Emerson Power plant applications

1. Power Plant ApplicationsPower Plant Applications Nigam SharmaNigam Sharma Sr. Regional Manager, Asia PacificSr. Regional Manager, Asia Pacific

2. AgendaAgenda  Power Plants Over View  Main Components of a Power Plant  Typical Controls Applications

3. Types of PlantsTypes of Plants  Thermal Power Plants  Coal Fired Utility  Oil and Gas Fired Plants  Bio-fuel Plants  Gas Turbine Plants  Gas and Oil Fired  Simple Cycle Gas Turbine Plants  Combined Cycle HRSG and Steam Turbine Plants (CCP)  Cogeneration Plants (Industrial or District Heating)  Oil & Gas Fired CCP  Bio-Fuel CFB plants  Nuclear Plants √√ √√ √√ XX

4. Thermal Plant OverviewThermal Plant Overview 1. Cooling Tower 2. Cooling Water Pump 3. 3-phase Transmission Line 4. Unit Transformer 5. 3-phase Electric Generator 6. Low Pressure Turbine 7. Boiler Feed Pump 8. Condensor 9. Intermediate Pressure Turbine 10. Steam governor valve 11. High Pressure Turbine 12. Deaerator 13. Feed Water Heater 14. Coal Conveyor 15. Coal Hopper 16. Pulverised Fuel Mill 17. Boiler Drum 18. Ash Hopper 19. Superheater 20. Forced Draught Fan 21. Reheater 22. Air Intake 23. Economiser 24. Air Preheater 25. Electrostatic Precipitator 26. Induced Draught Fan 27. Chimney Stack

5.  Boilers or Steam Generators  Generate steam at desired rate, pressure and temperature by burning fuel in its furnace.  The boiler is that part of the steam generator where phase change (or boiling) occurs from liquid (water) to vapour (steam), essentially at constant pressure and temperature.  Steam Turbine  Steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into useful kinetic (rotational) energy which rotates the steam turbine.  Most steam turbines rotate at 3000 rpm or 3600 rpm.  Electric Generator  Electrical generator is a device that converts kinetic energy to electrical energy, generally using electromagnetic induction.  Electric Generators are rotated by Steam Turbines at 3000 rpm or 3600 rpm Major ComponentsMajor Components

6. Bottom Ash System Economizer Hoppers F D FanGeneral Water Sump BOTTOM ASH HOPPER Settling Pond WATER TREATMENT Coal Bunker Conveyors Pulverizers Load Gen.HP IP L P Turbine Econ- omizer Re- Heat Super Heater DRUM Condenser P A Fan ID Fans HP FW Htr LP FW Htr Ash Transfer Water Clean-up Precipitators Stack Gas Scrubber Emissions Monitor Flyash Cond. Pump BFP Deaerator Cooling Water Feeder Downcomers Risers Air Heater Power Plant Process MapPower Plant Process Map Water Vapor & Scrubbed Gases

7. Basic Boiler TypesBasic Boiler Types  Up to an operating pressure of around 190Kg Bar in the evaporator part of the boiler, the cycle is Sub-Critical. In this case a drum-type boiler is used because the steam needs to be separated from water in the drum of the boiler before it is superheated and led into the turbine.  Above an operating pressure of 220Kg Bar in the evaporator part of the Boiler, the cycle is Supercritical. The cycle medium is a single phase fluid with homogeneous properties and there is no need to separate steam from water in a drum. Drumless or Once- through boilers are therefore used in supercritical cycles.  Advanced Steel types must be used in Supercritical boilers for components such as the boiler and the live steam and hot reheat steam piping that are in direct contact with steam under elevated conditions  Sub-critical Boilers: Steam conditions up to 220Kg bas/ 540°C are achieved  Supercritical Boilers: Steam conditions up to 300 Kg Bar/600°C/620°C are achieved using steels with 12 % chromium content.

8. Supercritical Once Through Power PlantSupercritical Once Through Power Plant  Power Generation Cycle Efficiency primarily depends on the temperature difference across steam turbine.  Higher boiler outlet temperature results in higher difference.  Higher steam temperatures is also linked to increased pressures to keep the steam volume within manageable limits.  At pressures in excess of 220Kg bar, the fluid is termed supercritical.  The increased pressure also increases cycle efficiency and, although this increase is a second-order effect compared with the effect of temperature, but it can still make an important contribution to increasing overall plant efficiency.  “SupercriticalSupercritical" is a thermodynamic expression describing the state of a substance where there is no clear distinction between the liquid and the gaseous phase (i.e. they are a homogenous fluid). Water reaches this state at a pressure above around 220 Kg Bar.

