OVERVIEW OF C&I

SYSTEMS
IN POWER PLANT

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 SALIENT FEATURES AND

MAJOR COMPONENTS OF

DDCMIS

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 SALIENT FEATURES OF DDCMIS

• INTEGRATED PLANT CONTROL FOR SG, TG

AND BALANCE OF PLANT CONTROL
• IT MAY BE REMEMBERED THAT
HISTORICALLY THE TERM DDCMIS USED TO
BE REFERRED FOR THE SO-CALLED “BOP-
C&I” . THE SG-C&I, i.e. FSSS etc. TG-C&I i.e.
ATRS, TURBINE PROTECTION etc. ORIGINALLY
WERE NOT CONSIDERED UNDER DDCMIS OR
DCS AS PER MANY SUPPLIERS. ONLY
RECENTLY THE TYPE OF SYSTEMS FOR ALL
THE SYSTEMS HAVE BECOME SIMILAR

Tuesday, November 30, PMI Revision 00 3

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 SALIENT FEATURES OF DDCMIS

• INTEGRATED PLANT OPERATION THROUGH FULLY

INTERCHANGEABLE OPERTAOR WORK STATIONS
(OWS) FOR SG, TG AND BALANCE OF PLANT
(SOMETIMES THIS MAY NOT BE POSSIBLE DUE TO
PACKAGING CONCEPT)

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 SALIENT FEATURES OF DDCMIS

• PROVISION OF EXTENSIVE SELF-

DIAGNOSTICS
• USE OF LARGE VIDEO SCREENS FOR
PROJECTIONS OF VARIOUS PLANT MIMICS
ETC.
• PROVISION OF FAULT ALARM ANALYSIS TO
GUIDE THE OPERATOR TO THE MOST LIKELY
EVENT
• PROVISION OF TREND ALARMS

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 SALIENT FEATURES OF DDCMIS

• PROVISION OF SAFETY HARDWARE FOR

BURNER MANAGEMENT SYSTEMS

• PROVISION OF FAIL-SAFE HARDWARE FOR

TURBINE PROTECTION SYSTEM

• PROVISION OF ADEQUATE RELIABILITY AND

AVAILABILITY WITH PROPER REDUNDANCY IN
SENSOR, I/O AND CONTROLLER.

Tuesday, November 30, PMI Revision 00 6

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 DDCMIS CONFIGURATION ST-1
AND ST-2 COMPARISON

maxDNA
SYSTEM
ENGG. STN
HMI
FOR HMI

PROCONTROL MMI LAN

SYSTEM
HMI
REDUNDANT
SERVERS
ENGG.STN.
FOR CONTROL SYS. I.P. BUS Max. 4
nos. rdundant

Redundant
F.G.Controllers

Measurement system / I/O

subsystem

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 MAJOR COMPONENTS OF
DDCMIS

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 MAJOR COMPONENTS OF
DDCMIS

• CONTROL SYSTEM

• MAN-MACHINE INFORMATION AND PLANT

INFORMATION SYSTEM (MMIPIS)

• REDUNDANT DATA COMMUNICATION SYSTEM

(DCS)

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 MAJOR COMPONENTS OF
DDCMIS

• SEQUENCE OF EVENT (SOE ) AND ANNUNCIATION

SYSTEM FUNCTIONS

• SYSTEM PROGRAMMING FACILITY

a) TUNING & CONFIGURATION FOR CONTROL
SYSTEM
b) MODIFICATION & PROGRAM DEVELOPMENT FOR
MMIPIS

• MASTER & SLAVE CLOCK SYSTEM

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 CONTROL SYSTEM

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 CONTROL SYSTEM
PROGRAMMING & MMIPIS M&S
CONFIGURATION SYSTEM CLOCK

DCS

SG- C&I BOP- C&I TG- C&I

SYSTEM SYSTEM SYSTEM

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 SG-C&I SYSTEM
• CONSISTS OF BURNER MANAGEMENT
SYSTEM (BMS), SOOT BLOWER CONTROL
SYSTEM (SBC), SECONDARY AIR DAMPER
CONTROL SYSTEM (SADC), AUXILIARY PRDS
CONTROLS (APRDS)
• FOR BMS, “SAFETY SYSTEM” HARDWARE IS
SPECIFIED, i.e. THE HARDWARE , WHICH
MEETS THE REQUIREMENT OF RELEVANT
NFPA AND VDE STANDARDS`

