Control Write Up Hcsd

This document is, unless otherwise agreed in writing, the property of TECPRO SYSTEMS LIMITED, and shall not be reproduced, copied, disclosed to any third party or used any purpose other than that for which it is supplied or disclosed. 5 4 3 2 1

REVISED AS PER COMMENTS

DOC.

Approval

P.K.M.

SOURAV

S.M.

18.07.11

0

FIRST SUBMISSION

DOC.

Approval

P.K.M.

SOURAV

S.M.

31.05.11

REV.

STATUS

TYPE

REASONS FOR REVISION

PREPARED CHECKED APPROVED BY BY BY

DATE

INDIA KMPCL 6X600MW Sub Critical Coal – Fired Power Station Project OWNER

KSK MAHANADI POWER CONSTRUCTION CO. LTD. : OWNER'S ENGINEERS

:

DEVELOPMENT CONSULTANTS PVT. LTD. CONSULTING ENGINEERS KOLKATA, MUMBAI, CHENNAI, NEW DELHI

CONTRACTOR

SEPCO ELECTRIC POWER CONSTRUCTION CORP. JINAN , CHINA : CONTRACTOR'S

ENGINEERS:

NORTHEAST ELECTRIC POWER DESIGN INSTITUTE (OF CHINA POWER ENGINEERING CONSULTING GROUP) Changchun, China

TECPRO SYSTEMS LTD. (ASHTECH DIVISION)

T

KOLKATA PUNE

CONTROL WRITE UP TSL DOC. No. 563-C&I-203 29/7/2011 B. G. Zarbade

Space for Approval Stamp

As attached

CLIENT DOC. No. KMP-0-AHSV404-N-203

REV.NO.: 1

TECPRO SYSTEMS LTD. (ASHTECH DIVISION)

KSK MAHANADI THERMAL POWER PROJECT HCSD SYSTEM (6 x 660 MW)

CONTROL WRITE UP CLIENT DOC. NO.: KMP0-AHS-V007-N-203 REV.-1

CONTROL WRITE – UP CHAPTER – I   1.0 

  HIGH CONCENTRATION SLURRY DISPOSAL SYSTEM 

 

1.1 

 INTRODUCTION  Ash  handling  system  is  provided  with  High  concentration  slurry  disposal system for which two common Fly ash silos for each 3x600  MW  unit  are  provided.  This  Fly  ash  Silos  will  feed  ash  to  three  independent  streams  of  HCSD  system.  Two  streams  shall  normally  be  working  and  one  stream  will  be  available  as  standby.  The  silo  shall  have  three  openings.  These  three  openings  of  Fly  ash  silo  will  be  connected  to  three  independent  streams  of  high  concentration  slurry disposal system for continuous disposal of high concentrated  slurry to ash disposal area with 65‐70% ash concentration. Water is  added in mixing tank with moist ash in a controlled manner through  continuous  automatic  “Instrument  Based”  monitoring  system  to  ensure that the basic slurry parameters remain constant during the  transportation of slurry through the pipe line.    The pump speed shall be varied through VFD drive over the range of  10% to 100% of maximum flow rate. Necessary remote and manual  speed  control  provision  is  there.  There  are  two  nos.  of  dedicated  transformer to feed the power supply to VFD and after VFD to HCSD  motor.  The  following  aspects  govern  the  basic  arrangement  of  high  concentration slurry system. 

  a) b) c) d)

Controlled Ash Feed.  Controlled water supply to maintain proper slurry density.  HCSD Pump.  Disposal Pipe line.  1

TECPRO SYSTEMS LTD. (ASHTECH DIVISION)

KSK MAHANADI THERMAL POWER PROJECT HCSD SYSTEM (6 x 660 MW)

