AUTOMATION CONTROL OF HYDEL POWER STATION A PROJECT REPORT SUBMITTED TO JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY, HYDERABAD SCHOOL OF CONTINUING

AND DISTANCE EDUCATION IN PART FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF DEGREE OF IN ELECTRICAL & ELECTRONICS ENGINEERING Submitted by Kum T.JAYA Roll. No N5063A2296 Under the esteemed guidance of Sreedevi,B.TECH Assistant Professor Department of Electrical & Electronics Engineering GOKARAJU RANGARAJU COLLEGE OF ENGINEERING & TECHNOLOGY,BACHUPALLY,HYDERABAD 2009 BATCHELOR OF TECHNOLOGY

GOKARAJU RANGARAJU COLLEGE OF ENGINEERING & TECHNOLOGY, BACHUPALLY,HYDERABAD Department of Electrical & Electronics Engineering CERTIFICATE This is to certify that the project work entitled AUTOMATION CONTROL OF HYDEL POWER STATION Is the bonafied work done by Kum T.JAYA Roll. No :(N5063A2296) In the Department of Electrical & Electronics Engineering at Gokaraju Rangaraju college of Engineering & Technology,Bachupally,Hyderabad And is submitted to JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY,HYDERABAD in partial fulfillment of the requirements for the award of degree of bachelor of technology in Electronics Engineering. This work has been carried out under my guidance

SCHOOL OF CONTINUING AND DISTANCE EDUCATION

SREEDEVI Raju Assistant Professor

Prof.T.VijayaRama HOD DETP OF EEE GRIET.

ANDHRAPRADESH POWER GENERATION CORPORATION LIMITED NSHESCHEME NAGARJUNASAGAR

CERTIFICATE This is to certify that a project titled AUTOMATION CONTROL OF HYDEL POWER STATION has been carried out by the student of Gokaraju Rangaraju college of Engineering & Technology,Bachupally,Hyderabad at N.S.H.E.Scheme,NS Power House,Nagarjunasagar.

Kum.T.Jaya,

(N5063A2296)

During the period of the project their conduct and character were found to be satisfactory.

Mr Y.Mallikarjuna ASSISTANT ENGINEER AUTOMATION & CONTROL N.S.H.E.Schem.

ACKNOWLEDGEMENT We owe our profound acknowledgement to all those people who made this project successfully. We would like to express our most sincere thanks to all those who are involved in our project, a deep sense of gratitude to AP POWER GENERATIOM CORPORATION LIMITED, for permitting us to work in their organization We take this precious chance to acknowledge to our guide Smt Sreedevi Assistant professor (GRIET) in the department in electrical and electronics engineering for her co-operation in completing our training. We are also highly thankful to Sri M.MALLIKARJUNA,M.TECH,A.E. for giving guidance to our training. We express our gratitude to Head of the department of Electrical & Electronics Engineering, and to our principal for thir timely advice and encouragement while pursuing this project as well as through out the B.Tech couse. We are also very especially thankful to Sri J.S.V.Uma Maheswara Sastry, SE, NSHES POWER HOUSE for allowing undergoing training program. We also express the over exhilaration and gratitude to all those who animated our project work and accentuated our stance.

Kum.T.JAYA Roll.No N5063A2296

INDEX ABSTRACT 1. OVER VIEW OF POWER PLANT 1.1 1.2 1.3 1.4 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4.1 4.2 4.3 4.4 4.5 4.6 4.7 Pumped storage scheme Right canal electro-Hydraulic station Left canal power House Ports of hydel stations 5 6 6 7 7 7 8 8 8 9 9 10 10 11 13 15 15 16 16 16 19 19 20 22 25 25 27 29 29 30 Speed error sensing unit Derivative unit Speed adjusting gear power output adjusting gear Speed droop Isodrome Unit Summation and amplification unit Magnetic amplifier Electro-Hydraulic transducer Relay section Synchronous compensator Joint governor Follow up circuit Rectifier transformer SCR output stage Regulator and operational control circuit Control electronics Power supply Protection 2 3 1 2 2

2. SPEED GOVERNOR

3. STATIC EXITATION SYSTEM

Excitation starter and field discharge equipment

4. SEQUENTIAL CONTROL Keltron versamac PLC Modes of operation Automatic programs Start permissible & break away condition Criteria Control consoles

Westing house PC-700 programmable logic control

4.8 4.9

Selection of control Start permissible & start not ready condition

32 32

4.10 4.11 4.12 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16

Selection not permissible Protection shutdown Release push button 35 36 Automation History of process control Characteristics of PLC Step by step Automation operation Programme selection Execution Progression of the programme Disturbance in status Auto inactive Additional facilities Method of indication of missing criteria Sorting as S.pu/pu working of PLC Applications of PLC Comparisons 48 51 44 41 39 39

33 33 34

5.AUTOMATION OF HYDEL UNIT

36 38 39 39 40 40 41 42 46 47

7.CONCLUSION

ABSTRACT

ABSTRACT Title: Automation control of Hydel Power Station Nowadays Electrical energy has become one of important daily needs in human life. It is not only used in house hold appliances and industrial applications such as transportation purposes. There are different resources of energy from which electrical energy can be produced are Hydel, Thermal, Solar, Nuclear etc of all this hydel power station is one of the important means. A Programmable Logic controller is a digitally operated electronic device that uses a program memory for intermediate storage of instructions that implement specific functions such as logic, sequence, counting, timing and arithmetic operations to control the processing of machines. In industries there are many productions tasks, which are of highly repetitive in nature. Although repetitive monotonous, each stage needs careful attention of operator to ensure good quality of final product. Many of times, close supervisor process cause high fatigue on operator resulting in loss of task of process control. Sometimes it is hazardous as in the case of potentially explosive process. Under all such conditions we can use programmable logic controllers effectively and efficiently in totally eliminating the possibilities of human error by automating the process. However with technological development, the programmable logic controllers are used today in a divers range of industrial and process control applications. Also they can be designed with communications capabilities that allow conversing with local and remote There are many closed loop controls that are used in Hydel power station keep every process parameters within the limits automatically. In automation control sequence important and critical element to be monitored and controlled closely with in the set limits. Otherwise, this may even cause damages to the turbine or generator. This project mainly deals with the automation control employed in Hydel Power station. In this the automation sequential controls equipment furnished for the reversible turbine generating consists of a control disk, sequential control panel, drives control and drives protection panels and interfacing the control equipment with the various field actuators. Each control consists of input, logic and output section. A Programmable Logic controller is a digitally operated electronic device that uses a program memory for intermediate storage of instructions that implement

specific functions such as logic, sequence, counting, timing and arithmetic operations to control the processing of machines.

