Power Plant Instrumentation and Control Handbook - Swapan Basu, Ajay Kumar Debnath

Power Plant Instrumentation and Control Handbook (eBook)

A Guide to Thermal Power Plants

Swapan Basu, Ajay Kumar Debnath (Autoren)

eBook Download: PDF | EPUB

2014 | 1. Auflage
942 Seiten
Elsevier Science (Verlag)
978-0-12-801173-7 (ISBN)

Covers systems in use in a wide range of power plants: conventional thermal power plants, combined/cogen plants, supercritical plants, and once through boilers
Presents practical design aspects and current trends in instrumentation
Discusses why and how to change control strategies when systems are updated/changed
Provides instrumentation selection techniques based on operating parameters. Spec sheets are included for each type of instrument.
Consistent with current professional practice in North America, Europe, and India

Swapan Basu is Chief Executive, Systems and Controls, Engineering and Consulting Kolkata, India. He has several decades of experience in practicing instrumentation & control systems for subcritical and supercritical thermal power plants, including combined cycle projects. Since 1979, he has led teams of engineers in India, Jordan, Singapore, South Korea, Syria, and the United States. He has a number of national and international technical papers to his credit.

The book discusses instrumentation and control in modern fossil fuel power plants, with an emphasis on selecting the most appropriate systems subject to constraints engineers have for their projects. It provides all the plant process and design details, including specification sheets and standards currently followed in the plant. Among the unique features of the book are the inclusion of control loop strategies and BMS/FSSS step by step logic, coverage of analytical instruments and technologies for pollution and energy savings, and coverage of the trends toward filed bus systems and integration of subsystems into one network with the help of embedded controllers and OPC interfaces. The book includes comprehensive listings of operating values and ranges of parameters for temperature, pressure, flow, level, etc of a typical 250/500 MW thermal power plant. Appropriate for project engineers as well as instrumentation/control engineers, the book also includes tables, charts, and figures from real-life projects around the world. Covers systems in use in a wide range of power plants: conventional thermal power plants, combined/cogen plants, supercritical plants, and once through boilers Presents practical design aspects and current trends in instrumentation Discusses why and how to change control strategies when systems are updated/changed Provides instrumentation selection techniques based on operating parameters. Spec sheets are included for each type of instrument Consistent with current professional practice in North America, Europe, and India

