Control System

The development of I.C. technology has evolved a new field of miniaturizing the earlier
giant looking electronic devices. Further advancement of I.C. came forward with the
concept of scale of circuit integration. Thus today we have circuits of VLSI scale(very
large scale integration) which carry more than one lach of transistors on a single wafer of
silicon of millimeter size. This advancement of I.C. gave birth to the microprocessor, use
of which amazingly has reduced the size of control equipment. Thus today a desk size
controller is capable to control a huge power plant more reliably and efficiently than the
old one which needed a very large room for its accommodation.

The control system of this power plant categorically relates to the microprocessor family.
In consistence with the variety of machines installed at this power station, the control, too,
is quite versatile. Thus at unit No.1,2,13,14 and 15 SIEMENS control of TELEPERM ME
and ISKAMATIC family is employed. At unit No. 9 & 10 ABB control of
PROCONTROL K and SIEMENS TELEPERM ME is in service. For unit 5-8 GE control
under the trade name of MARK IV SPEEDTRONIC is in action. For the FIAT machines
unit 3&4 the control equipment is the conventional relay type. Unit no 11&12 are being
controlled through ALSTHOM control CEG LEC.

SIEMENS control TELEPERM ME provides all the requirement of an automation

process, e.g. the open and closed loop operation, data acquisition, processing,
calculations, optimization, monitoring, signaling, operation and visualization of the
process in the interactive mode on a monitor via a control desk. From design point of
view the whole system is divided into the following subsystems.

As automation subsystem OS operation, monitoring and configuring subsystem IS

process information system CS 275 coupling sub system

The AS 220 EA automation subsystem forms the heart of TELEPERM ME. It is

selectively redundant automation system where the function modules and the input/output
bus control can be configured in 1 out of 2 redundancy or nonredundantly. The AS 220
EHF is the highly reliable and fail-safe design of the AS 220 E. The central unit of AS
220 EHF consists of three independent central processing units with synchronous
commands whose output signals are linked in a 2 out of 3 configuration. The central unit
consists of function blocks and organizational functions and thus forms the unit control,
group level and sub group level controls. The central processing unit then process these
blocks according to the plant configuration. The function block contain the basic function
like integrator, differentiator, adder, maximum/minimum value selector, close loop
controller, command blocks and step blocks. Since the function blocks are processed
sequentially, they can be used several times without having to extend the hardware.

The OS 265 operation and monitoring system is used for the monitor based operation and
supervision of power plant. It provides detailed plant graphic displays, function graphic
displays and individual displays for measured values, open and close loop controls. In the
event of fault the operator is directly guided into the relevant plant or detailed graphic
displays by flashing indicators on the screen.Thus all faults that occur including their
causes are recognized at an early stage and the process is protected from disturbance.
Process operations are carried out by touching the screen at the requisite point of display
block using a light pen.

The information subsystem MADAM S is a modular arranged data acquisition and

monitoring system, devised by SIEMENS. The system provides alarm annunciation,
analog value display, digital status display, plant mimic display, curve display and the
operating point display. The incident review log provides 10 minutes pre and post history
alarm sequence logs. Each page of the display accommodates 8 alarms. Likewise 8 analog
value and binary values are displayed on a page with a value updating cycle of 5 and 1
second respectively.

The CS 275 bus subsystem is used to transfer data between the components of the system
i.e. AS220, OS 265, MADAM S, WS30 and PG 750. The bus system is divided into a
LOCAL (upto 20 meters distance) and REMOTE (upto 4 km. distance) area. The system
employs distributed transmission control for transfer of data among the system
components. It uses "the flying master principle" i.e. each participant takes over the
transmission control. The rest of the participants become slave till they get their turn to
become master. This change of master status is carried out through bus protocol which
assigns the master function to any participant via REQUEST, COMMAND and TIME-
OUT CONTROL.

The ISKAMATIK system, on the other hand is an integration of different dedicated

modules which are hardwired to obtain a particular job. Three different categories of
modules are in use. Iskamatic module A is used for analog, Module B for binary and
Module C for protection circuits. Each module has a specified hardware and by
hardwiring the outputs of different modules, an automation process can be tailored to suit
any specific task.