OVERVIEW

1. OVERVIEW The Nagarjunasagar reservoir named after Acharaya Nagarjuna, the great disciple of Lord Buddha, extends up to the toe of the Srisailam dam where another major hydel project is existing. The Nagarjunasagar dam rising 123.2mt(404) above the Deepest foundation level has a gross storage capacity of 11,310 million cubic meters (400tmc) at the full reservoir level of el+181.051m (590) and a live storage of about 190tmc. Two canal systems take off from the right and left bank s of the reservoir providing irrigation for vast areas on both banks of the river. Water is also let into The River for irrigation lands in the Krishnas delta lower down the river. The project commands an area of 3.5 million acres of land and affords a power potential of 1000MW. Pumped Storage Scheme: The first stage of the scheme covers installation of 4Nos reversible types pump turbine motor/generator units. This equipment was supplied by M/s Hitachis Mitsubishi. M/s BHEL has also supplied some of the components of field excitation and pump units. The second stage of the scheme covers the installation of 3Nos reversible units-8 pen stocks of dia 4.8m(16) have been embedded in the body of the dam on the left bank to feed 8 generating units of (1*110+100.8)MW. The ultimate installation capacity of the power house 815.16MW. Right canal Hydro-Electric station: The canal taking off from the side of Nagarjunsagar dam is named JAWAHAR CANAL In affectionate memory of late Sri Jawaharlal Nehru, the prime minister of independent India. Right canal power House has an installed capacity of 3Units of 30MW each. Left Canal Power House: The left canal is called Lal Bahadur canal in every loving memory of the second Prime Minister of India Late Sri Lal Bhadur Sastry. Left canal power House has and installation capacity of 2 Units of 30MW. Parts of hydel Station: In hydroelectric power station, water kinetic energy and potential energy is used to generate electrical energy. The main parts of the station are. 1.Reservoir 2.Dam 3.Trach rack 4.Penstock-Ingate

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5.Pensotck 6.Turbain 7.Generator 8.Transformer&Switch gear etc Reservoir: The place where the water is stored used to generate electricity is called Reservoir. Electrical generation capacity depends upon the water level this known as water head Dam : On river, barrages are constructed corresponding to the water head for the generation of electricity. According to dams height, reservoir storage capacity is increased. Trash Rack: This is used to resistance wastage in the reservoir through the wicket gates in to the turbine runner. This is constructed with steel bats. Penstock Intake Gate: This is the gate placed at the entrance of Penstock at the reservoir. It controls the water entering into the penstock. Penstock: The steel pipes that are used to supply water to turbine from the reservoir through Penstock intake gate is known as penstock. In medium head and above medium head power stations, steel penstocks are used. In low head power stations, concrete penstocks are used. Turbine: It converts potential energy of water into kinetic energy. In Nagarjunasagar power plant, modern Francis turbines are used. Generator: It converts kinetic energy (mechanical) that is given by the prime mover to electrical energy. In Nagarjunasagar power plant, salient pole alternator is used. Transformers: Power transformer is used to step up the voltage from 13.8KV to 220KV. Here in excitation unit, unit auxiliary transformer and rectifier transformer are used.

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SPEED GOVERNOR

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2. SPEED GOVERNOR SPEED ERROR SENCING UNIT: Operation of this unit is based upon variation in impedance caused by the alternating current in a LC circuit fed from tachogenerator(Parallel coupled capacitor and chock coil) since the tacho generator is coupled to the turbine shaft. Its voltage and frequency is proportional to the speed of the turbine. Values of choke and capacitor are so selected that the Resonance occurs at a frequency of 50c/s which corresponds tot the rated speed of turbain under the resonance condition, the circuit resistant increases and current flowing through the circuit is practically nil. With the speed of rotation increasing and decreasing, leading or lagging current flows through the circuit respectively. The value of this current being proportional to the amount of speed change. DERIVATIVE UNIT: The derivative signal is incorporated by switching on the switch. The output of speed error sensing unit is fed to series R.C. Circuit and this current which is derivative signal is Fed to the control winding it stage magnetic amplifiers. The derivative signal provides stabilizing effect on the speed loop and improves governor transient response. Time constant is adjustable in 10 discrete steps through the selector switch. SPEED ADJUSTING GEAR(SAG): Speed adjusting gear consists of a motor coupled ten turn potentiometer enabling to generate a signal for adjusting of speed of the set before synchronization. This signal is fed to the transformer, secondary of which is connected to the control signal summation circuit. The motor is remote controlled through key mounted on hydro mechanical cabinet of governor and a duplicator key in main control room.

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POWER OUTPUT ADJUSTING GEAR (OAG): Power output changer of a motor coupled ten turn potentiometer enabling to generate a signal for changing the output of set. This signal through speed droop is fed to the transformer, secondary of which is connected to the control signal summation circuit. New balanced position is obtained when potentiometer under the effect of feed back comes to the position corresponding to (OAG) effect and the effect of gate position changing. Therefore isodrome signal practically remains unchangeable. The governor made according to such diagram ensures high speed of signal response to output change irrespective of isodrome settings. SPEED DROOP: A ten potentiometer with indicating digital is used to provide step less variation of speed droop up to 10% voltage is supplied to this potentiometer servomotor position feedback potentiometer and Output adjusting potentiometer. It contributes to the servomotor position VS speed characteristic of the system Slope of which is determined by the value of the speed droop setting.

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ISODROME UNIT: The operation of the electrical isodrome gear is based upon the property of R.C Circuit coupled resistant box and capacitor box to pass charging or discharging current that gradually drops to zero in accordance with the exponential law owing to variations in applied voltage. Voltage from feed-back potentiometer proportional to gate apparatus servo motor position is supplied to R.C circuit through the phase sensitive rectifier which comprises inlet transformer, reference voltage transformer, rectifier diodes and filter. At turbine no load operation isodrome time is adjusted by switch and intensity by switch. Switches are meant by adjusting isdrome parameters on load. Isodrome signal is passed to control windings of magnetic amplifiers. Condensers which are not connected to R.C Circuit are charged through resistant. SUMMATION & AMPLIFICATION UNIT: Signals from transformer T 101,T102 and T103 are fed into the primary of T104, then into the phase sensitive rectifiers, consisting of rectifying diodes D113 to D120 and reference voltage transformer T 105. from the phase sensitive rectifier-Output Signal is passed through resistance R120; R 121 series connected control windings of first stage magnetic amplifier. MAGNETIC AMPLIFIER: The amplifier is intended to obtain sufficiently strong electric signals applied over the coli an electro hydraulic transducer. In order to get higher gain coefficient, the amplifier incorporated two push-pull stages. The first stage comprises three individual input windings one designed to feed separate governing. In the second stage just one control windings is made use of Bias windings in both stages are fed with stabilized voltage. The second stage has proportional feedback adjustment of total gain coefficient is archived by changing resistant R116,C101,R206,to R213,R217 to R 224), its value being altered at a time if the change in isodrome intercity takes place. ELECTRO-HYDRALIC TRANSDUCER: The electro-Hydraulic transducer consists of electric and hydroMechanical sections. The electrical part of the transducers is essentially a magneto electric system the action of which is based on pushing of energized coil out magnet. A spring suspension keeps the coil in medium position. When current is flow through the coil winding, magneto electric forces cause the coil to shift, the amount and direction of this shift being in compliance with those of coil ampere turns reduced by current flowing through the coil Alternating current is supplied to the coil through capacitors and to create vibration.

