AUTOMATION SYSTEM

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 INSTRUMENTATION

Convert to Read by
Physical Quantity Measure/Detect
signal instrument
Sensor
Advantage of instrumentation?
Automation & Manual Control? In a process plant Exam.
Physical Quantity?
Automation are: Control, Protection &
Monitoring/measurement.
Instrumentation: Application of automation
Control system are? To achieve a desired output by a set of activities.
What is regulator.

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 INSTRUMENTATION ADVANTAGE

•Increase Efficiency and Accuracy

•Save time

Physical Quantity:
Temperature
Pressure
Level
Light
Flow
Viscosity

Electrical Quantity
I, V, R…………..mA,mV,
Without effective communication…. Automation fail

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 WOIS MONITOR Typical Automation for Wartsila Power Plant

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 WOIS MONITOR Engine Automation System

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 WOIS MONITOR Automation Overview

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 PLC (Programmable Logic Controller)

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 Analog and Digital

What is analog and Digital: Time dound

0 to 1, High-Low, True-False, Continuous
Communication……. Optical, satellite, EM, Radio
Analog Signal
Digital Signal
Analog Sensor
Digital Sensor
Temp sensor output: RTD type-resistance, Thermocouple type-mV which Called?
Pressure & Temperature transmitter: 4 to 20mA
Switch output: ????????

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 Signal

Analog Signal: 0 to 20mA, 4 to 20mA, 0 to 10V

Digital Signal: ON/OFF, (0 or 24V or 12V DC)
Analog INPUT
Analog OUTPUT
Digital INPUT
Digital OUTPUT

Transmitter & Receiver which one?

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 BLOCK DIAGRAM

Monitoring/me
INPUT CPU-Logic part Output
asuring device

Actuator/valve
Sensor

Transmitter-------------- sensor part

Receiver ---------------------- Actuator part
AI/DI
AO/DO
Actuator, human body control, regulator IN/OUT
Use block: temp sensor, pressure transmitter, IP converter,regulator,MC, S/W.
controller,Push-button,ammeter, voltmeter, temperature meter,solenoid

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 LOGIC

Digital:::: see book details

Logical gate: Knowledge of digital?
Logical Block: Define a process output…….
Ladder logic & Functional block are…………….?
Logical gate output & Boolean Algebra
Decimal to binary converter
Hardwire: PLC,cable,programmable device.
Softwire:Includes the set of instruction or programs that direct hardwire.
Memory size: 1K=……….. Bits
Memory device: ROM,RAM, EPROM etc
Communication:
Eathernet,modbus,Profibus, RS-232,PC/PPI(special type cable for PLC
programming), fiber optic

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 Motor On logic

1. Level OK/NOT
2. Delivery valve open/close
3. Magnetic contactor condition
Logic application
AND, OR, NOR gate output
Adder, subtractor, multiplex, demultiplex, timer
Logical block: Ladder logic, functional block is programming
language

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 Programmable logic controller (PLC)

A programmable logic controller (PLC) or

programmable controller is a digital
computer used for automation of
electromechanical processes, such as
control of machinery on factory assembly
lines, amusement rides, or light fixtures.
PLCs are used in many industries and
machines.

PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is
designed for multiple inputs and output arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and impact. Programs to control
machine operation are typically stored in battery-backed-up or non-volatile memory. A PLC is
an example of a hard real time system since output results must be produced in response to
input conditions within a bounded time, otherwise unintended operation will result.

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 Programmable logic controller (PLC)

Simatic S7-300 CPU

• Two different types CPU 3xx and CPU 3xx-2DP

• 31x-2DP with integrated Profibus DP interface
• CPU type 315-2DP used for Wärtsilä standard
projects
• Hardware
• Communication
• Software
CPU Indication LED: RUN, Stop,5V,BF
PLC trouble shoot: RUN LED-Green, power supply
on/off.Stop LED-Flashing need memory reset.

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 Programmable logic controller (PLC)

Simatic S7-300 power supply

• Power supply units for Siemens:

– PS305 2A
– PS307 5A
– PS307 10A
• Siemens PLC can be supplied directly
from 24 V DC-panel (normally used in in Wärtsilä projects)

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 Programmable logic controller (PLC)

Simatic remote I/O module ET 200M

• Remote I/O rack is Profibus DP slave

• Used for auxiliary units and panels
• Same measurement modules as in main rack

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 Programmable logic controller (PLC)
Back Plane

• DIN rail, made from Aluminium

• Dummy plate for connecting CPU and
measurement cards to panel wall

• Communication between cards

is made with Bus connectors

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 Programmable logic controller (PLC) Analog Input module

• Same module for different measurement types: mA, V, R, PT-

100 and TC (N, E, J, K)
• PT-100 measurement use 2 channels/measurement
• 8-channel cards for Wärtsilä projects
• Red LEDs for group faults/errors
• Maximum cable length 200m
• Mechanical coding element for the wiring connector to
avoid connecting to wrong type of card

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 Programmable logic controller (PLC) Analog Output module

• Same module for different signal types ±10V; 0 ... 10V;

±20mA ; 0 ... 20mA; 4 ... 20mA
• 4-channel cards for Wärtsilä projects
• Red LEDs for group faults/errors
• Maximum cable length 200m
• Mechanical coding element for the wiring connector to
avoid connecting to wrong type of card