Front
1
Power Plant Instrumentation
4
Copyright 5
Dedication 6
Contents 8
Foreword 10
Preface 12
Acknowledgments 14
Chapter I - Introduction 16
1. INTRODUCTION 16
2. FUNDAMENTAL KNOWLEDGE ABOUT BASIC PROCESS 16
3. PROCESS PARAMETERS AND RANGES 47
BIBLIOGRAPHY 52
Chapter II - Main Equipment 54
1. OVERVIEW OF TYPES, FUNCTIONS, AND DESCRIPTION OF MAIN EQUIPMENT 54
2. STEAM GENERATOR: BOILER 57
2.4 BOILER DRUM: ITS PRESSURE PARTS WITH LOCATIONS 82
2.5 MISCELLANEOUS BOILER EQUIPMENT 88
3. TURBINE TYPES 90
4. GENERATOR 118
5. BOILER FEED PUMP AND CONDENSATE EXTRACTION PUMP WITH ASSOCIATED MEASUREMENTS 124
6. DEAERATORS AND HEATERS 128
7. FUNCTION AND DESCRIPTION OF CW AND ACW SYSTEMS 132
8. DEMINERALIZING PLANT'S FUNCTION AND DESCRIPTION 137
9. BASIC SYSTEM FUNCTIONS AND DESCRIPTION OF COAL HANDLING 147
10. BASIC SYSTEM FUNCTIONS AND DESCRIPTION OF ASH HANDLING 153
10.1 PROPERTIES OF ASH 154
BIBLIOGRAPHY 161
Chapter III - Plant P& ID Discussions
1. INTRODUCTION (P& ID)
2. MAIN STEAM (P& ID)
3. REHEAT STEAM (P& IDS): COLD AND HOT REHEAT
4. EXTRACTION STEAM (P& IDS): BLEED STEAM
5. AUXILIARY STEAM (P& IDS)
6. FEED WATER SYSTEM (P& ID)
7. CONDENSATE SYSTEM (P& IDS)
8. HEATER DRAIN AND VENT (P& IDS)
9. AIR AND FLUE GAS SYSTEM (P& IDS)
10. COGENERATION P& ID
11. MISCELLANEOUS OTHER SYSTEMS (P& ID)
BIBLIOGRAPHY 243
Chapter IV - General Instruments 244
1. INTRODUCTION 244
2. PRESSURE MEASUREMENT: VARIOUS MEASURING POINTS AND RANGE SELECTION 247
3. TEMPERATURE MEASUREMENT: VARIOUS MEASURING POINTS AND RANGE SELECTION 255
4. FLOW MEASUREMENT, VARIOUS MEASURING POINTS, VARIOUS TYPES, AND RANGE SELECTION 271
5. LEVEL MEASUREMENT 298
BIBLIOGRAPHY 310
Chapter V - Special Instrument 312
1. SPECIAL INSTRUMENTS 312
2. VIBRATION AND TURBOVISORY INSTRUMENTS 313
3. GAS ANALYZERS 340
4. STEAM AND WATER ANALYSIS SYSTEM 363
5. SAMPLE CONDITIONING SYSTEM 389
6. BLOW DOWN AND DOSING CONTROL 395
7. ANALYZERS FOR AIR POLLUTION MONITORING AND CONTROL (NOX CONTROL) 399
BIBLIOGRAPHY 400
Chapter VI - Final Control Element 402
1. VALVES AND ACTUATORS 402
2. CONTROL VALVE TYPES 420
3. DAMPERS AND MISCELLANEOUS OTHER FCES 429
4. ACTUATORS 434
5. ACCESSORIES 442
BIBLIOGRAPHY 455
Chapter VII - Intelligent Control System 458
1. BASICS (DISCUSSION ON INTELLIGENT NETWORK SYSTEM) 458
2. PLC SYSTEM: INTRODUCTION 491
3. ANNUNCIATION AND SEQUENCE OF EVENT: PREAMBLE 526
4. INTEGRATED DCS-DDC MIS: PREAMBLE 531
5. MMI AND RECORDING: INTRODUCTION 555
6. MIS: INTRODUCTION 587
BIBLIOGRAPHY 598
Chapter VIII - Boiler Control System 600
1. BASIC CONTROL REQUIREMENTS 600
2. STEAM PRESSURE CONTROL WITH LOAD INDEX 601
3. AIR FLOW CONTROL 604
4. FUEL FLOW CONTROL 610
5. COAL MILL CONTROL-MILL AIR FLOW FOR TT BOILER 619
6. FURNACE DRAFT CONTROL 633
7. DRUM-LEVEL AND FEEDWATER CONTROLS 637
8. SUPERHEATER TEMPERATURE CONTROL 643
9. REHEAT TEMPERATURE CONTROL 649