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RELAY SECTION: The relay section is intended for switching on the governor circuit when changing governor operating conditions. Shutdown of the hydraulic turbine is performed by means of gate limiter OLG through relay when starting the hydraulic turbine the relay section switches on the electric Motor of gate limiter OLG and shifts the limiter up to its opening for starting. The extent of opening for starting can be varied by turning a cam in track contact which actuates relay closes when the gate limiter beings to remove in the direction of opening. Signal for opening is passed to the coil of electro-hydraulic transducer which results in gate servomotor displacement to the position adjusted by the gate limiter. After the hydraulic turbine speed reaches to automatic control. Synchronization to the turbine is carried out with the aid of frequency changer its electric motor being controlled by mean of key ICS. After connection to the network the unit control is automatically shifted to the power output changer OAG is also operated with key is contact and relay are provided in the governor for the purpose of increasing turbine output when frequency of the power system drops down. In case of Hydro set load row off relay gets energized through the contacts of relay the contacts of relay turns on the during motor and brings the output setter to no load setting. Motor is switched off by limit switch. In case of, turbine speed rises to 112% of its rated value, relay energiesresulting into faster closing action of the turbine through electro-hydraulic transducer. As the normal rotational speed is archived relay drops off and the unit is shifted to normal automation control rotation. Emergency shutdown of the turbine is affected by means of electromagnet actuated vale provided in the emergency protection system. This closes the guide apparatus through an emergency closure slide value, by passing the governor pulse is initiated from over speed protection device to the electromagnet. Over speed protection device consist device consist of an electric speed relay set for operation at 115% of the rated value and contact opening only when the main slide value shifted sufficiently towards closer. Also a contact of master controller is connected in series which closes only when the guide apparatus opening exceeds that for no load operation. SYNCHRONOUS COMPENSATOR: A change over to synchronous compensator operation is achieved by means of a key SCS. Relay comes into action there with removes current from

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magnetic amplifier and feeds signal for closing to the coil of electro hydraulically transducer. Adjustment according to head is carried out with the aid of two phases electrical control motor fed through a transistors amplifier which is provided in this module. A signal from head sensor is fed into the transistorized amplifier. A feedback release signal from potentiometer coupled to the gear for adjusting according to thread is fed into the same input. Provision is made in the governor for installation of remote indicator of gate opening and gate opening and gate opening limited. Pickups of the indicator R708 and R709 are located in hydro mechanical cabinet and should be electrically connected with their associated meters in the control room. JOINT GOVERNING: The change over to the joint governing operation is carried out by means of key. Relay gets energized which in turn energies relay and power to the joint governing system is supplied from power station network through a transformer of the out put setter. According to both the schemes provided, the joint governing signals are summed up with separate governing signal in the windings of d.c magnetic amplifiers. In case of scheme number two. Setting signal is passed through control winding 4H- 4K magnetic amplifier MA 101 and MA 102. Feed back signal is passed through the transformer to the winding 3H-3K of the same amplifier. The distinctive characteristics of this scheme is that total output generated by a group of hydro sets depends on number of operating units and is adjustable by output potentiometer. FOLLOWING-UP CIRCUIT: To ensure smooth change over from joint to separate governing. One transistorized power switch is used for controlling motor. This rings the output changer potentiometer in step with the gate feedback potentiometer. DESCRIPTION OF ELECTRONICS CABINET: Electrical equipment are placed in metal cabinet 600* 610*2110. two single fold doors at the front and at the rear of the cabinet provided access to cabinet internal equipment internal equipment. To facilitate cable lying to an outside terminal block adjustment of the electrical equipment. There is fluorescent lamp lighting the cabinet inside. Socket for connecting a soldering iron is also provided in the cabinet. The components of the electrical equipment are mounted inside the cabinet on nine modules. The modules have the following names. TERMINAL MODULE:

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Comprising of rows of terminal that connect the electrical components of the cabinet to other devices of the governor circuit outside the cabinet and sources of power supply. All modules mounted inside the cabinet have their own row of material is used to connect the panels to a bunch of conductors thus setting up and internal circuit of the electrical equipment cabinet. Units of adjustment according to head is not connected with the terminal box of electrical equipment cabinet transformer and automatic switch of tacho generator supply are also located on terminal module. DETECTOR MODULE: This comprise of 1. Turbine speed error sensing device and electric pendulum 2. Phase sensitive rectifier 3. D.C High gain magnetic amplifier 4. Transformers to feed and sum up electric signals. GOVERNER ADJUSTING MODULE This comprises of 1. Electrical isodrome gear 2. Speed droop potentiometer 3. Components of follow up drive 4. Relay for switching the governor operating conditions whenever a necessity to do so arises JOINT GOVERNING MODULE: Comprises of the rectifiers, potentiometers and relays necessary for joint governing operation. A set of plug to change over from one type of scheme of joint governing to another is also provided in this module. Relay module comprises relays which are necessary for switching over with in the governor circuit when the turbine is started shutdown or operating conditions are changed. PROTECTION MODULE: Comprises rectifiers, capacitors, semiconductors, transistors and relays providing for unit protection under emergency condition. Protection unit is located at the rear part of electrical equipment cabinet. UNIT OF ADJUSTMENT ACCORDING TO HEAD: For limiting the gate opening according to head in EH governors. This module a comprises transistorized amplifiers and a number of auxiliary devices and components necessary for amplification and summation of signal fed from the actual head pickup and feed back loop over the position of a mechanism under control.

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The module has a terminal block for external cable connections and is located n the rear part of the cabinet housing the electric equipment. The output setter consists of a stabilized power supply and one transformer to supply the two phase A.C motor along with two ten turn servo potentiometer with clutch these potentiometers are mounted with their indicating diagram.

STATIC EXITATION SYSTEM

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STATIC EXITATION In static excitation system, the ac power is tapped off from the generator terminals stepped and ratified by fully controlled thyristors bridges and then fed to the generator field thereby controlling the generator voltage output. A high controlled is achieved by using an inertial free control and power electronic system. Any deviation in thr generator terminal voltage is sensed by an error detector and causes the voltage regulator to advance or retard the firing angle of the thyristors thereby controlling the field excitation of the alternator. The below figure shows the block diagram of static excitation system.

It can be designed with out any difficulty to provide high response ratio, which is required by the system. The response ratio of the order 3 to 5 can be archived by this system. This equipment controls the generator terminal voltage and hence the reactive load flow by adjusting the excitation current. The rotating

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exciter is dispensed with and silicon controlled rectifiers are used which directly feed the field of alternator. The static excitation system consists of: 1) Rectifier transformer 2) SCR output stage 3) Excitation starter and field discharge equipment 4) Regulator and operational control circuit.