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 SG-C&I SYSTEM

• TRIPLE REDUNDANT CONFIGURATION FOR THE

FURNACE PROTECTION (MFT) PORTION OF BURNER
MANAGEMENT SYSTEM (BMS)
• FOR SBC, SADC, APRDS,MILL & OIL ELEV. SEQUENCE,
INTERLOCK AND PROTECTION, CONFIGURATION
SIMILAR TO OLCS/CLCS (DESCRIBED LATER)
• FOR MILL & OIL ELEV. LOGICS, SAFETY SYSTEM
HARDWARE SHALL BE USED

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 TG-C&I SYSTEM

• CONSISTS OF TURBINE PROTECTION SYSTEM

(TPS), AUTOMATIC TURBINE RUN-UP SYSTEM
(ATRS), AUTOMATIC TURBINE TESTING SYSTEM
(ATT), ELECTRO- HYDRAULIC TURBINE
CONTROL SYSTEM (EHTC) FOR MAIN & BFP
TURBINE, TURBINE STRESS CONTROL SYSTEM
(TSCS), GLAND STEAM PRESSURE CONTROL
GENERATOR SEAL OIL, PRIMARY WATER &
HYDROGEN CONTROL SYSTEM (RECENT
ADDITION).

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 TG-C&I SYSTEM

• TRIPLE REDUNDANT OR 2 X 100 % REPEATED

TWICE CONFIGURATION FOR THE TURBINE
PROTECTION SYSTEM (TPS). FOR THIS,
SAFETY SYSTEM HARDWARE / FAIL-SAFE
HARDWARE SHALL BE USED
• FOR OTHERS, CONFIGURATION SIMILAR TO
OLCS/CLCS (DESCRIBED LATER) TO BE USED

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 BOP-C&I SYSTEM

• CONSISTS OF OPEN LOOP CONTROL SYSTEM

(OLCS) AND CLOSED LOOP CONTROL SYSTEM
(CLCS)

• OLCS -THE SEQUENCE CONTROL, INTERLOCK OF OF

ALL THE PLANT SYSTEMS WHICH ARE NOT COVERED
IN THE SG-C&I AND TG-C&I. THIS INCLUDES MAJOR
AUXILIARIES LIKE FD/ID/PA FANS, AIR-PREHEATER,
BFP/CEP/CWP/ BCWP , DMCWP/CLCWP AND
ELECTRICAL BREAKERS.

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 BOP-C&I SYSTEM

• (CLCS) -THE MODULATING CONTROL FOR VARIOUS

IMPORTANT PLANT PARAMETERS, LIKE FW FLOW
(DRUM LEVEL), FURNACE DRAFT, COMBUSTION
CONTROL (FUEL FLOW AND AIR FLOW), PA HDR
PRESSURE CONTROL,
DEAERATOR/HOTWELL/HEATER LEVEL CONTROLS
ETC.

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 MMIPIS

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 MAN-MACHINE INTERFACE AND
PLANT INFORMATION SYSTEM
• LATEST STATE-OF-THE-ART WORKSTATIONS /PCs AND
SERVERS BASED ON OPEN-ARCHITECTURE AND
INDUSTRY STANDARD HARDWARE AND SOFTWARE TO
ENSURE BETTER CONNECTIVITY.
• e.g. HARDWARE FROM COMPAQ/DIGITAL, HP, SUN
MICRO-SYSTEM OR OTHER MAJOR SUPPLIERS (LESS
DEPENDENCE ON THE C&I SYSTEM SUPPLIER IN THE
LONG RUN)
• OPERATING SYSTEM WINDOWS-2000, OPEN-VMS OR
UNIX.

Tuesday, November 30, PMI Revision 00 20

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 MAN-MACHINE INTERFACE AND
PLANT INFORMATION SYSTEM
• 64/ 32-BIT SERVER/OWS WITH HIGH-SPEED AND
LARGE MEMORY (256/512 MB RAM, 8 GB HDD FOR
SERVER AND 128/256 MB RAM AND 4/6 GB HDD FOR
OWS) TO ENSURE FAST RESPONSE
• PROVISION OF LVS
• CONNECTION TO OTHER SYSTEM THROUGH
STATIONWIDE WAN

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 MMIPIS FUNCTIONALITIES
• VPC OPERATION
• OTHER OPERATOR INFORMATIONS THROUGH
VARIOUS DISPLAYS
• ALARMS, LOGS, HISTORICAL AND LONG TERM
STORAGE.
• PERFORMANCE AND OTHER CALCULATIONS

Tuesday, November 30, PMI Revision 00 22

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 MMI SYSTEM- P13 DCS ST-1 SIMHADRI
LVS -1 LVS -2 LVS -3 LVS -4