10. MISCELLANEOUS BOILER CONTROLS, INCLUDING OVERFIRE AIR DAMPERS 657
11. HP-LP BYPASS SYSTEM 679
12.0 BOILER OLCS: INTRODUCTION TO INTERLOCK AND PROTECTION OF BOILER BMS, SADC, AND SB CONTROL 688
BIBLIOGRAPHY 708
Chapter IX - Turbo Generator Control System 710
1. INTRODUCTION 710
2. ELECTRO HYDRAULIC GOVERNOR CONTROL SYSTEM 711
3. TURBINE PROTECTION SYSTEM 720
4. ATRS 723
5. ATT SYSTEM 728
6. THERMAL STRESS EVALUATOR 734
7. LPBP SYSTEM 736
8. TURBINE CONTROLS: SEAL STEAM PRESSURE CONTROL SYSTEM 739
9. HYDROGEN SEAL OIL SYSTEM AND DIFFERENTIAL PRESSURE CONTROL 741
10. GENERATOR CONTROL SYSTEM 747
11. CONDENSER LEVEL AND DEAERATOR LEVEL CONTROL SYSTEM 751
12. VARIOUS TG OPTIONS AND MISCELLENIOUS TG CONTROLS 754
BIBLIOGRAPHY 761
Chapter X - Coordinated Control System 764
1. INTRODUCTION 764
2. COORDINATE CONTROL MODE 766
3. TURBINE FOLLOW MODE 773
4. BOILER FOLLOW MODE 773
5. RUN BACK SYSTEM 774
6. DISCUSSIONS AND EXPLANATIONS 776
BIBLIOGRAPHY 781
Chapter XI - Balance of Plant Control System 782
1. BALANCE OF PLANT: INTRODUCTION 782
2. BFP RECIRCULATION CONTROL 782
3. CEP RECIRCULATION CONTROL 785
4. GSC MINIMUM FLOW CONTROL 789
5. DEAERATOR (PRESSURE) CONTROL 790
6. LP HEATER LEVEL CONTROL 793
7. HP HEATER LEVEL CONTROL 796
8. EJECTOR CONTROL AND TAS 798
BIBLIOGRAPHY 800
Chapter XII - Installation Practices 802
1. INTRODUCTION 802
2. PIPE VALVE FITTING MATERIAL SPECIFICATION AND RATING 811
3. MECHANICAL INSTALLATION OF INSTRUMENTS 814
4. ELECRICAL INSTALLATION OF INSTRUMENTS 830
BIBLIOGRAPHY 849
Appendix I - Process and Mechanical Standard Table 852
STANDARD PREFIXES 852
STANDARD UNITS 852
FLANGE DIMENSIONS 855
. VISCOSITY 859
DYNAMIC VISCOSITY 860
KINEMATIC VISCOSITY 861
BIBLIOGRAPHY 862
Appendix II - Electrical Data and Tables 864
MULTIPAIR INSTRUMENTATION CABLES: SIZE, RESISTANCE, AND OTHER PHYSICAL DATA 864
BIBLIOGRAPHY 873
Appendix III - ISA Standard, Materials, Human Engineering, and Control Room 874
1.0 ISA STANDARDS 874
2.0 MATERIAL COMPOSITIONS 875
3.0 ERGONOMIC CONTROL ROOM DESIGN CONCEPTS 877
BIBLIOGRAPHY 880
Appendix IV - Network Control and Communication 882
1.0 NETWORK CONTROL AND COMMUNICATIONS 882
2.0 FIBER OPTIC AND ASSOCIATED NETWORKS 882
3.0 ELECTROMAGNETIC SPECTRUM 882
4.0 LARGE INTEGRATED COMPUTER NETWORK 882
5.0 FIREWALLS 884
6.0 FAULT TOLERANT ETHERNET-AN APPROACH 885
BIBLIOGRAPHY 888
Appendix V - Super/Ultra Super Critical Power Plants 890
1.0 POWER PLANTS WITH SUPERCRITCAL AND ULTRA CRITICAL STEAM GENERATORS 890
2.0 SUPER AND ULTRA CRITICAL STEAM GENERATORS 892
BIBLIOGRAPHY 902
Appendix VI - Integrated Gasifier and Combined Cycle Plant (Pollution Control) 904
1.0 INTRODUCTION 904
2.0 BASIC PROCESS 904
3.0 CONTROL SYSTEM 909
BIBLIOGRAPHY 910
Appendix VII - A Few Operational Features of the Unit 912
1.0 INTRODUCTION 912
2.0 UNIT PROTECTION SYSTEM 912
3.0 HOUSE LOAD OPERATION 915
4.0 BUS TRANSFER SYSTEM (BTS) 916
BIBLIOGRAPHY 920
Index 922

