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HYDRO POWER GENERATION INDUSTRIAL TRAINING PRESENTATION ON presented by MD ABDUL RAHEMAN (10GAME1006) Under the guidance of M N SUNEETHA Executive Electrical Engineers Asst. Professor Respective sections Dept. of E and E Engineering K.P.C.L UVCE , Bengaluru 01 Bengaluru 01

Hydro electric power plant Automation

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Page 1: Hydro electric power plant Automation

HYDRO POWER GENERATIONINDUSTRIAL TRAINING PRESENTATION ON

presented by

MD ABDUL RAHEMAN(10GAME1006)

Under the guidance of

M N SUNEETHA Executive Electrical Engineers

Asst. Professor Respective sections

Dept. of E and E Engineering K.P.C.L

UVCE , Bengaluru – 01 Bengaluru – 01

Page 2: Hydro electric power plant Automation

1. Overview of SCADA:

General components of SCADA

system:

• Sensors

• Remote Terminal Units

• Master units

• Communication Links

• Software

Page 3: Hydro electric power plant Automation

General Functions of SCADA:

• Data Acquisition

• Supervisory control

• Plotting

• Alarms

• Logging

• Load shedding

• Load restoration

• Automatic generation control

Need for SCADA:

•To reduce total cost.

•To reduce man power.

•To reduce future capital requirements.

•To improve level of service.

•To avoid environmental accidents.

•To comply with regulatory

requirements.

•To attain and maintain competitive

edge.

•To replace existing aging systems.

•To manage complex systems

Page 4: Hydro electric power plant Automation

2. SCADA Configuration :

Fig 2 System overview of VUGPH

•UCB (Unit Control Board)

•CCB (Common Control Board)

•CRB (Control Room Board)

•SCB (Switchyard Control Board)

•Central Control Room Equipment

•Video over IP System

•Uninterruptable Power supply

Page 5: Hydro electric power plant Automation

i. Unit Controlled Board(U.C.B):Cubicle design:

DEVICE FUNCTION

15” Touch panel Main device for control and supervision

of the unit

Lamp (Green) North bus selected

Lamp (Orange) South bus selected

Lamp (Red) Circuit breaker close indication

Lamp (Green) Circuit breaker open indication

Lamp (Green) Indication for Readiness of unit operation

Lamp(Orange) Indication for Alarm

Lamp (Red) Indication for Trip

Push Button Alarm/trip reset

Push Button Horn reset

Push Button Lamp reset

Key operated cam switch Control point selector switch with 3

positions:

Local

Maintenance

Remote

Double Voltmeter For manual synchronization

Double Frequency meter For manual synchronization

Active power meter For MW

Reactive power meter For MVAR

Page 6: Hydro electric power plant Automation

Push button Emergency Shutdown Unit

Key operated cam switch Voltage raise/lower selector switch

spring return type

Selector switch Speed raise/lower selector switch spring

return type

Selector switch Synchronizing selector switch with 2

positions:

Auto : Synchronization in Auto

mode

Manual : Synchronization in

Manual mode

( Manual Synchronization is also

possible from CRB if UCB is in Remote

mode.

Selector switch Bus bar Selector switch with 2 positions:

North bus select in manual mode of

synchronizing

South bus select in manual mode of

synchronizing

Selector switch FCB open/close selector switch spring

return type

Selector switch Generator CB open/close selector switch

spring return type

SYN3000 For automatic and manual

synchronization

Page 7: Hydro electric power plant Automation

Functions of the UCB:

The controller of the UCB executes following software modules:

Control and Sequencing modules:

•Control modes and place of control

•Sequence control (automatic start and stop of the unit)

•Automatic & Manual synchronization

•Control of auxiliaries

Safety module:

•Alarm System

•Emergency trip system for mechanic faults (“mechanical protection”)

Temperature supervision

Page 8: Hydro electric power plant Automation

Control and Sequencing modules:

A . Place of control :

• Remote : Controlled from HMI in control room

• Local : at unit’s own unit control board

B. Control Mode :

• Auto mode

• Auto step by step mode

• Manual mode

C. Sequencing (automatic starting and stopping of the unit)

covers complete automatic control under normal conditions

provides fully automatic step by step control of TG set

includes control of all auxiliary equipments of TG set

Page 9: Hydro electric power plant Automation

D. Automatic & Manual Synchronization:

Provision for automatic and manual synchronization

Synchroscope , double voltmeter, double frequency meter and

open/close for the breakers will be provided

E. Control of unit auxiliaries:

The control and monitoring of unit auxiliaries such as:

• CW pumps motorized valves of CW system

• governor OPU pumps excitation system

• generator brakes Main inlet valve

•Monitoring of pre-conditions of each auxiliary

•Facility to select main & standby devices

•Automatic over depending on the duration of the operation or detection of any

alarm/trip signals,

Page 10: Hydro electric power plant Automation

Safety module:

All signals which are giving evidence of an abnormal condition in the plant, will be

processed in the safety module

The safety module comprises of the following functions:

A. Alarm system:

All external and internally created signals (e.g. temperature exceeded)

which are used in the safety module are treated as alarm

Every alarm signal causes an acoustic alarm and is displayed on the

touch panel.