Rectifier transformer: The excitation power is taken from generator output and fed through the excitation(rectifier) transformer, which steps down to the required voltage, for the SCR Bridge and then through field breaker to the generator field. The rectifier transformer used in the static excitation system should have high reliability, as failure if this will cause shunt down of power station. Dry type cast oil transformer is suitable for static excitation applications. The transformer is selected such it supplies rated excitation current at rated voltage continuously and is cable of supplying ceiling current at the ceiling excitation for a short time of 10 seconds. SCR OUTPUT STAGE: The SCR output stage consists of a suitable number of bridges connected in parallel. Each thyristor bridge comprises of 6 thyristors, working as a six pulse fully controlled bridge. Current carrying capacity of each bridge depends on the rating of individual thyristors. Thyristors are designed such that their junction temperature rise is well with in these specified rating. By changing the firing angle of the thyrtistors. Variable output is obtained. Each bridge is controlled by one final pulse stage and is cooled by a fan. These bridge are equipped with protection devices and failure of one brige causes alarm. If there is a failure of one or more thyristor bridge excitation current will be limited to a pre-determined value lesser than the normal current. However, failure of the third bridge results in tripping and rapid de-excitation of the generator. EXCITATION START UP AND FIELD DISCHARGE EQUIPMENT: For the initial build up of the generator voltage, a field flashing equipment is required. The rating of this equipment depends on the no load excitation requirement and field time constant of the generator. From the reliability point of view, provision for both AC and DC field flashing is provided. The field breaker is selected such that it carries full load excitation current continuously and also it breaks the maximum field current when the three-Phase short circuit occurs at generator terminals. The field discharge is normally of

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non-Linear type for medium and large machines i.e., voltage dependent resistor. To protect the field winding of the generator against over voltages, an over voltage protector along with a current limiting resistor is used to limit the over voltage across the field winding. The OVP operates on the insulation break over principle. The voltage level at which the OVP should operate is selected based on the insulation level of field winding of the generator.

CONTROL ELECTRONICS: Regulator is the heart of the system. This regulates the generator voltage by controlling the firing pulses to the thyristors. ERROR DETECTOR & AMPLIFIER: The generator terminal voltage is stepped down by the three-Phase power transformer and fed to the AVR. The AC input thus obtained is rectified, filtered and compared against a highly stabilized reference value and the difference is amplified in different stages of amplification. The AVR is designed with highly stable elements so that variation in ambient temperature dose not cause any drift or change in the output level. Three current transformers sensing the output current of the generator feed proportional current across variable resistors in the AVR. The voltage thus obtained across the resistors and be added vectorially either for compounding or for transformer drop compensation. GRID CONTROL UNIT: The output of the AVR is fed to a grid control unit, it gets its synchronous AC reference through a filter circuit and generates a double pulse spaced 60 elec. Apart whose position depends on the output of the AVR,i.e, the pulse position varies continuously as a function of control voltage. The two relays are provided, by energizing, which, the pulses can be either blocked completely or shifted to inverter mode of operation. PULSE AMPLIFIER The pulse output of the grid control unit is amplified further at intermediate stage amplification. This is known as pulse intermediate stage, the unit has a DC power supply, which operates from a three phase 380 volts supply and delivers+15Volts, -15 volts, +5V and a course stabilized voltage V. A built in relay is provided which can be used for blocking the six pulse channels. In a two-

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channel system, the changeover is affected by energizing/de-energizing the relay. PULSE FINAL STAGE: This unit receives input pulses from the pulse amplifier and transmits them through pulse transformers through the gates of the thyristors. A built in power supply provided the required DC supply to the final pulse amplifier. Each thyristor bridge has its own final pulse stage. Therefore, even if a thyristor bridge fails with its final puls stage,the remaining thyristor bridges can continue to cater to full load requirement of the machine/and thereby ensure(n-1) operation.

MANUAL CONTROL CHANNEL: A separate manual control channel is provided where the controlling D.C signal is taken from a stabilized D.C voltage through a motor operated potentiometer ,i.e., the signal is fed to a separate grid control unit whose output pulses after being amplified at an intermediate stage can be fed to he final pulse stage. When one channel is working, generating the required pulses, the other remains blocked Therefore, blocking or releasing the pulses of the corresponding intermediate stage affects a change over from auto to manual channel or viceversa. A pulse supervision unit detects spurious pulses or loss of pulses at the pulses bus bar and transfers control from auto channel to manual channel. FOLLOW UP UNIT: To ensure a smooth switch over from auto to manual control, it is necessary that the position of pulses on the both channels should be identical a comparison unit detects any deference in position of pulses and with a help of follow up unit activities the motor operated potentiometer on the manual channel to turn in a direction so as to eliminate the difference. However, while transferring control from manual to auto mode any difference in control levels can be visually checked on a balanced meter and adjusted to obtained null before change over. LIMIT CONTROLLERS: When a generator is running in parallel with the power network, it its essential to maintain it in synchronism without exceeding the rating of the machine and also without the protection system tripping. The automatic voltage regulator by itself cannot ensure this. It is necessary to supplement the basic voltage regulators by limiters to limit over excitation and under excitation.

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Limiters dont replace the protection system but only prevent the protection system from tripping unnecessarily under extreme transient conditions. The AVR also has a built in frequency circuit so the when the machine is running below the rated frequency, the regulated voltage should be proportional to frequency. With the help of a potentiometer in the AVR, the circuit can be made to respond proportionally to voltage above a certain frequency. The range of adjustment of this cut-off frequency lies between 40 and 60HZ The static excitation system is equipped with three limiters, which act in conjunction with AVR.

ROTOR CURRTENT LIMITER: This avoids the thermal overloading of the rotor winding and is provided to protect the generator rotor against excessively long duration over loads. The ceiling excitation is limited to a predetermined limit and is allowed to flow for a time, which is dependent upon the rate of rise of Field current before limited to the thermal unit value. ROTOR ANGLE LIMITER: The unit comprehends the rotor and DC signal proportional to the load or rotor angle by means of a simple analog circuit. When the rotor angle exceeds the limit settable with the differential potentiometer the excitation is increased immediately to reduce the load angle to the limit value. The rotor angle limiter takes over control de-coupling the output of the AVR. STATOR CURRTENT LIMITER: This avoids thermal over loading of the stator windings. Stator current limiter is provided to protect the generator against long duration of large stator currents. For excessive inductive current it acts over the AVR after a certain time lag and decreases the excitation current to limit the inductive current to the limit value. But for excessive capacitive current it acts on the AVR without time delay to increase the excitation and thereby reduce the capacitive current it acts on the AVR without time delay to increase the excitation and thereby reduce the capacitive loading. This is necessary, as there is a risk for the machine falling out of step in under excited mode of operation. SLIP STABILIZING UNITS: The slip-stabilizing unit is used for the suppression of rotor oscillations of the alternator through the additional influence of excitation. The slip as well as the acceleration signals needed for the stabilization is derived from the active

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power delivered by the alternator. Both the sign ALS, which are correspondingly amplified and assumed up, influence the excitation of the synchronous machine through AVR in a manner as to suppress the rotor oscillations. POWER SUPPLY: The voltage regulating equipment needs an AC supply 380V, 3Phase for its power supply units, which is derived from the secondary side of the rectifier transformer through an auxiliary transformer. This voltage is reduced to different levels required for the power packs by means of multi wingding transformers. A separate transformer supplies the synchronous voltage 3X380V for the filter circuit of each channel and the voltage relay. During testing and precommissioning activities when the generator voltage is not available, the step down transformer is used for testing purpose with the help of a regulator test/service switch. The supply for the thyristor bridge fan is taken from an independent transformer, which gets its input supply from the secondary of the excitation transformer. The control & protection relays need 48V & 24V DC which are delivered from the station battery by means of DC/DC converters, which are internally protected against overload. PROTECTIONS: The following protections are provided in the static excitation equipment. 1) Rectifier transformer over current instantaneous and delayed. 2) Rectifier transformer over temperature 3) Rotor over voltage 4) Fuse failure monitoring circuit for thyristors 5) Loss of control voltage (48V & 24V) 6) DV/DT protection of SCR by snubber network.