Chapter II

Main Equipment

Abstract

The power plant is conceived as a “basic heat engine” comprising a boiler, turbine, condenser, boiler feed pump (BFP), generator, heaters, water treatment, coal/ash/oil-handling plant, condensate polishing unit (CPU), CW and ACW system, cooling towers, etc. Boilers incorporate subsystems like fuel, air/draft/feed water with auxiliaries such as pulverizers (solid fuels), fuel oil, FD/PA/ID fans, BFPs, etc. A turbine drives the generator with subsystems like turbine oil, turning gear, HP/LP bypass, gland sealing systems, governor and isolation valves, condenser, ejectors, electro hydraulic governing control, protection and testing, supervisory instrumentation, CPU, and CEPs. Generators are based on two major parts: the rotor working as a DC magnetic field rotating inside hollow stator. Generators are cooled with almost pure hydrogen gas with a sealing system by oil. Hollow stator conductors are cooled with ultra pure water.

Keywords

basic heat engine; EHG; fuel/air/water system; mill/pulverizers; offsite plants; pump and heating unit; regenerative heating cycle; thermal stress evaluation

1. Overview of Types, Functions, and Description of Main Equipment

Modern large thermal power plants have evolved as a result of years of research work, experience, and state-of-the-art technologies; however, the basic equipment and/or subsystems are more or less the same, of course, with a lot of sophistication and technological development to increase efficiencies.

There are five (5) fundamental elements, as shown in Figure I/2.1, that may be referred to for an overall idea at a glance; they are the following:

• Boiler

• Turbine

• Condenser

• Boiler feed pump

• Generator

Some other subsystems are, namely, the regenerative heating cycle or offsite packages such as a water treatment plant (demineralization and pretreatment), a coal-handling plant (CHP), an ash-handling plant (AHP), an oil-handling plant (OHP), circulating water (CW) and auxiliary circulating water (ACW) systems, a condensate polishing unit (CPU), and others. This clause briefly describes the functions of the preceding elements vis-à-vis the main equipment with important auxiliaries.

1.1. Boiler

A boiler is a combination of several items that is a means for combustion to provide energy to be transferred to water until it becomes heated steam that is then used for transferring the heat to the turbine. Water is used as the working fluid to transfer the heat to a process because it is not expensive. As a result of the tremendous volume change after the water is converted to steam, it needs careful handling. The main subsystems or system auxiliaries are divided into three (3) principal categories: fuel and air/draft system, feedwater (FW) system, and steam system; each has various supplementary items or equipment to make them suitable for use in large and modern power plants.

1.1.1. Fuel and Air/Draft System

The fuel and air/draft system includes all necessary auxiliary equipment required to make fuel available to create the necessary heat. The equipment needed for the fuel system depends on the type of fuel used in the system. The amount of fuel and air required for steam generation is automatically controlled per steam demand. Mills/pulverizes are used for solid fuels, pumping and heating units are required for liquid fuels, and compressor/boosters are required for gaseous fuels, of course with a suitable type of burner and air supply arrangements. Supplementary equipment and/or items are comprised of the following:

Mills/pulverizers: For solid fuels, mills and pulverizers are supplied with the main equipment so as to achieve higher thermal efficiencies and for spontaneous ignition through burning of finely powdered fuel. The type of mills and pulverizers depends on the type of fuels. Associated feeders and so forth are also a part of this subsystem.

Pumps and heating units: For liquid types of fuels, supply pumps are needed and heating units are also required for a viscous type of fuel such as heavy fuel oil (HFO)/heavy sulfur heavy stock (LSHS) and others.

Fuel burners: This category covers both oil and solid fuel with various designs—for example. low NOx burners. Burner type also varies with type of atomizer, etc.

Air flow control elements: These are, for example, forced draft (FD) air fans, primary air (PA) fans, air dampers or registers for fuel air, auxiliary/secondary air, overfire air, etc.

Draft system or flue gas system: These include induced draft (ID) air fans and various flue gas dampers for evacuating the product of combustion from the furnace.