SPEEDTRONIC MARK IV.

General Electric Control: MARK IV SPEEDTRONIC, controls the operation and

monitoring of the gas turbine unit 5-8. It employs three identical computers, identified as
controllers R, S, and T which perform all calculations necessary to keep the gas turbine
running after it has reached complete sequence and also for the normal shut down of the
unit. Each computer is designed such that it drives its output in a defined direction on loss
of power or failure of any computer but for reliability the two-thirds voting concept is
provided in the system configuration. A fourth computer called as "The communicator" C
supervises the three controllers and initiates an audible alarm when there is disagreement
between any control parameter or logic signal in the three controllers. The discrepancy is
then displayed on the CRT for maintenance personnel to evaluate the problem. The
turbine however continues to run because the control is responding to the median value.
The field trip contacts are wired to the two contact input modules, named as (CIM1),
(CIM2) from here the signals are paralleled to the three optical couplers which feed them
to the separate digital inputs cards in R,S and T. The communicator C monitors the input
seen by R,S & T and performs the majority vote and feeds the voted and individual values
to the CRT for display.

Field contacts relevant to operation of the gas turbine are connected to the Contact Input
Module 3-6 and via optocouplers go the communicator C. Power for each computer is
supplied by an independent power supply which is separately fused from the 125 v dc
battery system. Voting of the logic outputs is performed by the logic driver card in the
relay drive module. Power for this cards is supplied from the two redundant 28 vdc power
sources under the supervision of computer C. Relays used for the trip circuits such as fuel
solenoids, have additional protection which removes power from the coil when a trip
condition occurs. This protects against the relay driver failing in the turned on mode.

For analog control system, the temperature input signals are connected to the I/O Modules
(ICM) and all others to the Modules (AI01-4) where they are filtered prior to being fed to
the controllers R,S & T or the communicator C. These incoming signals are then
multiplexed on the computer card dedicated to specific functions and then wired to an
other analog input card for a second stage of multiplexing and the final analog to digital
conversion. Median selection of key parameters such as fuel stroke reference, FSR is
calculated in C and fed back to R, S and T to bias their individual calculation and in case
of computer failure to up date the computer prior to reinitializing it for an automatic
restart. All analog control loops are calculated in the software except for the fuel servos
which are regulated in hardware. In this case the controllers R, S and T calculate the
required fuel which is converted from digital to analog, compared with the LVDT
position, and/or flow divider feedback and then used to drive the three coil servos. The
application of three coil servos extend the voting principal to the gas turbine.
The thermocouple inputs are processed similar to other analog inputs. Here the trip and
essential control thermocouples are connected to separate input modules, (TCM.R),
(TCM.S) and (TCM.T), for filtering, cold junction reference and offset measurement prior
to being fed to the controllers ®, (S) and (T). The monitoring thermocouples are wired to
one of the input module (TCM1-3) which feed to the communicator, "C".

The monitoring system provides a lot of information for the operator and the maintenance
personnel. Some of the features are:

The "normal display" shows all the key gas turbine parameters relevant to a
particular operating mode, i.e. startup, running and shutdown and automatically
1
changes displays when the operating mode changes. Any display can be copied
through the panel mounted printer.
Two (2) field selectable "demand Displays" can be provided with thirty two
(32) points each including any control or logic signal displayed in engineering
2
unit. It can be logged at specified time intervals or printed manually on
demand.
256 alarm messages ae available, and additional alarms are dedicated to
3
internal diagnostics.
Gains, time constants and setpoints can be displayed and changed from the
operator interface module, (OPM) and the changes will be retained in BRAM,
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BATTERY-BACKED RAM, for up to ten (10) days at 25 degree C if DC
power is removed from the panel.
The status of all contact inputs can be displayed simultaneously to assist in
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troubleshooting.
Logic signals can be forced from the Orator Interface Module (OPM), if the
6 correct security code is entered in the computer by qualified maintenance
personnel.
Two (2) levels of security codes prevent unauthorized adjustment of guarded
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signals.
Key parameters are recorded time/date wise over a period of 72 hours by an
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historical log monitor.