Uninterruptible Power Supply System in SHP are required to provide electricity for computerized control and data acquisition system, communication system etc. when normal plant power system fail. As per IEEE: 944 Recommended practice for application and testing of uninterruptible power supplies for power generating stations; UPS systems are used to provide electricity for essential loads when normal plant power system fails. Loss of power to such loads as the plant computers, communication networks, security system and emergency lights.
DC BATTERY (48/110V)
FUSE FLOATED BOOST CHARGER AC FROM STATION SERVICE
D.C. BUS TO COMPUTER CONTROL SYSTEM FEEDER BREAKER
MCB
TO EMERGENCY SUPPLY
UPS SYSTEM
D.C. FEEDERS
AC-220V FROM STATION SERVICE
Fig. 3.3 Typical DC system for SHP up to 3000 kW UPS system is defined as one designed to automatically provide power without delay or transient during any period when normal power supply is in capable of performing acceptably.
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On line static (solid state) UPS system with sine wave output are required. An off line system take about 25 ms for transfer to DC which may impair critical control by computer system. Normal range of sizes for hydro plant up to 25 MW uninterruptible power supplies is given below:
Plat size (MW) 5 - 25 MW 0.1 to 5 MW Micro Hydel
UPS size (kVA) 1 5 kVA 1 or less kVA i) Electronic load controller (ELC) may use its on converter and conditioned Dc supply system from UPS or otherwise ii) If remote controlled PC may be used with its own UPS
Remarks
i) Use power line conditioner (power supply system) ii) May use standard single PC UPS
84
ANNEXURE-II LIST OF GENERATOR PANEL INDICATION AND RELAYS Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Designation L1 L2 L3 L4 L5 L6 L7 L8 L9 R Y B IPB PB1 PB2 TS DMF H ANN T A R BAPB 27 32P 51V 59 60 64S 46 Inscription DC Supply on AC Supply on Generator Circuit Breaker Close Generator Circuit Breaker Open Generator Circuit Breaker Trip Generator Circuit Spring Charge Trip Coil Healthy DC Supply Failed Spare R Phase Bus Healthy Y Phase Bus Healthy B Phase Bus Healthy Immediate Action Trip Push Button Controlled Action Shut Down Push Button Spare Push Button Temperature Scanner Digital Multi Function Meter Hooter Annunciator Test Push Button Accept Push Button Reset Push Button Bell Accepted Push Button Under Voltage Relay Reverse Power Relay Voltage Controlled Over Current Relay Over Voltage Relay PT Fuse Failure Relay Stator Earth Fault Relay Negative Phase Sequence Relay Colours Yellow Red Red Green Amber Blue Yellow Red Red Red Yellow Blue Red Green Red
Black Black Black Yellow
85
31 32 33 34 35 36 37 38 39 40
40 95 87G 52G KWTR BL 86G1 86G2 86G3 86G4
Loss of Field Relay Trip coil Supervision relay Generator Differential Relay Generator Circuit Breaker Kilowatt Transducer Electrical Bell Master Trip Relay Master Trip Relay Master Trip Relay Master Trip Relay ANNEXURE-III
LIST OF PROTECTION ELEMENTS IN MICRO PROCESSOR BASED RELAYS Symbol 21 24 26 27 27NT 32 38 40 46 49 50BF 50P 50N 50/27 51P 51N 51N 59 59N 64R 78 81 87G CTS VTS Description Under Impedance Over Fluxing Field Winding Temp Under Voltage 100% Stator E/F Reverse Power Bearing Temp Loss of Field Negative Phase Sequence Stator Winding Temp Breaker Failure Instantaneous Phase Over Current Instantaneous Neutral Over Current Unintentional Energisation at Stand Still Time Delayed Phase Over Current Time Delayed Neutral Over Current Voltage Controlled Over Current Over Voltage Residual Over Voltage Restricted E/F Pole Slipping Protection Over/ Under Frequency Generator Differential Current Transformer Supervision Voltage Transformer Supervision
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3.4 GL For Monitoring Control Protection and Automation of SHP Stations