Soot blowing system: Periodic cleaning of soot buildup, which damages boiler metals and causes inefficient operation, on the radiant furnace surfaces, boiler tube banks, economizers, and air heaters is accomplished using a soot blowing system that blows hot steam on a regular basis.

1.1.2. Feedwater System

The feedwater system provides necessary piping, heat exchangers to preheat water, a recirculation system (if so designed), and feed control valves to control the required amount to meet the steam demand.

Pressurized and preheated water supplied to the boiler as the working fluid to be converted into steam is popularly called feedwater in a normal running condition. There are two sources of feedwater: the major part is condensate that is nothing but condensed steam from the condenser and many other heat exchangers used in the processes; the minor part (3∼5%) is the continuous and/or intermittent makeup water (demineralized, DM water) that must come from outside of the boiler.

It also includes blowdown and chemical dosing systems to drain a part of the feedwater when it contains dissolved solids unacceptable to boiler metal, or a reason for scale formation that resists heat transfer causing localized overheating vis-à-vis boiler tube failure, foaming causing carryover to turbine, and so on.

Chemical dosing: This is done to clean the feedwater to avoid blowdown causing both heat and water loss making it slightly alkaline to minimize metal loss due to a chemical reaction.

Boiler circulating water system: In some plants, a boiler circulating water pump (BCWP) is deployed for better circulation of feedwater in the boiler with its suction connected to a steam drum and a discharge connected to a boiler water wall header. Furnace height may be reduced by having BCWP.

1.1.3. Steam System

The steam system includes evaporation of water up to superheating, reheating of cold steam (for a hot reheat system), collection and transfer of the steam through a piping system to the turbine. Throughout the system, excess steam pressure is regulated and/or vented through suitable valves automatically.

1.2. Turbine

The turbine accepts steam from the boiler at a high temperature and pressure, and converts the heat energy into mechanical energy for driving the generator. The following are the associated subsystems:

• Turbine oil system (lubricating, control, and power oil)

• Turning gear/barring gear

• HP/LP bypass system

• Governor and isolation valves

• Gland sealing systems

1.2.1. Turbine Oil System

This subsystem is one of the most important items; it supplies the lube oil to all the bearings, hydraulic control oil, jacking oil, and actuator power oil through individual oil coolers, strainers, redundant pumps, etc.

1.2.2. Turning Gear/Barring Gear

The turning gear (or barring gear) is basically a gear arrangement provided to rotate the turbine generator (TG) rotor shaft at a very low speed before turbine startup and after unit shutdown at low speed (∼1% of rated speed) by the turning the gear until the temperature comes down sufficiently.

1.2.3. HP/LP Bypass System

These subsystems are supplied to protect the boiler reheater from a burnout when no steam is passing through the turbine with the boiler generating steam during start up or running or tripped condition.

1.2.4. Governor and Isolation Valves

These valves are provided for both high- and intermediate-pressure turbines. Both are hydraulically operated and are special valves with high controllability and isolating capability, respectively.

1.2.5. Gland Sealing Systems

Turbine glands are a part of the turbine so that steam cannot escape from the higher pressure parts of it and air cannot enter the lower parts of the turbine. However, many parts of the turbine operate at such a high pressure that it cannot prevent leakage to the full extent. On the other hand, the lower pressure parts operate at a subatmospheric region so air ingress cannot be totally eliminated. This subsystem is provided to seal the glands in such a way that leakage of steam from the high side is controlled at a certain pressure and extra steam from the control valve outlet is diverted to the low-pressure (LP) side glands to arrest air ingress by maintaining a certain pressure.

1.3. Condenser

The function of condenser is to condense the steam coming from the turbine exhaust. High vacuum is maintained to extract steam and...

Erscheint lt. Verlag	10.11.2014
Sprache	englisch
Themenwelt	Technik ► Elektrotechnik / Energietechnik
Themenwelt	Technik ► Maschinenbau
ISBN-10	0-12-801173-4 / 0128011734
ISBN-13	978-0-12-801173-7 / 9780128011737

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