9. Supercritical Once Through Power PlantSupercritical Once Through Power Plant  Supercritical coal fired power plants have higher efficiencies of almost 45%  Supercritical Power plants have lower emissions than subcritical plants at any given power output.

10. Various Boiler TypesVarious Boiler Types

11. HP FW HTR LP FW HTR HP L PSecondary Super Heater Power Plant ProcessPower Plant Process MapMap Once-Thru Boiler BFP Water Vapor & Scrubbed Gases Load Gen. Turbine Econ- omizer Re- Heat Condenser ID Fan Precipitators Stack Gas Scrubber Emissions Monitor Flyash Deaerator Cooling Water Bottom Ash System Economizer Hoppers F D Fan Settling Pond Ash Transfer Water Clean-up Cond. Pump General Water Sump Coal Bunker Conveyors Pulverizers P A Fan Feeder Primary Super Heater IP Air Heater BOTTOM ASH HOPPER

12. Circulating Fluidized Bed BoilersCirculating Fluidized Bed Boilers  A bed of sand, ash and fuel particles is fluidized by the combustion air, which is blown into the bed through the bottom.  Due to high air/flue gas velocity the fuel is carried over in the combustion gases.  The solid material is then separated in a cyclone and recycled to the lower section of the bed.  CFB combustion process is ideally suited to burning  low-quality fuels,  fuels with a high moisture content  'waste-type' fuels.  All coals, lignite, petroleum coke, biomass, waste coal, refuse-derived fuels, agricultural and pulping waste, and municipal solid waste

14. Typical Large Steam TurbineTypical Large Steam Turbine  Steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into useful kinetic (rotational) energy by expansion.  The expansion takes place through a series of fixed blades (nozzles) and moving blades.  The moving blades rotate on the turbine rotor and the fixed blades are concentrically arranged within the circular turbine casing which is substantially designed to withstand the steam pressure.  Most steam turbines rotate at 3000 rpm or 3600 rpm.

15. Basic Steam TurbinesBasic Steam Turbines  The Turbine designs for a Supercritical plant are similar to the sub-critical except that special materials required for the casings and walls for withstanding high Temperatures and pressures in Supercritical Steam Turbines.  High Pressure (HP) Turbine: In order to cater for the higher steam parameters in supercritical cycles, materials with an elevated chromium content which yield higher material strength are selected.  Intermediate Pressure (IP) Turbine Section: In supercritical cycles there is a trend to increase the temperature of the reheat steam that enters the IP turbine section in order to raise the cycle efficiency. As long as the reheat temperature is kept at 560 DEGC there is not much difference in the IP section of Sub critical and Super Critical plants.  Low Pressure (LP) Turbine Section: The LP turbine sections in supercritical plants are not different from those in subcritical plants.

16. Combined Cycle PlantsCombined Cycle Plants  Term Combined Cycle is used to describe process that uses combination of more than one thermodynamic cycles.  Combined Cycle Power Plant (CCPP) means a combination of gas turbine generator (Brayton cycle) with turbine exhaust waste heat boiler and steam turbine generator (Rankine cycle) for the production of electric power.  CCPP Common Combinations  One CT and One Steam Turbine (1 on 1)  Two CTs and One Steam Turbine (2 on 1)  X CTs and Y STs (X on Y)  CTs always paired with a HRSG  2 on 1 common - all generators work out to be comparable size

17. Simple Cycle Combustion (Gas) TurbineSimple Cycle Combustion (Gas) Turbine Thermal Efficiency = 35-40% 35-40% Electricity Generator 3% Aux. Power + Losses Air 100% Fuel Combuster Stack 57-62% Compressor Turbine

18. Combined Cycle Power GenerationCombined Cycle Power Generation Thermal Efficiency = 45-55% 35-40% Electricity Generator 6% Aux. Power + Losses Air 100% Fuel Combuster Stack 20% Compressor Turbine 28%Steam Condenser HRSG Steam Supplementary Fuel (Optional) Exhaust Gas Steam TurbineGenerator 12-15% Electricity Lake

19. Typical Combined Cycle PlantTypical Combined Cycle Plant Gas Supply Station Gas Supply Gas Turbine Stack Heat Recovery Steam Generator HRSG Stack Generator Transformer Transmission Deaerator Boiler Feed Pump Cooling Towers Condensate Extraction Pump Generator Transformer Transmission Gas Turbine IP LP Generator Cooling Water Switch Yard Demineralization Plant Raw Water FW FW Switch Yard Air Intake Condenser Bypass Damper

