Standard Technical Features of BTG System for Supercritical 660 ...

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Standard Technical Features of BTG System for Supercritical 660/800 MW Thermal Unitsb) Stream concept shall be maintained. The different equipment shallbe clubbed in such a manner that failure of a controller set affectsonly one stream of the process path, e.g. in air and flue gas path, IDfanA, FD-fan A, and rotary air pre heater– A can be clubbed onone set of controllers.c) Inter-related controls shall be provided in one group, i.e. when theloop /sequence of one equipment depends on the availability ofanother sequence /loop or equipment than these controls shall bepreferably be clubbed together e.g. PA fan controls depend on theavailability of mills/mill control, so, control of half the number ofmills can be clubbed with control of the relevant PA fan.d) While formulating the controller groups, it shall be ensured that thefailure of one function does not jeopardize the plant operation orcause shut down. For example if 6 mills are required for full loadplant operation, then the grouping of mills shall be done in such amanner that not more than 3 mills shall be clubbed in one set ofcontroller.e) For each of the functional groups, separate sets of controllers, I/Omodules, communication controllers, power packs/ modules etc.shall be provided. Mixing of hardware of two or more functionalgroups (FG) shall not be acceptable. It shall be ensured that failureof any set(s) of hardware of any FG does not affect other FG(s) anddata communication between other FG(s) and MMIPIS.ii)The control system shall have on-line simulation and testing facility.Further, it shall be possible to on-line configure and tune controllersthrough configuration and tuning station for control system.iii)The system shall have the flexibility to easily reconfigure any controllerat any time without requiring additional hardware or system wiringchanges and without disabling other devices from their normal operationmode. Modifications shall not require switching off power to any part ofthe system.iv) The executive programs for the controller modules shall be firmwarebased, which shall be non-volatile and shall not be alterable except byreplacement of parts. The application programs for the functionalcontrollers shall be software based or firmware based as per OEM'sstandard practice.v) All the 100% hot/redundant backup controllers shall be identical inhardware and software implementation to their corresponding maincontrollers and shall be able to perform all its tasks. The backupcontroller shall track its corresponding main controller. There shall be anautomatic and bumpless switchover from the main controller to itscorresponding backup controller in case of main controller failure and142
Standard Technical Features of BTG System for Supercritical 660/800 MW Thermal Unitsvice versa without resulting in any change in control status. In case ofswitchover from main controller to the 100% hot backup controller, theback-up controller shall work as the main controller.Facility shall also be provided for manual switchover from main to 100%hot back-up controller and vice versa from the programmer's console.17.2.4 Binary controls/open loop control system (OLCS) functioni) The OLCS shall include sequence control, interlock & protection forvarious plant auxiliaries, valves, dampers, drives etc. The sequencecontrol shall provide safe and automatic startup and shutdown of plantand of plant items associated with a plant group. The interlock andprotection system shall ensure safe operation of plant/plant items at alltimes and shall automatically shut down plant/plant items when unsafeconditions arise.ii) The OLCS shall be arranged in the hierarchical control structureconsisting of group level, subgroup level & drive level (as applicable).It shall be possible to perform automatic unit startup & shutdown byissuing minimum number of command from the OWS.The group level shall control a set of functional sub-groups of drives.Appropriate start-up and shut down commands shall be issued to the subgroupcontrol and various checkbacks shall be received from sub-groupsor drives. Each sub-group shall execute the sequential start-up and shutdown programmes of a set of inter-related drives along with systeminterlocks and protections associated with that sub-group as well as basicinterlocks and protections related to individual drive falling under thatsub-group. The drive level shall accept commands from the sub-groups,push buttons (wherever provided), etc., and transmit them to therespective drive, after taking into account various interlocks andprotections and the safety of that particular drive.iii)iv)A sequence shall be used to move a set of groups and sub-groups froman initial steady state (for instance 'OFF') to a final steady state (forinstance 'ON'). The sequence initiating command for the unit and grouplevel shall be issued from TFT/KBD.Manual intervention shall be possible at any stage of operation and thesequence control shall be able to continue at the correct point in theprogramme on return to automatic control. Protection commands shallhave priority over manual commands, and manual commands shallprevail over auto commands.v) Open or close priority shall be selectable for each drive.143
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