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STANDARDS/MANUALS/ GUIDELINES FOR SMALL HYDRO DEVELOPMENT

Sponsor: Ministry of New and Renewable Energy Govt. of India

IEEE Std 1020 IEEE Std 1010 IEEE Std 60545:1976

IEEE std 4214 ANSI/ IEEE std 242:1996

SECTION-II 2.0 MONITORING OF SHP

SECTION-III 3.0 3.1 CONTROL OF UNITS OF SMALL HYDROPOWER PLANT GENERAL

Fig. 1: Turbine Control 3.3.2 Generator Control

Fig. 2: Generator Controls 3.3.3 Plant Control

Fig. 3: Overview of Plant Automatic Control

Comparison of various options for control systems are given in table 1

100-500 & above 2. Load control governor 50-100

Analogue, Electronic Gov. & Plant Controller

50-100 Above 100

Iso. Grid Iso. Grid Iso. Grid Iso. Grid

At high extra cost

Very high cost High Moderate to high Moderate

SHP 100 kW to 5 MW Above 5 MW

Suitable See note 2

Recommended for units above 5 MW

5 to 100 kW 100 kW to 2500 kW

Iso. Grid Iso.

Data not available Suitable Indigenous system not available

Recommended Recommended with high speed PC suitable for harsh area

Operation Attended (supervision) Unattended

TO REMOTE CONTROL CENTRALISED CONTROL

STATION OPTICAL FIBRE COMMUNICATION NETWORK (DUAL)

UNIT 1 LOCAL/MANUAL CONTROL PLC USER INTERFACE

UNIT 2 LOCAL/MANUAL CONTROL PLC USER INTERFACE

STATION SERVICE LOCAL CONTROL USER INTERFACE

SWITCHYARD CONTROL PLC USER INTERFACE

LOCAL CONTROL SYSTEM

STATION COMMUNICATION LINK PROCESS (UNIT, SWITCHGEAR GATES, ETC.)

COMPUTER BASED CONTROL

LOCAL USER INTERFACE BACKUP CONTROL

3.13 Communication Links a. Communication links with remote control

Communications with Auxiliaries

vi. vii. viii. ix. x. xi. xii. xiii.

SECTION-IV 4.0 4.1 PROTECTION OF SHP GENERATING UNITS GENERAL

Criteria of selection of protection system

(d) (e) (f) (g) (h) (i) (j)

LEGEND 331661132 kV BUS

ISOLATING SWITCH HV CIRCUIT BREAKER LINK

EXCITATION BREAKER WITH DISCHARGE RESISTOR CURRENT TRANSFORMER

CT 5P10 GENERATOR TRANSFORMER-1 64T

CT 87GT GENERATOR TRANSFORMER-2 64T SATTAION AUX. T/F

LIGHTNING ARRESTOR FUSE EARTH

DG SET 11 KV CIRCUIT BREAKER 11 KV CIRCUIT BREAKER

P.T. 41G GENERATOR-

P.T. 41G GENERATOR-2

FIG. 2.3.1 TYPICAL SINGLE LINE DIAGRAM

S.S. FROM EXCITOR 2

FIRST STAGE ALARM

33CW/80CW 38TG TO 86 EB 38QB

TURBINE GUIDE BEARING R.T.D.

TRIP 52-1 & 41 G TURBINE SPEED NO LOAD AND ALARM

RESISTOR RATED 15 SEC.

FIG. 2.3.2 TYPICAL UNIT METERING SINGLE LINE DIAGRAM

GENERATOR CONNECTED IN PARALLEL TO GRID

Governor OPU oil pressure low stage-II

Over current in the excitation circuit 47

Er. S. K. Tyagi, Consultant, AHEC, IIT, Roorkee

Controlling the process: Process information gathered serves two purposes: 51