20. Most Common Combined CycleMost Common Combined Cycle – 2 on 1 Process– 2 on 1 Process Air Air GT GT HRSG HRSG ST Gen Gen Gen Steam Steam Stack Gas Stack Gas Legend GT – Gas Turbine Gen - Generator ST – Steam Turbine HRSG – Heat Recovery Steam Generator

21. Common Cogeneration PlantsCommon Cogeneration Plants  Cogeneration is the simultaneous production of power/electricity, hot water, and/or steam from one fuel.  Cogeneration plants can reach system efficiencies exceeding 80%  Industrial Plants  Multi utility plants; Electricity, Process Steam, Heating Steam, Hot water, Chillers etc.  District Heating Plants  Extraction steam for residential heating  Oil or Gas fired  Combined Cycle Cogen  Conventional Boilers Cogen  Circulating Fluidized Bed Boilers Low Calorific Value, high moisture, low Sulphur fuels Bagasse, Rice husk, Rice Straw, Wood Chips etc

22. Industrial Co-GenerationIndustrial Co-Generation Bagasse Rice Husk Rice Straw Wood Chips Etc. Thermal Efficiency = 80%

23. District HeatingDistrict Heating 15% Steam Stack Air 15% Electricity Boiler Steam Turbine Generator 5% Aux. Power + Losses Heat Exchanger 55% Steam Condenser 10% Losses Feedwater Loop Thermal Efficiency = 70%

24. Power Plants ControlsPower Plants Controls CapabilityCapability

25. Typical Boiler Plant Control FunctionsTypical Boiler Plant Control Functions  Fuel Management  Fuel control  Mill control  Burner Safety & control  Air Management  Fans Control  Steam temperature Management  SH Steam Temp Control  RH Steam Tem Control  Feed Water Management  Boiler Drum Level Control  Deaerator Level Control  Soot Blower Controls  Emission Management

26. Typical Steam Turbine Control FunctionsTypical Steam Turbine Control Functions  Speed loop Control  MW loop Control  Speed or MW demand and rate selections  Initial MW pickup  1st stage pressure loop  Load limiting  Inlet pressure limiting (adjustable)  Fail safe turbine trip design  Valve testing & Valve calibration  Individual valve curves  Critical Overspeed detection & protection  Hotwell Level & Condensate extraction Controls  HP & LP Bypass Controls  HP & LP Heater level Cascade Controls  Gland steam Press control  Turbine Stress Calculations  Turning Gear Controls  Main Oil, Safety Oil Pumps Control  Seal Oil Pumps  Extraction controls

27. Typical CCPP Control FunctionsTypical CCPP Control Functions  HRSG (Heat Recovery Steam Generator) Boiler Controls  Un-fired HRSG Bypass Damper Control Feedwater - Drum Level Control Live Steam Temperature Control Turbine Bypass Control Deaerator Level Control Hotwell Level Control Advanced Controls  Fired HRSG (additional controls) Fuel Controls Air Control Burner Management Temperature Control  Gas Turbine Controls  In most cases GT controls are supplied by OEM

28. Typical Balance of Plant ControlsTypical Balance of Plant Controls  Balance of Plant Controls (Miscellaneous Controls)  Water Treatment Plant Controls  Circulating Water System  Raw Water system  Turbine Cooling Oil Temperature Controls  Generator Cooling Oil Temperature Controls  Ash Handling System Controls  Fuel Handling Systems Fuel Skid Controls (CCPP) Coal Handling System Controls  Environmental Controls Flue Gas De-Sulphurization Controls Scrubber Controls  Motor Controls  Electrical Controls & Monitoring

29. Basic level:  Single drive control with electrical protections, auto/manual modes  Single loop control with protection of actuators, auto/manual modes  Interlocks between the control loops and drives Control of technological groups for Boiler and Turbine:  Coordinated loops control (common setpoint, interactions)  Cross interlock feedbacks and priorities  Sequences  Turbine start-up, roll-off, and other turbine coordinated controls  Burner Management System Coordinated Unit Control:  LDC - Load Demand Computer - selection of boiler / turbine modes  Unit remote control from Dispatch Center  Main unit control sequences  Run-backs & Run-ups Concept of a Unit ControlConcept of a Unit Control

30. Binary Control Drive Control Standards for:  low voltage motors  high voltage motors  open/close valves or dampers  electrical actuators Sequential Control Features of a sequence:  consists of a sequence head and sequence steps  sets time relations between performed steps  allows start, stop and resume by operator  incorporates emergency logic and procedures  incorporates interaction logic and operator’s permissives Concept of a Unit ControlConcept of a Unit Control