CONTROL WRITE UP CLIENT DOC. NO.: KMP0-AHS-V007-N-203 REV.-1

  There are many control features, which have to work for guaranteed  monitoring of proper slurry density in a continuous manner so that  the slurry pump can operate uninterruptedly.    1.2  MAJOR EQUIPMENTS FOR HCSD SYSTEM    • ROTARY FEEDER WITH VFD [ SEPCO SCOPE]    One  (1)  no.  Rotary  Feeder  is  provided  in  upstream  of  each  screw  Feeder and takes fly ash input from HCSD silo. It is to be noted that  the Rotary Feeder has variable speed control and have ash disposal  capacity  of  225  TPH.  The  speed  of  Rotary  Feeder  is  automatically  adjusted as per the reading of Mass Flow meter to maintain required  ash  flow  for  slurry  consistency  (60%  ‐  70%).For  variation  of  Rotary  Feeder  speed  a  VVVF  drive  is  provided.  Mass  flow  meter  is  continuously monitor the feeding rate of fly ash from Rotary Feeder  to  Mixer  tank  through  Screw  Feeder  and  Paddle  Feeder  and  thus  control of ash feeding rate into the system is achieved.     • SCREW FEEDER [ SEPCO SCOPE]    Screw  Feeder  is  provided  in  between  Rotary  Feeder  and  Paddle  Feeder  for  transportation  of  dry  fly  ash  from  Rotary  Feeder  to  Paddle  Feeder  because  of  their  eccentric  location.  The  capacity  of  Screw Feeder shall be same as Rotary Feeder.    • PADDLE FEEDER [ SEPCO SCOPE]    This is a twin Paddle mixture unloader having capacity 225 TPH. This  is  provided  in  upstream  of  Slurry  mixing  tank  where  dry  fly  ash  is  been moist and discharge to ART (Agitated Retention Tank).        2

TECPRO SYSTEMS LTD. (ASHTECH DIVISION)

KSK MAHANADI THERMAL POWER PROJECT HCSD SYSTEM (6 x 660 MW)

CONTROL WRITE UP CLIENT DOC. NO.: KMP0-AHS-V007-N-203 REV.-1

• AGITATED RETENTION TANK (ART) [ TSL SCOPE]    The ART is a rubber lined cylindrical tank with vertical spindle, twin  blade, dual impeller type high torque agitator. The output of Paddle  Feeder  fed  into  ART  where  required  slurry  concentration  and  rheology  is  maintained  and  monitored.  The  ART  is  provided  with  Level  Transmitter  for  continuous  level  control  measurement,  Nucleonic  and  Non‐nucleonic  type  Density  meter  for  density  measurement  and  PH  meter  for  measurement  of  PH  value  of  ash  slurry.  The  ART  is  provided  with  proper  flushing  and  drain  connection.    The mixing tank (ART) will have five level controls.  a) High High Level (90 %).  b) High Level (80%)  c) Operating level (70%).  d) Low level (10%).  e) Danger low level (0%).    Zero level (0%) is set at the start of the lower part of tank.  The 90%  level is the maximum slurry level allowable in the tank.    • CHARGE PUMP [ SEPCO SCOPE]  Total  Three  (3)  nos.  charge  pump,  one  for  each  HCSD  stream  has  been  providing  at  the  suction  of  HCSD  pumps  for  each  3X600  MW  unit. The pump parameters are 265 cu.M/Hr. @30 MWC.    Charge pump can be started under the following condition:    o Either suction valve or water line valve should be open.  o If  suction  valve  is  open,  then  agitator  tank  level  should  be  high.  o If  water  line  valve  is  open,  then  water  pressure  should  be  above preset value.  3

TECPRO SYSTEMS LTD. (ASHTECH DIVISION)

KSK MAHANADI THERMAL POWER PROJECT HCSD SYSTEM (6 x 660 MW)

CONTROL WRITE UP CLIENT DOC. NO.: KMP0-AHS-V007-N-203 REV.-1

  The pump will trip is the above conditions are not fulfilled.    • MEASURING LOOP PUMP [ TSL SCOPE]   

One Hose pump each having capacity 1.5 cu.M/Hr. @30 MWC   provided with each slurry mixing tank for measuring the slurry  density of a mixing tank by non nucleonic density meter.      1.3  HCSD PUMP [ SEPCO SCOPE]    There  are  three  sets  of  HCSD  Pump  (2W  +  1S)  each  having  ash  disposal  of  225  TPH  (Dry  ash  basis)  for  two  Fly  ash  silo  with  motor  and  VFD  are  provided  for  total  three  streams.  Capacity  of  HCSD  Pump  is  265cu.m/hr  @  300  MWC.  Among  the  three  independent  high concentration slurry disposal streams, two are working for two  F.A  Silo  and  one  is  common  standby.  Three  HCSD  Pumps  are  connected  with  three  nos.  slurry  disposal  line  with  necessary  interconnection and instrumentation.    The starting permissive of HCSD Pump from HCSD PLC are as follows:     • HCSD Pump not failed.  • HCSD  Pump  ready  to  run  (Feed  back  from  HCSD  PLC  to  main  PLC)  under the following condition:    a) VFD ready to run.  b) Pump ready to run.  c) Propelling pump on.  d) Lub pump on.  e) Suction flow normal.  f) Propelling liquid pressure normal.  g) Air pressure normal.      4