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SEQENTIAL CONTROL

SEQUENTIAL CONTROL
INTRODUCTION:

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The automatic sequential control equipment furnished for the reversible turbine drive generators, units 6,7&8, consists of a control desk, sequence control panel, drive control and protection panels and interfacing relays which interfacing the control equipment with the various field actuators which is shown in below fig. the sequential control panel of unit 6 is made of wasting house while 7 & 8 is made of keltron. The drive control & drive protection panels consist of hard-wired wasting house numa logic 300 series solid state controls, while the interfacing relays are of ASEA make for all the three units. A Westinghouse makes type X solid state auto synchronizer and auto synchronizing relays are provided for each unit. Facilities for transformer tap indication are provided at the control desk. Facilities for alarm annunciations system is furnished separately by others.

To facilities random coupling of all the 8 Units for B-B start/SFC start a microprocessor based interface panel is provided. This interface panel is of wasting house make. The main tasks of the equipment supplied are to provided for automation start/Stop of this units as a) Spin generator b) Generator c) Synchronous condenser generator d) Spin pump e) Pump f) Back to back generator Functionally, the overall system supplied by M/s BBC for Units 2 to 5 to avoid any confusion to the operating personnel. Hence through the technology and the equipment inside the panels is completely different from that M/s BBC, as far as the operator is concerned there is no difference in the system including control consoles and control desks. However, some additional facilities are provided, viz. a) Missing criteria indication for

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i) ii) iii)

disturbance in start permissible condition progress criteria failure disturbance in status criteria

b) Digital display of commands are given out at each step c) Digital step display on the control desk, in addition to the local control panel d) Manual control start, to start the generator and run it up to 100% speed with all the inter locks required and to stop the machine if need be. The sequencer for Unit -6 is a Westinghouse 700 series programmable controller technical feature of westing house PC-700PLC. WESTINH HOUSE PC-700 PROGRAMMABLE LOGIC CONTROL: It consists of compact 16 bit microprocessor based programmable controller. The control system comprising of the this unit can be broadly into three sections.

INPUT SECTION:-

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Which provided the input information required to keep track of status of operation The input section consist of two type of input cards, viz. NL708M,24V DC input module used for monitoring the input from control desk and NL 701,5V DC input module are used for monitoring the inputs from drive control. LOGIC SECTION:Which analyses and processes the input information from the input section to determine the output commands to be generated the logic section consists of a controller or central processing unit and memory to store information programs. The CPU is used to process and analyze input information and to generate the output commands based on the instructions given to it by the software programs. All components are solid state devices. A program loader feeds the memory with the necessary program to perform a given operation.

OUTPUT SECTION:Which activates field actuators based on the information given to it by the logic section the output section of 4 types of out put cards viz.NL753H type,5V DC out put cards with signal output compatible to the driver control system for output to input modules are provided with built in leds to inside the availability of inputs/Outputs these leds are visible. The drive control NL728 type,24V DC out put modules for output to the control desk, NL753H type register output cards for the command/step digital displays and NL-735 type 24V output modules with relay contacts for annunciation purpose. The I/O modules are provided with built-in LEDs to indicate the availability of the I/Os these LED are visible when they glow through the translucent plates mounted in front of the cards. NLR 704 vertical racks are used to house the modules. As well as for inter connection between the modules. The processor co-ordinates all the various operations of the PC-700 memory-user memory, is to store the ladder diagram instructions programmed from the program loader and for calculation/processing data and I/O image memory containing status of various input/output circuits at the beginning of a sampling, and which is updated with each pass. The user memory is in RAM backed by a Ni-Cd battery. The programme can be retained for a maximum period of 30 days without input supply to the processed. The NLTL-783 tape loader allows the storage of programs developed for the PC-700 on digital cassettes. The provides a safety against accidental erasure of program memory and also a back up for the software programs. The tape loader is connected to the processor through the program loader, which initiates

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the loading of a programmed from tape, at the storage of a programme to tape on-line programming is possible. As such therefore, extra care should be taken before attempting this on-line programming. The PC-700 is built up of the following modules(PCB cards); 3Nos, Nl 708 M, 24V DC input module. 26 Nos nl 701,5V DC input signal module. 8 Nos Nl 753H,5V DC output signal module 4 Nos Nl 728,24V DC output module.

Keltron versamac PLC:

Versamac is also modular in design and layout, and supports a leader diagram program with capabilities for sequence generation through sequence tables. The over all structure is broadly similar to the westing-house unit.

Each PLC unit utilizes three 6u height 19 racks, one which is for an 8 bit microprocessor functioning as the CPU and a few I/O modules. LEDs are given on a separate local panel for indicating criteria input and output command outputs. Random access memory is provided for storing/updating I/O status information and erasable programmable read only memory is provided for storage of programs. Programming of the sequencer is done through a CRT terminal and key board, using the relay ladder diagram and symbols. OPERATION OF SEQUENCER INTRODUCTION: As explained earlier, operationally, the system is made identical to that of the sequence control system of NSPSS stage I The function of each push button in control console is identical to that of stage I i.e. except in case of the additional push buttons provided for missing criteria & manual control start.

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MODES OF OPERATION: There are six modes of operation. 1. Stand still 2. Spin generator 3. Generator 4. Synchronous condenser generator 5. Spin pump 6. Pump

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In addition to these steady state modes of operation the units can be run as back to back generators also, which is a transient mode of operation, i.e any unit as back generator will take another unit connected to it as spin pump up to 100% speed and after the other unit is synchronized as spin pump the B-B generator comes back to stand still. Provision is also made in the control circuit to start the units in the pump direction using static frequency control equipment. AUTOMATIC PROGRAMS: 1. The Automatic operation of the unit is possible only through the following programs a) Generator to stand still b) Spin generator to stand still c) Synchronous condenser Generator to stand still d) Pump to stand still e) Spin pump to stand still f) Transient to stand still 2. Stand still to spin generator 3. Stand still to generator 4. Stand still to synchrous condenser Generator 5. Spin generator to generator 6. generator to Spin generator 7. Spin generator to synchronous condenser generator. 8. Synchrous condenser generator to spin generator 9. Synchronous condenser generator to Generator 10.Generator to Synchronous condenser Generator 11.Stand still to generator(Back to back) 12.Stand still to Spin pump (Back to Back) 13.Stand still to pump (SFC) 14.Stand still to Spin Pump(SFC) 15.Stand still to pump(SFC) 16.Spin pump to pump START PERMISSIBLE CONDITIONS & BREAK AWAY CONDITIONSD: 8 Permissible Conditions and 3 Break conditions are considerer for the 6 modes of operation and the change Over from one mode to another mode.