31. Modulating Control  Control Structures:  Basic level - single loop executing a direct control of actuator  Cascade level calculating setpoint for basic level loop  Coordinating level responsible for unit load and cross feedbacks between parts of the unit  Supervisory optimization structure, which calculates corrections for other control loops, based on feed-forward and Smith prediction philosophy  Control Algorithms:  Mathematical algorithms  Universal PID type (PID, PIDFF)  Dedicated for power applications: Smith predictor, drum level correction, steam table, PID with variable parameters  Value tracking for bumpless transfer during auto / manual switch  Advanced algorithms Concept of a Unit ControlConcept of a Unit Control

32. Coordinated Unit ControlsCoordinated Unit Controls

33. Coordinated Unit ControlsCoordinated Unit Controls ADS Interface Unit Master Boiler Master Fuel Master Air Steam Temp Feedwater Boiler Turbine Turbine Master Mill 1 Mill n ID Fans FD Fans Furnace Draft S-heat Spray R-heat Spray BF- Pump Turbine Valves Load Demand

34. Front End Front End SystemFront End System ADS Interface Unit Master Boiler Master Fuel Master Air Steam Temp Feedwater Boiler Turbine Turbine Master Mill 1 Mill n ID Fans FD Fans Furnace Draft S-heat Spray R-heat Spray BF- Pump Turbine Valves Load Demand

35. ADS Interface Fuel Master Air Steam Temp Feedwater Boiler Turbine Front End Mill 1 Mill n ID Fans FD Fans Furnace Draft S-heat Spray R-heat Spray BF- Pump Turbine Valves Load Demand Load Demand Computer (LDC) Load Demand ComputerLoad Demand Computer

36.  Invented by Westinghouse for coordinated unit control  Allows to control a unit in different modes of operation:  Turbine Follow Mode: Turbine control with throttle pressure – The turbine follows the boiler load, LDC tracks the actual unit load and calculates setpoint for the boiler (MW loop is not in use)  Boiler Follow Mode: Boiler control with live steam pressure – The boiler adapts the steam generation to the consumption required by the turbine, LDC tracks the actual unit load and calculates the setpoint for turbine valve position (MW loop is not in use)  Coordinated Control Mode: Either turbine or boiler controls live steam pressure and boiler or turbine respectively (MW loop is in use for turbine or boiler) Load Demand ComputerLoad Demand Computer

37.  LDC is a software model of the process, which calculates on-line all required control setpoints using “feed-forward”  Operator sets the required load or MW demand  LDC calculates the main setpoints separately for the boiler and the turbine control structures  The structure for boiler recalculates setpoints for loops controlling air and fuel  Tunable function generator algorithms calculate setpoints for loops controlling the actuators  LDC allows to keep unit in automatic control also during runbacks or trips Load Demand ComputerLoad Demand Computer

38.  Four Modes  Coordinated  Turbine Follow  Boiler Follow  Manual (separated)  Bumpless transfer between all modes  Interlocks prevent Unit Master from controlling unless either Boiler or Turbine Master in Auto  Rate limiting on ramped signals Load Demand ComputerLoad Demand Computer

40.  Turbine Master (Fixed Pressure)  regulates turbine to satisfy megawatt demand  Recognizes boiler’s response capabilities Turbine MasterTurbine Master

41.  Turbine Master (Variable or Sliding Pressure)  Alternative to fixed pressure mode  Throttle pressure varied with load while turbine valves remain in fixed position  Valves allowed to move on load changes for fast response  Throttle pressure allowed to vary to maintain proper valve position  Not suitable for all boilers Turbine MasterTurbine Master

42.  Boiler Master  Sets boiler firing rate  Interlocked to lower control loops  Dynamic control to improve responsiveness  Runbacks and rundowns based on boiler capabilities Boiler MasterBoiler Master

43. ADS Interface LDC Boiler Master Fuel Master Air Steam Temp Feedwater Boiler Turbine Turbine Master Mill 1 Mill n ID Fans FD Fans Furnace Draft S-heat Spray R-heat Spray BF- Pump Turbine Valves Load Demand Fuel MasterFuel Master

44. FuelFuel MasterMaster  Fuel Master  Develops base control signal for coal mills  Performs fuel/air cross limiting  Incorporates a mill model to improve coal flow measurement  Uses boiler as calorimeter

45. FuelFuel MasterMaster  Mill Controls  Regulates coal flow  Regulates primary air flow  Regulates coal/air temperature leaving mill  Feeder overrides on high mill amps and/or mill differential pressure  Primary air flow takes priority over coal/air temp.  Includes interlocks to air dampers for safety and interface to BMS