B. Mechanical Trip System:

The mechanical trip system handles all mechanical fault conditions of the

unit, which require an emergency shutdown

All electrical failures are detected and processed by the electrical protection

system

Page 11: Hydro electric power plant Automation

One hardwired contact from unit electrical protection relays indicating internal

failure of any relay will be interfaced with the respective UCB.

These signals will be integrated in the trip scheme to create ESD.

Each signal which has to initiate an emergency shutdown

And is handled independently by the control system through mechanic trip

system within the safety module

It causes an alarm as well as a shutdown of the unit

additionally a normal stop sequence of the sequencing software will also be

initiated

Any trip has to be reset manually of the “trip reset” button after all fault signals

have disappeared and the unit has come to stand still.

The reset can be carried out from the HMI in control room “REMOTE” mode or

from the UCB in “LOCAL” mode either through the touch panel or by the push

button provided on the UCB.

Page 12: Hydro electric power plant Automation

C. Temperature Monitoring:

All temperature values are supervised up to four limits. The limits are split into two main

groups: Upper and lower limits as follows –

Limit Type Definition

Too High Trip “Temperature too high”

High Alarm “Temperature high”

Low Alarm “Temperature high”

Too low Starting prevention “Temperature too low”

Table 9.2 Temperature Limit Table

The mechanical safety module always compares the actual temperature values

with set limits and initiates the requisite action such as alarm or trip

Each temperature signals can be monitored on the HMI in the control room or

the touch panel on the UCB in form of a bar graph.

Page 13: Hydro electric power plant Automation

Hardwired logics:

In addition to the trip signals the emergency shutdown logic will be

implemented in hardwire also

Emergency shutdown can be initiated through the push button provided on

the respective UCBs and Control Room Board in the control room.

The emergency shutdown will work in case of failure of the UCB controller.

Sequence of Event Recording:

The binary input modules of the controller are capable of acquiring the data

with a resolution of 1ms

transmit the same spontaneously to the control system

This data along with the time stamp can be viewed in the “Chronological

Event List (CEL)” on the HMI in the control room and on the touch panel in the

UCB. This feature is available on other control boards also.

Touch Panel- Local HMI:

The UCB is provided with 15” touch panel mounted on the control board

for the purpose of local operation.

Page 14: Hydro electric power plant Automation

ii. Common Controlled Board(C.C.B): Cubicle design:

Device Function

15” Touch Panel Main device for control and

supervision of the unit

Lamp (Orange) Indication for alarm

Lamp (red) Indication for trip

Key operated cam switch Control Point selector switch with 2

positions:

Local

Remote

Push button Alarm trip/reset

Push button Horn reset

Push button Lamp test

The CCB configuration is the same as that of UCB

This component control all relevant plant facilities which are responsible for

common auxiliaries e.g. Drainage, dewatering, Air compressor, low voltage

system/switchgear, DG set, Battery etc

Page 15: Hydro electric power plant Automation

Functions of the Common Controlled Board(C.C.B):

Control and sequencing module:

• Control modes and place of control : The AUTO Step by Step control Mode is not

available for CCB.

• Sequence control (automatic change-over scheme)

• Control of station auxiliaries

Safety Module:

• Alarm system

Hardwired logics:

Interlocking of breaker operation to avoid paralleling of power sources at the

415V bus bar or at SSB or UABs will also be provided in hardwired logic in

the respective control panels.

Touch Panel- Local HMI:

The UCB is provided with 15” touch panel mounted on the control board for the

purpose of local operation.

Page 16: Hydro electric power plant Automation

iii. Control Room Board(C.R.B):

The control room board contains all equipment necessary for metering, network

node for different interfaces, NTP timeserver

A. CRB Configuration:

The CRB consists of

•GPS-NTP Timeserver

•Pushbuttons, emergency pushbutton for all the units operation

• Auxiliary devices, such as miniature circuit breakers, relays, terminals etc. as

required

B. Unit synchronization:

Provision for automatic and manual synchronization

Synchroscope , double voltmeter, double frequency meter and open/close for

the breakers will be provided

synchro-check function will be part of SYN-3000 synchronizer.