STRAT PERMISSIBLE CONDITIONS:

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1. SP1-SD to G or S.G 2. SP2-SD to B-B G 3. SP3-SD to S. Pu 4. SP4 SD to Sy.C.G 5. SP5-S.Pu to pu 6. SP6-Sy.C.G to G 7. SP7 S.G or G to Sy.C.G 8. SP8-S.G to G BREAK - AWAY CONDITIONS: 1. BC1-SD to G or B-B G 2. BC-2 SD to S.Pu 3. BC3-SD to SFC

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34

CRITERIA: PROCED CRITERIA: Each set of the program is assigned with a set of criteria and commands. The set of criteria required to be fulfilled prior to entering a step are called Proceed Criteria. SUPERVISION CRITERIA: To ensure safe operation of the unit, certain important criteria which are essentially required for safe operation of unit are supervised for several steps after the initial step to which they are assigned as proceed Criteria. These Criteria are called Supervision criteria. OVER-RUN CRITERIA: Over-run criteria decided the step from which the program shall be started and the steps to be bypassed when any program is executed from a transient state. CONTROL CONSOLES: Control consoles are provided both on the Sequence control panel and on the control desk. The control console of the units consist of all the push buttons and indicating lamps required for selection/execution/Indication of all the programmers of the unit is shown in below figure.

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The following additional push buttons are provided on control consoles of Unit6 to 8: 1. Missing criteria 2. Generator start not ready 3. Synchronous condenser generator start not ready 4. Pump start not ready

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SELECTION OF CONTROL: The Unit can be controlled 1. Locally 2. At the control Room 3. From a remote Location Selection of control can be done with the corresponding push button and the selection mode is indicated by the lamps in the push buttons. The unit can be operated only from the control consol selected however, indications on the both the consoles are operative irrespective of console selection. While the unit can be operated in all possible modes from either of console from remote console, the unit can be operated only as a Generator. The programme to Generator is selected and executed with a single command from the remote station. START PERMISSIBLE CONDITION/START NOT READY CONDITION: The Non- Availability of all the criteria required for the various start permissible conditions is indicated by the lamps in start not ready push buttons. The lamp glows when any of the criteria required are missing. TABLE: START NOT READY INDICATINGS STATUS OF THE START UNIT PERMISSIBLE INDICATING LAMP THAT CONDITIONS FOR SOME WILL GLOW CRITERIA MISSING SD SG SyCG SD SG or G SD SPU SP1 & SP2 SP8 SP6 SP4 SP7 SP3 SP4 It may be noted from above table that while all the programmers to S.G, G, Sy.C.G, S.Pu or Pu required the same start permissible conditions to be fulfilled, the programme to shunt down does not require any permissible condition to be fulfilled. To ensure safety of the unit, it is programmed in such way that the unit can be shut down from any stage whether transient or steady state without any pre conditions. Pu.start not ready Sy.C.G.Strat not ready Generator start not ready

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SELECTION NOT PERMISSIBLE: If a selection is not permissible is made the same is indicated by the indicating lamp selection not permissible. PROTECTION SHUNT DOWN: In case of protection shunt down the programme under execution changes over automatically to shut down and the indicating lamp protection shuntdown flashes. RELEASE PUSH BUTTONS: Since all the manual commands are by means of push buttons, to avoid inadvertent operations all important commands are inter-Locked with the Release push buttons. The release button is required for the following ON/OFF commands of drive: 1. Circuit Breakers 2. Isolators 3. Mechanical Brakes 4. Penstock Intake Gate 5. Synchronizing 6. AVR change over Manual/Auto 7. Gate Limiter Raise/Lower 8. Selection of Individual/Joint Governing 9. for the Executecommand to start any programme

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AUTOMATION OF HYDAL UNIT

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AUTOMATION OF HYDEL UNIT

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AUTOMATION: Automation is basically the delegation of human control functions equipment aimed towards achieving. Higher productivity, Superior quality of end product, Efficient uses of energy and raw material and Improved safety in working condition.

HISTORY OF PROCESS CONTROL There are various methods used in the process control and automation are as follows and they are Manuel control Hard-wire control Electronic control using logic gates Programmable logic controller

MANUAL CONTROLLER In manual control all actions related to process control and automation is taken by operations. By using this method we can have the following drawbacks. Major drawback of this method is human errors and consequently effect and quality of final product. Mannual control has its own limitations with regard to mass production techniques and this method cannot provide the consumer with quality goods at an affordable price. The safety is efficient use of raw material and energy are all subject to the correctness and accuracy of human actions. HARD -WARED LOGIC CONTROL: This is the first step toward automation. Here contractors and relays together with timers and counters were used in achieving the desired level of automation. This method served the purpose for many years. But it also has certain limitations. Bulky and complex wiring involving a lot of rework to be implement changes in control logic. The work can be started only when the task is fully defined and this leads to longer project. ELECTRONICS CONTEROL USING LOGIC GATES:

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With the advent of electronics, logic gates started replacing the relays and auxiliary contractors in control circuits. Electronic timers etc. replaced by metallic and motorized timers. With within of these changes we got the benefits like. Reduced space requirements Energy saving Less maintains and hence greater reliability However when with electronics, the implementation of changes in control logic as well as reducing the project lead-time is not possible. This method of control and automation was also quite popular for some time. It has one limitations that is this method is defined if and only if the task is fully defined. PROGRAMMABLE LOGIC CONTROL: With the coming of microprocessors and associated peripheral clips, the whole process of control and automation under went a radical change instead of achieving the desired control and automation through physical wiring control devices, the PLC it is achieved through PLCs in recent years experience an unprecedented growth as universal element in industrial automation. It can be used effectively from single control like replacing small number of relay to complex automation problems. CHARACTERISTICS FUNCTIONS OF PLC: The national Electric Manufactures Association (NEMA) currently defines a programmable controller as a Digital Electronic Device that uses a programmable memory to store instructions and to implement specific functions such as logic, sequence, timing, counting and arithmetic to control machines and process. It is field programmable by the user. This characteristic allows the user to write and change program in the field without rewriting or sending the unit returns back to the manufactures for this purpose. It contains preprogrammed functions. PLC features logic, timing, counting and memory functions so that the user can access through some type of control orient programming language. It scans memory, inputs and outputs in a deterministic manner. This critical Oriented feature allows the control engineer to determine precisely how the machine or process will respond to the logic. It provides error checking and diagnostics. A PLC will memory periodically run internal tests of memory, processor and I/O systems to

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ensure that what it is doing to the machine or process and what it was programmed to do. It can be monitored. A PLC will provide some from of monitoring capability either through indicting lights that show the status of inputs and outputs by an external device that can display the program execution status. It is packed appropriately. PLC is designed to withstand the temperature, Humidity, vibration, and noise found in most factory environments. It has general purpose suitability. Generally a PLC is not designed for a specific application but it can handle a wide variety of control tasks effectively. This unit can be operated in step by step automatic. STEP BY STEP: Step by Step should be selected before selecting any programmed. The step by step operation can be selected with the step by step push buttons and selection is indicated by the built in lamp push button. The selection can be reset by using the preselect Reset push button before the execution of program. It is also reset in case of a protection shut down. If step by step is selected the programmed selected and executed proceeds only one step at a time. After the criteria required for the next step are fulfilled, the execute push button glows and till the execute push button is pressed for the program does not proceed further to next step. This method is mostly useful during testing and commissioning. To ensure safety of unit, in the event of a protection shunt done, the step by step selection is automatically rest and the shut down programme is executed as and when it becomes necessary. AUTOMATIC OPERATION: There is no separate selection as such for automatic operation. If the step by step mode is not selected the unit under auto-operation as it is the default mode of operation. PROGRAMME SELECTION: The programme selected is indicated by a steady glow of corresponding arrow. Thus progrmme selected is rest either a new selection in which case the arrows switch over to correspond to new selection mode or by preset reset push button in which case the selection gets rest totally and arrows are switched off. The selection mode gets reset automatically if the sane is not executed within 10 seconds.