46. ADS Interface LDC Boiler Master Fuel Master Air Steam Temp Feedwater Boiler Turbine Turbine Master Mill 1 Mill n ID Fans FD Fans Furnace Draft S-heat Spray R-heat Spray BF- Pump Turbine Valves Load Demand

47. Air FlowAir Flow ControlControl  FD Fan Control  Controls combustion air flow  Firing rate sets air flow requirement  Includes damper interlocks  Interlocked to ID fans for auto mode  Includes fuel/air cross limiting (O2 trimming)

48. Air FlowAir Flow ControlControl  Furnace Draft Control  Regulates ID fans to provide proper exhausting force for gas flow through boiler  Uses FD fan demand as feedforward  Utilizes three furnace pressure transmitters (middle-of-three) for control  Fully meets NFPA requirements for: Rapid closing of ID inlet dampers on MFT Directional blocking on low furnace pressure  Includes damper interlocks for starting/stopping

50. FeedwaterFeedwater ControlControl  Feedwater Control  Regulates feedwater flow and controls drum level  Two modes of operation Single element for use during startup Three element for normal operation  Drum level signals are density compensated

51. Drum levelDrum level ControlControl

53. SteamSteam TemperatureTemperature  Superheat Temperature Control  Regulates main steam temperature  Standard consists of two stage attemperation  Includes integral windup protection  Includes interlocks for spray and block valves

54. SteamSteam TemperatureTemperature  Reheat Temperature Control  Regulates reheat steam temperature thru the use of sprays & burner tilting arrangement  System tracks until spray valve open  Interlocks for both spray and block valves included

55. Furnace 2 nd S.H. PID PID PID PID X Firing Rate Boiler Master Desired Spray (20%) WW Outlet Temp LDC Out Econo mizer Fuel/Air 4th S.H. 3rd S.H. PID FW Flow Control FW/FR ratio DMC Algorithm SUM RH Tilts/Damper Setpoints 2nd , 3rd and 4th SH 1st S.H. APC Steam Temperature ControlAPC Steam Temperature Control SchemeScheme

56.  A Safety System  Permits safe start-up, operation, and shutdown of the boiler  Supervises Fuel insertion/withdrawal from boiler conforming to established safety standards  Monitors and controls igniters and burners  Separate Flame Scanners used to detect igniter and main flames  Three type of flame scanners  Ultraviolet, typically used for natural gas and light oils  Infrared, typically used for medium to heavy oils and pulverized coal  All Fuels, typically used with gas igniters & coal as main fuel  Other Field Devices  Safety shut-off valves  Pressure, temperature, flow & valve position limit switches  Blowers to cool scanners or provide combustion air for igniters Burner Management SystemBurner Management System DefinitionDefinition

57.  Critical safety signals are wired as redundant I/O for maximum boiler safety.  An automatic start sequence ensures correct completion of boiler air purge and satisfies safety permissives before fuel firing, preventing operator error.  Continued monitoring of boiler conditions actuates a safety shutdown trip if unsafe conditions develop.  Operator maintains control capabilities from the operator console or burner front digital logic stations.  First-out indications are provided for identification of the cause of boiler trip  Automatic Boiler Purge Prior to Restart  Flame Detection, Monitoring & protection  Master Fuel Trip  Burner/Mill Start-Up and Shutdown  Sequences  Safety Interlocking  Alarming of Abnormal Conditions Burner Management SystemBurner Management System

58.  6 to 8 Pulverizers (Mills) needed in each boiler to supply Pulverized coal to the burners  One mill normally supplies pulverized coal to one burner level. Additional mills supply each additional burner level on a one-for-one basis.  There are between four and eight burners per level. This depends upon the type of furnace, e.g. wall fired, tangential, split furnace, etc.  With dual fuel firing, there will also be oil guns /gas nozzles on one or more burner levels. There will be four to eight guns / nozzles per level. Mills, Burners and LevelsMills, Burners and Levels

59. Burner ArrangementsBurner Arrangements Wall-Fired Tangential Corner-Fired Slag Crushed Coal Air Secondary Furnace Primary Furnace Cyclone (B&W Exclusive)

60. Burner ArrangementsBurner Arrangements Multiple Elevations To other burners this elevation Drive Motor Pulvorizer or ‘Mill’ Feeder Coal Bunker Air in Boiler One of six; one per burner elevation