The breaker open/close commands will be hardwired to the CBs in the

SWITCHYARD and status of the CBs will also be monitored through

hardwired signals from the SWITCHYARD.

Page 17: Hydro electric power plant Automation

C. NTP Time Server:

For time synchronization of the whole automation system

Via GPS receiver and the Ethernet station bus the time server

synchronizes every single component using the Network Time Protocol

(NTP)

The antenna will be mounted at a suitable location in the open within a

distance of 50m from the GPS server.

Page 18: Hydro electric power plant Automation

iv. 220kV Switchyard Control Board:

The 220kV Switchyard Control Board contains all equipment, necessary for interfacing

with bay controllers and supervision of the 220kV Circuit Breakers and Isolators

A. Configuration: •1AK1703 ACP rack equipped with

•Redundant power supply

•Redundant processor modules

•Redundant control system Ethernet interface to the power plant station bus system for

communication to the other functional areas using optical fiber

•Hardwired input/output modules (non-redundant)

•Interface to bay controllers

•Interface to protection relays

•Interface for engineering tool access

•Push buttons, selection switches, emergency push button for local operation

•Auxiliary devices, such as miniature circuit breakers, relays, terminals etc. as required.

•Fiber optic converter for interfacing with bay controllers

•Control point selection switch

Page 19: Hydro electric power plant Automation

B. Functions of SCB:

The Switchyard Control Board is configured to execute the following functions:

Interfacing with bay controllers:

The SCB interfaces with the bay controllers over IEC 60870-5-103 protocol over a fiber

optic link

The SCB will acquire the data concerning status of various devices such as CB’s and

isolators, electrical parameters of respective feeders, abnormal conditions from bay

controllers

display the same on the HMI in the control room

The operator commands given at the HMI in the control room are passed on to the

respective bay controllers through the SCB

Page 20: Hydro electric power plant Automation

Inter bay operation:

The SCB will carry out the following inter bay operations:

•Bus bar changeover – performing the switching sequence for change over of entire bus bar

section by coordinating different bay controllers. The bay specific interlocks are part of the bay

controllers.

•Inter tripping connections across different bay level

•Inter-bay data logic, such as summed up events signal or calculated values.

•Operation of bus bar PT isolators.

Acquisition of Switchyard related data:

The SCB will be interfaced with the common field devices of the switchyard such as

auxiliary power supply and common switchyard signals.

Page 21: Hydro electric power plant Automation

Synchronization of line CBs:

Automatic synchronization of the CBs by the respective bay controllers depending on the

command issued from HMI in the control room.

The synchronization of the CBs is also possible from individual bay controllers switching

it to local mode

The bay controllers perform the synchrocheck function before closing the CBs

Based on the selection of the bus, the SCB switches the selected bus PT connection to the

bay controllers

The breaker open/close commands will be hardwired to the CBs in the Switchyard.

status of CBs will also be monitored through hardwired signals from the switchyard.

Alarm System:

The alarms from the bay controllers will be acquired by the SCB

And displayed on the HMI in the control room and on the touch panel

Every alarm signal causes an acoustic alarm and is displayed on the touch panel as well

as control room HMI in the alarm list.

Page 22: Hydro electric power plant Automation

v. Butterfly Valve Control Board:

The butterfly valve control board controls the operation of the butterfly valve.

A. Butterfly valve RTUs:

For tele-control of two Butterfly Valves, a RTU for each Butterfly Valve is

provided

The scope includes the data transmission and the hardwired I/O interfacing to the

primary control systems (i.e. transmission of position indications and up/down

pulses).

B. Control Board:

Consisting of 1 cubicle for each Butterfly Valve, each equipped with:

1 RTU with respective inputs and outputs

1 set of auxiliary devices (MCB’s, relays, terminals etc) as required

C. Interfacing of both BFV with SCADA

Interfacing of both with SCADA to VUGPH will be done by optical fiber cable through

Ethernet switches.

Page 23: Hydro electric power plant Automation

vi. START-STOP SEQUENCE:

A start-stop sequence is an inbuilt feature of SCADA

The sequencing of starting and stopping of the generating unit under normal, emergency,

controlled operation etc. is programmed in the processor of SCADA system (UCB).

The starting and stopping is executed in steps on obtaining the feedbacks of the previous

step and fulfilling of the preconditions only the next step will be executed.

A. Standstill Conditions:

When the Hydel plant is not in operation, there are some conditions which should be

fulfilled

which might result in the saving of energy which was used for operation of those

components.