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EXECUTION: The programme selected can be executed by pressing the release and execute push buttons simultaneously. The push buttons shall be kept pressed for at least 2 seconds for the selected programme to start. This in additional safety precautions to avoid starting of a programme due to inadvertent operation of the push buttons. The steady light in the arrow now turns to slow flashing and the steady light in the status push button switched off. PROGRESSION OF THE PROGRAMME: The selected programmed, thus executed, proceeds step after step ensuring that the commands given out are properly executed by checking the proceed criteria. The step number of the step executed is indicated in the 4 digital, 7-segment LED display in the two digital 7- segment LED displays in the LCP only. PROGRESSION CRITERIA FAILURE: The time in which the commands of each step are to be executed is defined, taking into account the time required for the corresponding drives to operate. So, unless the proceed criteria for the next step are not fulfilled within the predefined time, the same is indicated by the flashing light in the indication lamp progression criteria failure. It will become steady once accepted. Simultaneously the missing criteria push buttons also glows. The programme proceeds further only after the missing criteria are fulfilled. FREEZE: Freezing of the programme is useful to change the dirtection of the program before it is completed.E.G the programme for SD by Sy.c.g. can be halted at a permissible step and the SD G programme can be selected and executed. The program under execution can be stopped only at any permissible step using push button FREEZE. The programmed is indicated by the flashing light in Freeze push button and will become steady once accepted. The slow flashing in arrows changes over to fast flashing indicating the disturbance in running programme. END OF PROGRAMME: After the last step is executed the programme comes to an end, and the unit reaches a steady state, if all the criteria defined for the status are

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fulfilled. This is indicated by the steady light in the corresponding mode push buttons.

DISTRUBANCE IN STATUS: If any of the criteria required for the steady status are lost for the some reason, the status lamp starts flashing indicating the disturbance in the status. This disturbance flashing can not be accepted by using the accept push button. The status lamp will become steady only after the missing critera are fulfilled. The missing criteria can be found out by the missing criteria indication system. AUTO INACTIVE: Auto inactive is also a selection to be made/reset when the machine is in a steady state. The selection can be made with the push button auto inactive and can be reset by preselect reset push button. The selection is indicated by the lamp in the push button. When auto inactive is selected, the commands from the sequence control to the drive control are totally blocked while all other indications such as arrow display, step display And missing criteria display is available. In auto inactive the sequence control will act a guide to the operator while he operated the machine manually. To ensure safety of the unit when any protection acts, it is programmed in such away that auto inactive selection gets is reset at the shunt down programme is executed automatically when the protection shunt down acts. ADDITIONAL FACILITIES PROVIDED IN THE CONTROL SYSTEM OF UNITS: The following additional facilities are provided in the control system supplied by SANAG for units 6 to 8 MISSING CRITERIA INDICATION: A facility to indicate criteria numbers of the missing criteria on demand, directly in the digital display is provided in the following cases: a) START NO READY b) PROGRESSION CRITERIA FAILURE, c) STATUS DISTRIBUTED

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1.Digital step display on the control desk in addition to the display on the LCP. 2. Digital display of the commands given out at each step in the LPC. 3. Manual control start. MISSING CRITERIA: For the indication of missing criteria, the same digital display in which the step number is indicated is made use of for recalling the missing criteria, a push button with built in signal lamp is provided in both the control consoles. METHOD OF INDICATION OF MISSING CRITERIA: FOR START NOT READY: In the control consoles of units 6 to 8, the 3 Nos. start not ready indicating lamps are replaced by push buttons with built in signal lamps. To find out the missing criteria corresponding to any of the start not ready lamps, the START NOT RADY push button should be depressed until the lamp in the missing criteria push button glows. Now if the missing criteria push down is pressed, the criteria number of the first missing criteria is indicated in both the digital displays. If there are more missing criteria the lamp continues to glow. By pressing the missing criteria push button repeatedly, all the missing criteria are indicated in the as sending order. When the last missing criteria is indicated on the digital display, the missing criteria lamp will switch off and after a small delay the digital display will display what it was showing before the missing criteria were indicated. FOR PROGRESSION CRITERIA: During the execution of any programme, if any of the criteria required for the progression of any step are not fulfilled within the specified time, the progression criteria failure lamp glows and simultaneously the lamp in the mission criteria push buttons also glows. Now by pressing the mission criteria push button, the missing criteria indicated in the digital display. FOR THE STATUS CRITERIA INDICATION: After reaching any steady status, the corresponding status lamp glows with a steady light. If for any reason any reason any of the status criteria changes state, the status lamp will start flickering. To find out the missing criteria, the push button with the flickering status lamp shall be kept pressed till the lamp in the missing criteria push button glow. Now by pressing the missing criteria push buttons the missing criteria are indicated in the digital display

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DIGITAL DISPLAY COMMANDS: In addition to the digital display of step numbers, commands given out in the last step executed are indicted in the digital displays mounted inside the local control panel. These displays are not provided in the control desk. MANUAL CONTROL START: While the first two additional facilities are provided in the sequence control, another important additional facility manual control start is provided in the control. To facilities starting the unit and taking it up to 100% speed, with all the necessary interlocks taken care of in case of any failure in the sequence control start is provided in the drive control. The control console for this purpose is provided on the door of the drive control panel housing mechanical drive cards and machine input cards. To manual control start operation is carried out in four steps starting the unit up to 100% speed, viz.0301,3002,0401 and 0402 and two steps for stopping the unit from 100% speed, viz 0105 and 0201. This is mainly useful to run the unit as generator/Spin generator. After starting the unit, using this console on the drive control panel, voltage building up and synchronizing shall be done from the control desk. Similarly only after the main breaker and field breaker are switched off from the manual control start control console. Each step is provided with a push button release, lamp test and manual control start buttons are also provided in addition to the start not ready indication lamp. Manual control start can be selected only when the sequence control panel is switched off or when the control is kept under AUTO INACTIVE manual control can be selected by using the manual control push buttons. The release push button is provided to avoided inadvertent operations as in the case of sequence control. Separate commands are to be given at each step. It is interlocked in such a way that commands to the next step can be given only after the previous step is complete, which is indicated by the steady light in the corresponding step button. The step under execution is indicated by a flashing lamp in the corresponding push button. The commands and the criteria interlocked for each step are identical to the automatic sequence control. For detailed manual control start scheme. STARTING AS S. Pu/Pu: BACK To BACK METHOD: the