61. The Burner "Front"The Burner "Front" Startup Sequence (Light-off by burner pairs) - Purge air-10 Minutes - Purge air Off - Open Dampers - Ignition Spark ON - Ignition Valve OPEN - Prove Igniter ON - Main Fuel ON - Prove Main Flame ON - All Ignition OFF on Combustion Control Fuel Ignition Transformer Igniter Damper Damper Purge Air Main Burner Ignition Flame Main Flame Ignition Flame Det. Main Flame Det Cooling Air Wind Box

62.  Enhanced safety and availability  Greater operational flexibility  Significant auxiliary fuel savings  Continuous safety monitoring  Consistent start-up and operation  Full integration of all facets of the firing system  Integrated Air damper controls  Improved plant availability  Reduced maintenance costs  Prevention of boiler explosion  NFPA 8502 code compliance  Expandable solutions Ovation BMS FeaturesOvation BMS Features

63. Turbine Master Boiler Master Feedwater Combustion Fuel Valve FD Fan ID Fan Pump (Turbine) Pump (Shaft) Pump (Standby) Load Demand Computer High Limit Low Limit Ramp Rate Operator Set Limits Runbacks Rundowns Block Increase Block Decrease Contingency Digital Control LocalRemote Valve Positioner Pass Dampers Spray Steam Temp. Steam Turbine ControlsSteam Turbine Controls

64. Ovation Turbine Control ArchitectureOvation Turbine Control Architecture  Redundant systems  - Processor - I/O interface  - Power supplies - Network interface  System same as rest of plant  Controller hardware and I/O  User Interfaces  Network  Standard I/O cards for specialized turbine applications  Speed cards  Valve cards

65. Turbine Control Requires Specialized I/OTurbine Control Requires Specialized I/O  Speed Detector Module  Valve Positioner Module  Servo Driver Module

66. Speed Detector ModuleSpeed Detector Module  5ms update rate for overspeed detection  Variable update rate for speed regulation  Controller-independent speed detection and tripping using dual on-board form C outputs for fast reaction to over speed conditions  Open-wire detection for low resistance source less than 5000 Ohms  Redundant power feeds  1000V dielectric withstand electrical isolation between logic signal and field inputs  Hot swap capability

67.  Self calibrating & Self Diagnostics  PI control loop with 10 millisecond loop time  Programmable PI gain and integral time constants  Normal mode or SLIM interface for local manual operation  Up to three redundant servo valve actuator coil drive outputs  Supports redundant coil and redundant LVDT capability (Redundant configuration)  Interfaces to LVDT interface to primary excitation and dual secondary feedback windings  24/48V dc input for emergency valve closure independent of controller  16 bit micro-controller watchdog timer for servo valve actuator coil drive  Supports single mode (full arc) or sequential (partial arc) modes of valve operation  Watchdog timer for I/O bus  Redundant configuration option  Redundant 24V power auctioneering  Local calibration & tuning capability without trim pots  Open-coil and shorted-coil diagnostics  Runs seating and back-seating logic Valve Positioner ModuleValve Positioner Module

68.  Self calibrating & Self Diagnostics  PI control loop with 10 millisecond loop time  Programmable PI gain and integral time constants  Normal mode operation only 2 servo valve actuator coil drive outputs  Supports redundant coil and dual LVDT capability.  2 DC-LVDT or AC-LVT outputs & 2 DC-LVDT or AC-LVT inputs  16 bit micro-controller  Watchdog timer for servo valve actuator coil drive  Watchdog timer for I/O bus  Redundant feedback option for AC-LVT  Redundant 24V power auctioneering  Local calibration & tuning capability without trim pots  Open-coil and shorted-coil diagnostics  Runs seating and back seating logic  Hot swap capability Servo Driver ModuleServo Driver Module

69.  Main Stop Valves or Throttle Valves, used primarily during start-up, machine protection  Governor Valves or Control Valves, control the turbine over most of the operating range  Reheat Stop Valve, on-off type valve to backup the intercept valve  Intercept Valve, used to prevent steam from entering turbine after load loss  Full Arc Admission / Partial Arc Admission  Single Valve Mode / Sequential Valve Mode Steam Turbine Valve TerminologySteam Turbine Valve Terminology

70. Governor Control FunctionsGovernor Control Functions  Control of:  Turbine stop valves  Control valves  Reheat stop valves  Intercept valves  Monitor & Control of:  Speed  Main steam pressure  Chest pressure  1st stage pressure  Reheat pressure  Load

71. Typical Large SteamTypical Large Steam TurbineTurbine HP TURBINE IP TURBINE LP TURBINE SPEED SENSING CONTROL SYSTEM CONTROL INPUT STEAM GEN INTERCEPT VALVE(S) REHEAT STOP VALVE(S) REHEAT AND/OR MOISTURE SEPARATOR CONDENSER (W) GOVERNOR/ (GE) CONTROL VALVE(S) (W) THROTTLE/ (GE) STOP VALVE(S) CROSSOVER GENERATOR GENERATOR BREAKER