Page 24: Hydro electric power plant Automation

•Cooling water pumps OFF

•Generator brakes OFF & Brake jack released

•220KV CB OPEN

•Excitation OFF

•MIV CLOSED

•BPV CLOSED

•MIV OPU OFF

•Turbine OPU OFF

•UGB Oil vapour exhaust OFF

•LGB Oil vapour exhaust OFF

•All 6 Needles CLOSED

•Transformer Oil Pump OFF

The standstill conditions are as follows:

These Conditions don't have any sequence

Any of the above conditions failing to respond, will lead to an alarm to the operators and

he can take appropriate actions.

Page 25: Hydro electric power plant Automation

B. Pre-conditions:

•ESD & QSD relays RESET

•Generator brakes OFF & Brake Jack release

•220kV Earth switch open

•220kV CB open

•Excitation OFF

•MIV closed

•BPV Closed

•Selector switch GEN/COND in generator position

•HPOS OFF

•CB(52G) Trip coin HEALTHY

•All 6 Deflectors CLOSED

•OPEN status of the MIV

•CW Pumps selection on HMI

Page 26: Hydro electric power plant Automation

•Following should be in remote mode:

HPOS motor

UGB vapour exhaust motor

LGB vapour exhaust motor

Transformer oil pumps

Pre-conditions for Turbine operation- No load operation:

•Turbine operation mode completed

•Excitation ready

•Transformer cooling oil pump ON

•Transformer Oil Flow OK

•Transformer Alarms/trips not active

•Transformer Cooling water flow OK

•220kV CB OPEN

Pre-conditions for No Load Operation-Line operation:

•No load operation mode completed

•North bus or South bus isolator CLOSE

•220kV CB not tripped/no alarms •220kV CB OPEN

Page 27: Hydro electric power plant Automation

C. Start Sequence:

Each step has to be completed mandatorily for the next step to be executed.

Each step is followed with a feedback

Different sensors are being installed at different parts for the required system to collect

the data and sent to the SCADA servers

If any of the above mention feedback is unavailable, the next start step will not be

activated and sequence will be shifted to Stop sequence automatically in an AUTO

operation.

For every step there are some pre conditions as well as the feedbacks

Without the preconditions getting fulfilled, it is not possible to start any step

For every step there is time supervision

If time taken is more than it is considered as fault and the Stop sequence is initiated.

Page 28: Hydro electric power plant Automation

START SEQUENCE

Command Pre-conditions Feedback

Start Step: 1

Turbine Oil Pump Unit On

Pre-condition for Standstill-

Turbine operation

Turbine Oil Pump Unit

Main/Standby feedback

Start Step: 2

MIV Oil Pump Unit ON

Step 1 completed MIV Oil pump Main/Standby

ON feedback

Start Step: 3

CW Pump ON

Step 1-2 completed CW Pump A/B/C ON feedback

Start Step: 4

Transformer Cooling Oil

pumps ON

Step 1-2-3 completed 1. Transformer pumps A/B

ON feedback

2. Cooling Oil flow fail

Start Step: 5

HPOS Motor ON

Step 1-2-3-4 completed

Start Step: 6

1. Start LGB Oil Vapour

Exhaust motor

2. Start Oil Vapour

Exhaust Motor

Step1-2-3-4-5 completed

Start Step: 7

1. Start Step Valve

2. BPV OPEN

All the steps 1-6 should be

finished with all the feedbacks

required.