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In this method another generator is utilized as back to back generator to start the required unit as s.pu/pu. Both will be connected to the starting bus through their starting isolators. SELECTION OF EXECUTION: To start one of the unit in the pump direction, the selection of s.pu/pu shall be done through its control consoles and one of the other 7 units shall be selected as back to back generator. Now the programmed shall be executed from the control console of the units selected as s.pu/pu. The back to back generator programme in the selected as back to back generators also start simultaneously with the s.pu/pu. The back to back generator does not need a separate execute command. STATIC FREQUENCY CONVERTER: All the controls required to start any of the 7 reversible units in the pumping direction using SFC equipment have also provided. SELECTION AND EXECUTION: The selection of the required units as S.pu/pu and the SFC mode of starting are to be selected from its own control consoles using the respective push buttons. The programme also to be executed from the same control console. All the commands required to be given to the SFC equipment are generated in the interface panel of stage-1. RANDOM COUPLING INTERLOCKING: Logic required for the interlocking to operated the units as back to back generator /pump is programmed in the microprocessor provided in the inter facing panel. It co-ordinates with the interface logic required for unit 1 to 5. The interface logic in the interface panel provided in stage 1 takes care of the total logic required for random coupling of all the 8 units as back to back generator/s.pu/pu. WORKING OF PLC: The process of working of PLC can be easily explained in four stages. BREAKING INPUT SIGNAL STATUS TO THE INTERNAL MEMORY OF THE CPU: The field signals are connected to the input modules. At the output of input modules, the filed status converted into the voltage level required by the CPU is always available. At the beginning if each cycle the CPU brings all field input signals from input module and stores into its internal memory as process image input.

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PROCESSING OF SIGNAL USING USER PROGRAM: Once the field input status is brought into the memory of CPU, the execution of user program, statement by statement begins. Based on the user program the CPU performs logic and arithmetic operations on the date from pore diagram. It also process times and counts as well as flag states. STORING THE RESULT OF THE PROCESSING IN THE INTERNAL MEMORY: The result of the use program scan are than stored in the internal memory of CPU. This internal memory is called PROCESS OUT PUT IMAGE.

SENDING PROCESS OUPUT IMAGE TO OUTPUT MODULE: At the end of the program run, at the end of scanning cycle the CPU transfers the signal states in the process image output to the module and further to field controls. INPUT AND OUTPUT MODULE: INPUT MODULE: The input modules act as an interface between the field input and the CPU. It converts the field signals generated by the sensors, transducers, limit switches, push buttons etc.. to a standard control signal for processing by PLC. The standard control signal delivered by input module could be 5v or 9v where as the field signal received by it could be the 24v Dc or 230v AC. It requires isolates the field signal from CPU. It sends one input at a time to CPU by multiplexing action. Depending upon the nature of the input signal coming from the field input module could be analog or digital input module. The typical analog current input modules are 4 20ma, and analog voltage input modules are 050mv, s5135 U programmable controllers employs digital input and out put modules. As shown in the block diagram the process signal s are conditioned in the input circuit of the module for processing at the internal level of the module. Most digital input modules supply isolated signals to the date register. An external signal at the enable input can disable processing of the input and disconnected the module from the bus system. The module address is set on an addressing switch, the controller issues a DRY acknowledgement signal to the CPU, if the address on the system bus recognized by the address decoder is identical with the address set. Then the

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data will be transferred to the CPU from the data register through the bus driver. ADVANTAGES OF PLC: PLC has a lot of advantages and some of them are explained below. REDUCE SPACE: PLC is fully solid-state devices and hence extremely compact as compared to hard-wired controller where in electromechanical devices are used. ENEGY SAVING: Average power consumption is just on e tenth of power consumed by an equivalent relay logic control. EASY OF MAINTENANCE: Modular replacement, Easy trouble shooting, Error diagnostics with programmer ECONOMICAL: Considering one time investment in PLC is most economical system. Cost of PLC recovers with in short period. GREATER LIFE AND RELIABILITY: These are static devices. Hence lesser number of moving parts, reducing wears and tears. TERMEDOUS FLEXIBILITY: To implement changes in control logic, no wiring is required. So considerable time is saved. It can carry out complex functions such as generation of time delays, counting, comparing arithmetic and logical operations etc. Also online(without disturbing process) and offline programming is possible. SHORTER PROJECT TIME: The hard wired control system can be constructed only after the task is fully defined. In PLC, however the construction of the controller and wiring are independent of control program definition. APPLICATIONS OF PLC: In industry, there are many production tasks, which are highly repetitive nature. Although repetitive and monotonous, each stage needs careful attention of operator to ensure good quality of final product. Many a times, close supervision of processes cause high fatigue on operator resulting

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in loss of task of process control. Sometimes it is hazardous as in the case of potentially explosive chemical processes. Under all such conditions we can use PLC effectively in totally eliminating the possibilities of human errors. Few examples in industries where PLC are used for control purpose are: Tire industry Ship unloaded Wagon loaders Steel plants Pulp factory Printing industry Dairy automation Coal handling section etc

COMPARISON
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COMPARISION: HARD WARE CONTROLS Vs PROGRAMMABLE CONTROLS HARDWARE CONTROL CIRCUIT: It is a conventional circuit. It consist of auxiliary contactor, timers and coils. Hardware has to be drawn through the circuit and terminal blocks have to the arranged for connection at different places. ADVANTAGES: 1. Initial cost is less 2. Less qualified persons are required DISADVANTAGES: 1. Regular maintenance is required 2. Trouble shooting is difficult 3. Actual wiring has to be for any change in logic 4. Less accurate in operation. PROGRAMMABLE CONTROLLER: Programmable controller are introduced to eliminate above problems and for following reasons. 1. Relay had limitations has control devices. 2. Manufacturing and process equipment were becoming more sophisticated

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ADVANTAGES: 1. A number of control programs can be run on the same PLC for different applications. 2. Fast implementation of changes in control program. 3. Large quantities of contacts are available. 4. High speed operation. 5. PLC operation status can be seen on the video display unit in minute display details step by step that makes trouble shooting easier 6. More reliable than relays DISADVANTAGES: 1. High initial cost. 2. Qualified persons are required to maintained system.

CONCLUSION

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CONCLUSION
The programmable Logic controllers used for Automation & control at NSPH are versatile and simple and simple. This PLC system gained more popularity due to the advent of LSI/VLSI technology. This replaced the old version of complicated relay logic that were normally slow in operation, prone to frequent troubles due to mal operation of relays. This is totally avoided in digital logic controls. Because of the advantage of flash memories. The software programs could easily be altered as per necessarily even after years of commissioning. Facilitating easy updating of plant logic. The PLCS are highly adaptable and can easily be coupled to the stand alone system like Excitation system and Governor System etc., there by opening the possibility of pre fabricated logics and easy coordination resulting in smaller commissioning periods. The high speed Digital controls are capable of accurately controlling the plant operation. Every control viz. proportional, integral & differential controls and their combination is possible to be realized. The usage of digital soft ware programs rules out the ageing effects caused by employing inductor, capacitors incorporated in Analog controls. The modular design of PLCS reduced the size of control panels, brought in cost reduction and plant esthetics this modular designer also reduced the cost of inventory and hence the cost of spares. In case of fault, the operation of entire power station can easily be diagnosed and the fault be located and attended quickly and accurately, thereby reducing the down time of the machines. FUTURE SCOPE: The latest developments in Digital Communication Technology High Speed data transfer are now opening new frontiers to more sophisticated controllers

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called Distributed Digital Controllers like Max DNA controller which are more powerful versatile, fast and even more flexible and economical

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