72. 1 3 5 2 6 3 5 1 2 4 6 4 Main Steam Supply Governor/ Control Valves Governor/ Control Valves Throttle/ Stop Valve 1 Throttle/ Stop Valve 2 Nozzle Block Full Arc / Single Valve Mode = All Governor/Control Valves opened together Partial Arc / Sequential Valve Mode = Governor/Control Valves opened independently Steam Flow Through Nozzle BlockSteam Flow Through Nozzle Block

73. Typical Startup and Loading ProgramsTypical Startup and Loading Programs  Pre Warm  Pre Roll Conditions  1st Stage Shell Metal Temp Change  Hot Reheat Temp Change  HP allowable Ramp Rate  Reheat allowable Ramp Rate  1st Stage Shell Steam Temp  Speed Soaks (1000, 3000 and 3600 RPMs)  Initial Load Pickup and Soak

74. Steam Turbine System AuxiliariesSteam Turbine System Auxiliaries  Motor Operated Valves  Solenoid Operated Valves  Vapor Extractors  Turning Gear  Turbine Drain Valves  Jacking Oil Pumps  Gland Steam System  Seal Steam System  Lube Oil System  Auxiliary Steam System  Emergency Leak-off System  Vacuum Breakers  Bentley Nevada Modbus Link  Turbine Supervisory

76.  Turbine bypass systems can contribute to flexible plant operation mainly by supporting:  Repeatedly attainable fast startups with the greatest possible regard to the lifetime of heavy-walled components.  Quickest possible restoration of power supply to the grid after any disturbance  Saves startup time by avoiding boiler trip on turbine trip.  Ensures high reliability and availability of the plant  Bypass systems contribute to the overall target of safe and efficient supply of electric power at minimum total cost.  Steam bypass systems bring substantial fuel savings while they solve many of the problems caused by using baseload generating units for cyclic operation Turbine Bypass SystemTurbine Bypass System

77.  The steam bypass system is generally used during the following modes of operation:  Start-up and shutdown,  Steam turbine trip,  Steam turbine no-load or low-load operation  Fast Run back  Fast load throw off  House load operation Turbine Bypass SystemTurbine Bypass System

78. Turbine Bypass System for Thermal PlantTurbine Bypass System for Thermal Plant

79. Turbine Bypass System for CCP PlantTurbine Bypass System for CCP Plant

80. Typical Large Steam TurbineTypical Large Steam Turbine Extraction Steam and Heater SystemsExtraction Steam and Heater Systems I P Turbine H P Turbine High Pressure Heaters High Pressure Heaters High Pressure Heaters Boiler Feed Pumps Low Pressure Heater Low Pressure Heater Deaerater Heated Feedwater to Boiler BFP Recirc. Condensate To Hotwell LP Turbine

81. Automatic Turbine Start-up Control &Automatic Turbine Start-up Control & Rotor Stress MonitoringRotor Stress Monitoring  Safe Turbine Start-up and Shut down Sequencing  OEM guidelines are incorporated using the flowcharts and rotor stress constants  ATC mode automatically determines:  Speed & Load Targets  Speed Rates & Speed Holds  Load Rates & Load Holds  Run backs  Integral Turbine Protections

82. Typical ATC and RSM ProgramsTypical ATC and RSM Programs  HP and IP rotor stress calculations  Steam chest metal required temperature calculations  Turning gear checks before startup  Eccentricity and vibration monitoring  Water detection and drain valve control  Bearing temperature monitoring  Generator monitoring and checks before synchronization  Heat soak calculations allowing for shorter heat soak time

83. Damper Control Steam Temp Feedwater HRSG Turbine Turbine Master S-heat Spray R-heat Spray BF- Pump Turbine Valves Load Demand Computer High Limit Low Limit Ramp Rate Operator Set Limits Runbacks Rundowns Block Increase Block Decrease LocalRemote GT #1 GT #2 ST MWST MW DELTADELTA BALANCERBALANCER + - Load Demand Computer – CCP PlantsLoad Demand Computer – CCP Plants

84.  Front end (LDC Indexer) develops total plant MW demand  GT MW demand is total plant demand minus actual ST MW generation  GTs are in megawatt control mode  ST is in IPC control mode  As plant load index increases, the ST TP set point increases  f(x) has minimum pressure (floor value)  f(x) curve slides pressure on 100% valve point Basic CC PlantBasic CC Plant ControlControl