TECPRO SYSTEMS LTD. (ASHTECH DIVISION)

KSK MAHANADI THERMAL POWER PROJECT HCSD SYSTEM (6 x 660 MW)

CONTROL WRITE UP CLIENT DOC. NO.: KMP0-AHS-V007-N-203 REV.-1

• HCSD Pump Auto/manual selection from HCSD SCADA.      The starts permissive of HCSD Pump from main PLC are as follows:    • Manual suction valve open.  • Mixture run feed back.  • Mixture tank level not low.  • IAC Pressure normal.  • HCSD PLC ready.  • Paddle feeder health.  • Rotary feeder healthy.  • Mixing tank density (minimum) below preset value.  • VFD Ready to RUN     

   

*****************

5

TECPRO SYSTEMS LTD. (ASHTECH DIVISION)

KSK MAHANADI THERMAL POWER PROJECT HCSD SYSTEM (6 x 660 MW)

CONTROL WRITE UP CLIENT DOC. NO.: KMP0-AHS-V007-N-203 REV.-1

CHAPTER II Control Systems   1. HCSD CONTROL SYSTEM    The entire HCSD system for unit‐1,2,3,4,5&6 is PLC based control system.  The  overall  control  and  sequential  operation  of  the  total  HCSD  system  is  achieved through   this main programmable logic controller (SEPCO Scope).  The  control  of  the  HCSD  system  is  basically  from  main  system  PLC  and  HCSD pump PLC when the ART control panel shall act as a local panel with  local  actuation  facility  of  Agitator  and  Measuring  loop  pump  with  local  feedback and annunciation.  

The  ART  control  panel  (TSL  SCOPE)  shall  be  connected  with  main  system  PLC through hardwire cable (By SEPCO). PLC of HCSD system shall correct  the  speed  of  the  pump,  control  ash  feeding  from  silo  and  for  other  necessary action on the feedback given by ART control panel.   

The  Agitator  and  Hose  pump  shall  be  running  from  main  PLC  as  well  as  through ART control panel.     All  interlocks  /  annunciations  from  field  instruments  related  to  ART  tank  provided by TSL shall be demonstrated during commissioning.    The  control  and  Instrumentation  scope  for  the  HCSD  System  is  limited  to  the supply of Control panels & field Instruments related to ART Tank as per  P&ID 563‐01‐02 REV 3.     Various voltages / currents for the system are as follows.      1)  ART Panel Output for lamp: 24V DC  2)  ART Panel light, space heater: 240V AC   

6

TECPRO SYSTEMS LTD. (ASHTECH DIVISION)

KSK MAHANADI THERMAL POWER PROJECT HCSD SYSTEM (6 x 660 MW)

CONTROL WRITE UP CLIENT DOC. NO.: KMP0-AHS-V007-N-203 REV.-1

CHAPTER III PROTECTION AND INTERLOCK                     Protection and interlock for the HCSD System is attached herewith.

 

7

PROTECTION INTERLOCK

1

2

1

2

HCSD PUMP [ 6 nos.]

MIXING TANK AGITATOR [ 6 nos.]

Ref. Drg. 3

563-01-02

Equipment

563-01-02

S.N.

Interlocks Starting Permissive 4

Running Permissive 5

Annunciation

Indications/ Mimic

6

7

1.Manual suction valve open.

1.Manual suction valve open.

1.VFD Trip (OS)

1.HCSD Pump ON Red Lamp (OS)

2.Agitatot run feed back.

2.Agitatot run feed back.

2.HCSD Pump Failed (OS)

2.HCSD Pump OFF Green Lamp (OS)

3.Agitatot tank level not low.

3.Agitatot tank level above Danger 3.Mixing Tank Level Danger Low. Low (OS)

3.GEHO Pump Trip Amber Lamp (OS)

4.IAC Pressure normal.

4.IAC Pressure normal.

4.Density Low (OS)

4.Mixure Tank Level Danger Low Red Lamp (OS)

5.HCSD PLC ready.

5.HCSD PLC ready.

5.Density High (OS)

5.Mixure Tank Level Low Red Lamp (OS)

6.Paddle feeder health.