Page 29: Hydro electric power plant Automation

Start Step: 8

Service seal Valve OPEN

Bypass valve OPEN Service seal valve OPEN

Start Step: 9

MIV OPEN

1. BPV OPEN

2. Service Seal Valve OPEN

3. No Service seal pressure

4. Pressure equalised

MIV OPEN

Start Step: 10

BPV CLOSE

1. MIV OPEN

2. Service Seal OPEN

BYPASS CLOSE

Start Step: 11

TG ON

1. MIV OPEN

2. Bypass CLOSE

3. TCOP ON

4. Transformer cooling oil

flow OK

1. Needles OPEN

2. Deflector OPEN

3. Rated speed

TURBINE OPERATION COMPLETED

Start Step: 12

Excitation ON

1. Turbine Operation

completed

2. Pre-conditions for Turbine

operation

3. No load operation

1. Check Generator voltage

should be equal to 11kV

2. No alarms from excitation.

NO LOAD OPERATION COMPLETED

Page 30: Hydro electric power plant Automation

Start Step: 13

Auto changeover UAP

Supply Preferential

1. No Load operation

completed

2. Pre-conditions for No

Load operation- Line

operation

3. UAP Preferential

supply healthy

4. UAP Preferential

5.Breaker control in

AUTO mode

1. UAP supply source

Preferential

2. UAP Supply healthy

3. UAP Non Preferential

Breaker OFF

4. Two CW Pumps

running

5. CW inlet pressure OK

6. CW flow OK

Start Step: 14

Auto synchronizer ON

1. 89N or 89S CLOSE

2. 89G CLOSE

3. CB OPEN

4. Earth Switch OPEN

220kV CLOSE

Start Step: 15

Power Control Mode

ON

GCB CLOSE 1. 220 kV GCB CLOSE

2. Machine synchronised

3. Active Power set point

is given to TG

4. Machine running at

Base load of 10 MW

Page 31: Hydro electric power plant Automation

D. Shutdown Sequence:

For every step to work it is necessary that all the feedbacks are proper. If any step is not

completed then the emergency shutdown of the system is carried out.

SHUT DOWN SEQUENCE

Command Pre-conditions Feedback

Stop Step: 1

1. Special Stop Command to TG given

2. Decrease the Load to 0 MW

220 kV CB CLOSE MW decreased to 0 MW.

Stop Step: 2

Decrease MVAR to minimum

220 kV GCB CLOSE MVAR reduced to 0

MVAR

Stop Step: 3

220 kV GCB OPEN

220 kV GCB OPEN 220 kV GCB OPEN

Stop Step: 4

Changeover of preferential supply to non-

preferential supply

1. 220 kV CB OPEN

2. UAP Non

Preferential

supply healthy

3. UAP Non

Preferential

Breaker healthy

4. AUTO Mode

1. Supply changed to

CAP

2. UAP preferential

breaker OPENS.

Page 32: Hydro electric power plant Automation

Stop Step: 5

Excitation OFF

220 kV CB OPEN Excitation OFF

Stop Step: 6

TG OFF

220 kV CB OPEN Excitation OFF

Stop Step: 7

MIV CLOSE

Needles and deflectors

CLOSE

MIV CLOSE

Stop Step: 8

SSV CLOSE

1. Needles and

deflectors CLOSE

2. SSV OPEN

SSV CLOSE

Stop Step: 9

HPOS Motor ON

Speed less than 240

RPM

HPOS motor ON

Stop Step: 10

Pneumatic Brakes OFF

Speed at 75 RPM Brakes applied feedback

from limit switches,

Stop Step: 11

MIV OPU OFF

Speed at 0 RPM Brakes applied feedback

from limit switches

Stop Step: 12

Start Stop Valve OFF

MIV OPU OFF MIV OPU Main & Standby

Pumps OFF

Stop Step: 13

Turbine OPU Pumps OFF

Stop Step 1-12

completed

Turbine OPU Pumps OFF

Stop Step: 14

Pneumatic Brakes OFF

Stop Step 1-13

Completed

Brakes Released feedback

from limit switches

Page 33: Hydro electric power plant Automation

Stop Step: 15

Auxiliaries OFF

Speed 0 RPM 1. CW pumps OFF

2. LGB Oil Vapour

Exhaust Motor

OFF

3. UGB Oil Vapour

Exhaust Motor

OFF

4. Transformer Oil

Pump OFF

5. GOV&MIV

OPU OFF

Page 34: Hydro electric power plant Automation

E. Sequence for Quick Shut Down (QSD):

In this first reduce the load to base load (5MW) by closing the needles and deflectors

and then trip the unit

If the feedback for MW=5 is not received within 20seconds, then system

doesn’t wait anymore, but issues ESD command.

Sl No. Conditions

1 Temperature of generator hot air is very

high

2 Temperature of generator cold air is very

high

3 Main pilot line filter is 75% clogged

4 Oil pressure is too high or too low in oil

pressure tank

5 Oil level is too low in oil pressure tank

Following are the conditions for QSD:

Table 9.10 Conditions for QSD

Page 35: Hydro electric power plant Automation

Fig 9.3 Sequence for QSD

Page 36: Hydro electric power plant Automation

F. Sequence for Emergency Shut Down:

S. No. CONDITION

1 Temperature of Stator winding is very high

2 Temperature of any generator core is very high

3 Temperature of any generator tooth is very high

4 Unit protection system fault occurs

5 Unit protection DC supply failure

6 Oil level of upper bearing very high

7 Fault in UCB processor

8 Generator Backup Earth fault protection

9 Cooling water pump trips

10 Vibrations in the guide bearing are too high

Table 9.9 Conditions for ESD

Page 37: Hydro electric power plant Automation

Fig 9.2 Sequence for ESD

Page 38: Hydro electric power plant Automation

vii. Relay Protection

Fig Protection scheme for generator

Page 39: Hydro electric power plant Automation