WORKSTATIONS
WSPOSE PANEL
LAN
SERVER2 SERVER1
IPB
ACCESS
COUPLER

SG PACKAGE TG PACKAGE STN. C&I

(17 L.B.) (20 L.B.) (65 L.B.)
IPB - 1

IPB - 2

IPB - 3

IPB - 4
 IPB to WSPOSE CONNETION
IPB Line B MMI
WSPOSE-1
IPB Line A SERVER-1
70
FK01 70
70FA01 CK
70 01
70FV01b 70FV01b
FK01

WSPOSE-2 SERVER-2
70
FK01 70
CK
70 01
FK01
 WSPOSE MODULES

US (15V)
VOC 5V
Z 0V

ADDRESS BUS
Serial CKA RECEIVE
To RAM
DATA BUS RECEIVE
parallel CKD
16K X16
DATA BUS TRANSMIT RT GB
Parallel CIFD
To serial
20 INC

CONTROL BUS TRANSMIT

Control RAM
logic
1/2K X16
VME
64 POLE CONNECTOR STRIP
BUS
|X|X|
70CK01
PCIF
Tuesday, November 30, PMI Revision 00 26
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Tuesday, November 30, PMI Revision 00 34
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 SOE

Tuesday, November 30, PMI Revision 00 35

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• SEQUENCE OF EVENT (SOE ) AND ANNUNCIATION
SYSTEM FUNCTIONS

• ORIGINALLY THESE USED TO BE STAND-ALONE

SYSTEM (DIODE AUCTIONEERING, DBTC ETC
REQUIRED)
• NOW INTEGRATED -THEREFORE THE DIODE
AUCTIONEERING, DBTC ETC NOT REQUIRED
• SOE - 1mS RESOLUTION, STORAGE OF REPOTRS FOR
LONG DURATION
• ANNUNCIATION LOGIC THROUGH OLCS/CLCS
CONTROLLERS.

Tuesday, November 30, PMI Revision 00 36

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 SYSTEM
PROGRAMMING
FACILITY

Tuesday, November 30, PMI Revision 00 37

2021
 SYSTEM PROGRAMMING FACILITY

• LATEST TREND - COMBINED CONTROL

SYSTEM TUNING & MMIPIS PROGRAMMING
• SELF-DOCUMENTATION
• ENGINEERING WORKSTATIONS

Tuesday, November 30, PMI Revision 00 38

2021
 Object-Oriented Configuration

• Graphical object-oriented
configuration software tool
• Includes self-documentation
of configuration
• True object-oriented
features including
encapsulation and
inheritance
• Library of standard
algorithms or “objects”
Tuesday, November 30, PMI Revision 00 39
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C
 MASTER & SLAVE
CLOCK SYSTEM

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 MASTER & SLAVE CLOCK SYSTEM

• RECEIVES TIME SYNCHRONISATION SIGNALS

EITHER FROM THE GEO-POSITIONARY
SATELITE (NPL SIGNAL)

• DISTRIBUTES THIS SIGNAL TO THE MMIPIS

AND THE CONTROL SYSTEM.

Tuesday, November 30, PMI Revision 00 41

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 OTHER RELATED TOPICS

Tuesday, November 30, PMI Revision 00 42

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 OTHER RELATED TOPICS

• POWER SUPPLY SYSTEM

• CABLING & TERMINATION OTHER

SG/TG C&I SYSTEM/ EQUIPMENT
• PACKAGING CONCEPTS- SCOPE OF
SUPPLY OF C&I SYSTEM/PACKAGE

Tuesday, November 30, PMI Revision 00 43

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 OTHER RELATED TOPICS

• OPERATION PHILOSOPHY , CONTROL

AREA AND BACK-UP INSTRUMENTATION
& GEOGRAPHICAL DISTRIBUTION -
COMBINED CYCLE PLANTS
• REDUNDANCY
• DESIGN CRITERIA

Tuesday, November 30, PMI Revision 00 44

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 POWER SUPPLY SYSTEM
• CONTROL SYSTEM POWER SUPPLY TWO SETS OF DC POWER
SUPPLIES - ONE SET FOR SG/TG-C&I AND OTHER FOR BOP-C&I
EACH WITH 2 X 100 % CHARGER AND 2 X 100 % BATTERY

• OTHER IMPORTANT AC LOADS LIKE MMIPIS, PANEL

INSTRUMENTS, ANALYSERS ETC. SHALL BE POWERED FROM
UPS COMPRISING OF 2 X 100 % CHARGER, 2 X 100 %
INVERTER AND 1 X 100 % BATTERY