85. Emerson Gas TurbineEmerson Gas Turbine ControlControl Automatic startup and shutdown  Surge control limited starting and under load  Feed-forward fuel control schedule during starting  Temperature override control during starting  Speed control from tuning gear to minimum load  Load control from minimum to base load  Loading rate control  Temperature control at load  Minimum and maximum limits on fuel flow

86. Ovation Gas Turbine Controls OfferOvation Gas Turbine Controls Offer Numerous AdvantagesNumerous Advantages Advanced control and turbine protection schemes  Local and remote operation capability  Improved data acquisition for predictive maintenance and scheduling  Integrated power and BOP control systems  Maximize efficiency through load management  More precise and reliable fuel control  Advanced graphical interface  Historical logging and trending  Diagnostics for preventative maintenance

87. Modern Power Plant ConsiderationsModern Power Plant Considerations  Power industry is experiencing a dramatic changes fueled by Deregulation and consolidation.  Older business models are changing to cope with Competition between utilities, environmental concerns, and increasing power demand.  Availability, reliability, efficiency & lesser operating costs have become key elements of everyday plant operation considerations.  Today’s control system networks have become Information networks  Modern power plants tending to achieve vertical and horizontal integration of plant wide controls under single hardware/software platform, using Smart Filed Devices and Industrial standard communication across various layers of information & control networks.  Integrated Plant Optimization suites enable efficient optimized continuous plant controls throughout the plant operation range.  Plant Web Digital architecture enables easy integration of field devises while ensuring high quality field intelligence made available to the right persons, minimizing operational & maintenance costs while maximizing safety.  Integrated Plant Simulator for efficient operation and management of the plant

88. Air Controls Fuel Management Feedwater Control Burner Management Condensate Control Emergency Diesel Circulating Water Turbine Bypass Combustion Control Coordinated Controls AGC Cooling Tower Switchyard/ Metering SCR Injection Reagent Handling Ammonia Handling Sootblower PLCI/O Fly Ash PLCI/O Bottom Ash PLCI/O Dry ESP PLCI/O Wet ESP PLCI/O Condensate Polishing PLCI/O Air Preheater PLCI/O Coal Handling PLCI/O Limestone Stockout PLCI/O Gypsum Handling PLCI/O Aux Boiler PLCI/O Makeup Water PLCI/O Demin Water PLCI/O PLCI/O Limestone Reclaim PLC Stations Hardwired DataLinks Turbine StationEmissions StationVibration Monitoring Station Hardwired DataLinks Turbine Control Emissions Monitoring Motor/ Transformer UPS Monitoring Vibration Monitoring Fire Detection DCS Operator Stations DCS Engineer Station Historian Typical Power Plant Controls ArchitectureTypical Power Plant Controls Architecture PLCsPLCs DCSDCS 33rdrd PartyParty SystemsSystems Local Display Local Display Local Display Emerson Confidential

89. Air ControlsAir Controls Fuel Management Fuel Management Feedwater Control Feedwater Control Burner Management Burner Management Condensate Control Condensate Control Emergency Diesel Emergency Diesel Circulating Water Circulating Water Turbine Bypass Turbine Bypass Combustion Control Combustion Control Coordinated Controls Coordinated Controls AGCAGC Cooling Tower Cooling Tower Switchyard/ Metering Switchyard/ Metering SCR Injection SCR Injection Reagent Handling Reagent Handling Ammonia Handling Ammonia Handling Turbine Control Turbine Control Emissions Monitoring Emissions Monitoring Motor/ Transformer Motor/ Transformer UPS Monitoring UPS Monitoring Vibration Monitoring Vibration Monitoring Fire Detection Fire Detection Engineer Station Historian SootblowerSootblower Fly AshFly Ash Bottom AshBottom Ash Dry ESPDry ESP Wet ESPWet ESP Condensate Polishing Condensate Polishing Air Preheater Air Preheater Coal Handling Coal Handling Limestone Stockout Limestone Stockout Gypsum Handling Gypsum Handling Aux Boiler Aux Boiler Makeup Water Makeup Water Demin Water Demin Water Limestone Reclaim Limestone Reclaim Emerson’s Modern Power Plant ControlsEmerson’s Modern Power Plant Controls Asset Mgmt Station Wireless and Web-based Interfaces Fieldbus-based Ovation Expert System SimulatorOperator Stations Emerson Confidential

90. Total Solutions From The Power IndustryTotal Solutions From The Power Industry SpecialistsSpecialists Business Level Optimization & Predictive Maintenance Expert Control Instrumentation Applications

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