6.Paddle feeder health.

6.Mixure Tank Level High Red Lamp (OS)

7.Rotary feeder healthy.

7.Rotary feeder healthy.

7.Density High Red Lamp (OS)

8.Mixing tank density (minimum) below preset value

8.Mixing tank density (minimum) below preset value

8.Density Low Red Lamp (OS)

9.VFD Ready to RUN

9.VFD Ready to RUN

1.Start Command Initiated

1.Stop Command NOT Initiated

1.Mixure Tank Level Low (OS)

1.Start Red Lamp (OS/ ART Panel)

2.MCC Available

2.MCC Available

2.Agitator TRIP (OS / ART Panel)

2.Stop Green Lamp (OS/ ART Panel)

3.MCC Not disturbed

3.MCC Not disturbed

3.Mixure Tank Level Danger Low (ART Panel)

3.Trip Amber Lamp (OS/ ART Panel)

4.Tank Level above LOW

4.Tank Level above DANGER LOW

4.Mixure Tank Level Low (ART 4.Tank Level Danger Low Red Panel) lamp (OS)

5. Remote Selected from OS

5. STOP push button not pressed.

5.Mixure Tank Level High (ART 5.Tank Level Low Red lamp (OS) Panel) 6.Tank Level High Red Lamp (OS)

Controls Provided 8

Controlled From 9

Start / Stop P.B. Switch (OS)

OS

Start / Stop P.B. OS / ART Switch (OS / PANEL ART Panel)

PROTECTION INTERLOCK

2

3

CHARGE PUMP [ 6 nos.]

4

ROTARY FEEDER VFD [ 6 Nos.]

5

MEASURIN G LOOP PUMP / HOSE PUMP [ 6 Nos.]

Interlocks Starting Permissive 4

Running Permissive 5

7

1.Stop Command NOT Initiated

1.TRIP (OS)

2. MCC available. 3. Seal water Pressure NORMAL. 4. MCC NOT Disturbed. 5. Agitator Tank Disc. valve open 6. Agitator tank Level above LOW

2. MCC available. 3. Seal water Pressure NORMAL. 4. MCC NOT Disturbed. 5. Agitator Tank Disc. valve open 6. Agitator tank Level above

2.Seal water Pressure LOW (OS) 2.Stop Green Lamp (OS) 3.Trip Amber Lamp (OS)

1.Start command initiated.

1.Stop Command NOT Initiated

1.TRIP (OS)

2.MCC not disturbance.

2.MCC not disturbance.

2.Stop Green Lamp (OS)

3. VFD ready to run

3. VFD ready to run

3.Trip Amber Lamp (OS)

4. Screw feeder RUNNING

4. Screw feeder RUNNING

1.Start command initiated.

1.Stop command not initiated.

2.MCC not disturbance.

2.MCC not disturbance.

3.MCC available.

3.MCC available.

563-01-02

6

6

Indications/ Mimic

1.Start command initiated.

4.Mixing tank Level above LOW

SCREW FEEDER [ 6 Nos.]

Annunciation

563-01-02

1

Ref. Drg. 3

563-01-02

Equipment

563-01-02

S.N.

4.Mixing tank Level above DANGER LOW 5. Discharge pressue Not LOW

1.Start command initiated.

1.Stop Command NOT Initiated

2.MCC not disturbance. 3. VFD ready to run 4. Paddle feeder RUNNING

2.MCC not disturbance. 3. VFD ready to run 4. Paddle feeder RUNNING

1

1.TRIP (OS / ART Panel)

Controls Provided 8

Controlled From 9

Start / Stop P.B. Switch (OS)

OS

1.Start Red Lamp (OS)

1.Start Red Lamp (OS)

Start / Stop P.B. Switch (OS) OS

Start / Stop P.B. 1.Start Red Lamp (OS/ ART Panel) Switch (OS/ ART PANEL)

2. Discharge Pressure HIGH (OS 2.Stop Green Lamp (OS/ ART / ART PANEL) Panel) 3.Trip Amber Lamp (OS/ ART Panel) 4. Discharge Pressure HIGH Red Lamp (OS) 5. Discharge Pressure NORMAL Red Lamp (OS) 1.TRIP (OS)

1.Start Red Lamp (OS) 2.Stop Green Lamp (OS) 3.Trip Amber Lamp (OS)

OS / ART PANEL

Start / Stop P.B. Switch (OS) OS