• HEAVY DUTY Ni-Cd BATTERIES HAVE BEEN ENVISAGED FOR

LONGER LIFE & LESSER MAINTENANCE

Tuesday, November 30, PMI Revision 00 45

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 CABLING & TERMINATION
• EXTENSIVE GROUPING OF SIGNALS BY LARGE
SCALE USE OF JBs AT STRATEGIC LOCATIONS

• USE OF CABLES WITH HIGHER NO OF PAIRS

• USE OF CAGE-CLAMP CONNECTION FOR SYSTEM

CABINETS, MARSHALLING PANELS & OUTGOING
SIDE OF JBs, CJS BOXES etc.

• USE OF PLUG-IN SOCKET AND CONNECTORS FOR

TRANSMITTERS, SWITCHES, LS/TS etc.
Tuesday, November 30, PMI Revision 00 46
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 IMPORTANT SG/TG RELATED C&I
SYSTEM
• FLAME MONITORING SYSTEM

• COAL FEEDER C&I

• ELECTROMATIC SAFETY VALVES

• FURNACE TEMP PROBES

• ACCOUSTIC PYROMETER FOR FURNACE TEMP PROFILE

• BOILER FLAME ANALYSIS SYSTEM

• COAL BUNKER LEVEL MONITORING SYSTEM

• ELECTRONIC DRUM/SEPARATOR LEVEL MONITORING SYSTEM

• TURBINE SUPERVISORY SYSTEM

• TDBFP TURBINE SUPERVISORY SYSTEM

• IN PACKAGED SYSTEM, THESE ARE UNDER SG & TG PACKAGES.

Tuesday, November 30, PMI Revision 00 47

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 OPERATION PHILOSOPHY
• CENTRALISED OPERATION OF MAIN PLANT THROUGH OWS & LVS

• OFF-SITE PLANTS TO BE CONTROLLED FROM THEIR LOCAL

STATIONS WITH STATION-WIDE LAN DATA LINK

• MINIMUM BACKUP INSTRUMENTATION ( ORIGINALLY

CONSERVATIVE, NOW REDUCED. CRITERIA - HANDLING
EMERGENCY & SAFE SHUT-DOWN)

• GEOGRAPHICAL DISTRIBUTION - ALTHOUGH NOT VERY USEFUL

FOR POWER PLANTS AS COMPARED TO PROCESS/INDUSTRIES,
BEING ADOPTED FOR FEW AREAS WHERE SIGNALS ARE
CONCENTRATED (REDUCTION OF CABLING, MUCH LESS
ERECTION & COMMISSIONING TIME)

Tuesday, November 30, PMI Revision 00 48

2021
 DESIGN CRITERIA
• PROVENNESS
– SUPPLIER’S EXPERIENCE
– SYSTEM EXPERIENCE
– PROVENNESS VS OBSOLESCENCE
• RELIABILITY AVAILABILITY
– HARDWARE QUALITY (PUBLISHED MTBF etc.)
– CONFIGURATION
– REDUNDANCY
– FAULT TOLERANCE
• STANDARDISATION AND UNIFORMITY OF H/W
– SAME SERIES & FAMILY OF H/W AS FAR AS POSSIBLE
– DIFFICULTIES BECAUSE OF PACKAGING CONCEPTS &
RESPOSIBILITY CENTRE & INTERFACES (EVEN IN TURNKEY
PACKAGE)

Tuesday, November 30, PMI Revision 00 49

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 DESIGN CRITERIA
• OPERABILITY
– DESIGN CONCEPT - FAIL SAFE ETC.
– FALSE TRIP VS SAFETY
– OPERATOR CONVENIENCE DURING NORMAL RUNNING &
EMERGENCY
– MANAGEMENT REPORTING

• MAINTAINBILITY
– STANDARDISATION (AS INDICATED ABOVE)
– MODULAR DESIGN AND EXPANDABILITY
– DIAGNOSTIC, FAULT IDENTIFICATION AND FAULT TOLERANCE
– GUARD AGAINST OBSOLESCENCE
– AVAILABILTY OF SPARES
• OTHER CRITERIA
– UNIT OPERATION PHILOSOPHY
– MARKET TRENDS AND EVOLUTION OF INFORMATION TECHNOLOGY
– FEEDBACKS FROM EXISTING SYSTEMS
Tuesday, November 30, PMI Revision 00 50
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 THANK YOU

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