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 Programmable logic controller (PLC) Digital Input modules

• Input types: 24 VDC, 120 VAC and 120/230 VAC

• Inputs are optically isolated
• Green LEDs to indicate signal statuses at the inputs
• Maximum cable length:
– Unshielded 600m
– Shielded 1000m
• Mechanical coding element for the wiring connector to avoid
connecting to wrong type of card

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 Programmable logic controller (PLC) Digital Output modules

• Output types: 24 VDC, 120 VAC and 120/230 VAC

• Green LEDs to indicate signal statuses at the outputs
• Mechanical coding element for the wiring connector to
avoid connecting to wrong type of card

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 Programmable logic controller (PLC)

ETHERNET

Communication modules
• CP 343-1 TCP
– Ethernet communication
• CP 342-5
– Profibus DP communication
• CP 343-5
– Profibus FMS communication

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 Analogue Input Connection Diagram

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 Analogue Output Connection Diagram

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 Digital Input Connection Diagram

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 Digital Output Connection Diagram

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 Operating Modes

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 PID Area
A proportional–integral–derivative controller (PID controller) is a generic control loop feedback mechanism (controller)
widely used in industrial control systems – a PID is the most commonly used feedback controller. A PID controller calculates
an "error" value as the difference between a measured process variable and a desired setpoint. The controller attempts to
minimize the error by adjusting the process control inputs.

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 PID (error value)

Set Value(u) Process value (y) Err value(e)

5 3 2
5 4 1
5 5 0 Execution
stop

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 Operating Mode

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 Power Conversion
Mechanical to electrical power
Where 2 and π are constants by nature and the n
(speed) we like to keep as constant as possible.
The goal off course is the stable grid frequency
(50 or 60 Hz) which leads to the stable engine speed
(rpm >>1/s). PN=120f
P = ωT
What is mechanical power
in the rotating engines?
ω=2πn
ω = angular speed, rad/s
P= ωT=2 π n*T
(T=F*l=PA*l)

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 Pressure, Force, Torque
That formula from previous page leaves us only one adjustable
parameter to control the power of the rotating machine.
T = torque
Torque is the power with which the piston(s)
turns the crankshaft and so rotates the engine.
How to adjust the
mechanical power ?

Pressure, force and torque

F = pA , force is pressure multiplied by area
T = Fl , torque is force multiplied
by the length of the arm (stroke/2)
Area of the piston and the length of the
stroke is up to the design, pressure is the
only thing which we can adjust while running
the engine.
Torque can be adjusted by adjusting the pressure over the
piston (BMEP) and that’s adjusted by the amount of fuel and
the timing of combustion.
(Main gas valve duration/ignition or governor and actuator)

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 Operation devices
1. WOIS: Its function?
2. Operation Desk: CFC, CFA, CRP panel
3. Main Control unit, Synchronizing control unit
4. Name of module on CFC panel:…………………….
5. Engine start/stop sequence.
6. Synchronize condition. Button on synchronoscope.

WOIS function:1.To view and interact with the performance of the entire plant through graphical
presentation of production & propulsion.
2. Provide an integrated view
3. Enable fault diagnostic. Trend analysis.

Operation: Start, loading, stop

Interface??

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 Operating Mode

Type of Installation

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 Operating Mode
What to control at Power Plant ?

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 Operating Mode
Speed Droop Control

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 Operating Mode
Speed Droop Control

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 Operating Mode
Speed Droop Control

• Droop control is a universal load sharing mode and it can be used both for parallel operation in
an island system and for parallel operation with the utility.

Speed droop control in island mode operation

In island/speed droop controlled system, changes in active load will be shared (proportionally)
equally between parallel units.
4% droop means: → 0,04 * 50Hz = 2Hz → ±1Hz frequency deviation at 50Hz system.
Speed droop control in parallel with grid operation
• When operating parallel with grid, the grid determines the system frequency. A droop
controlled generating set can be operated parallel with the grid in base load principle.

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 Operating Mode
True kW Control

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 Operating Mode
True kW Control

• Base loading means that a unit is running at a constant load and its output will not
be affected by system changes.
• Base loading is used in parallel operation with the grid and it can be accomplished
by kW control.
• Only for base load against grid

• Eliminates grid fluctuations from the engine output

• Full output can be obtained
• Minimized thermal stress
• Improved stability
• Ramp control for kW reference (mA set point)

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 Operating Mode
Speed Droop/ kW Control

» when in kW control the speed reference is

following, i.e. bumpless change over to droop
control
» parallel with utility always use kW control

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 Operating Mode
Island operation mode

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 Operating Mode
Isochronous speed control

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 Operating Mode
DG-set control at base
load system

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 Operating Mode
DG-set control at base
load system

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 Operating Mode
Generator control methods

Island system Utility system

• On ships and power plants which are isolated • Base load stations
from other systems; mine sites and small islands • System voltage is determined by utility,
• System voltage is determined by generators generators usually cannot affect the
and their voltage control system voltage
• Generator reactive load varies depending on • Generator reactive load is proportional
system loading to engine load
• Goal: stable system voltage • Goal: stable power factors on generators
• Parameter: voltage • Parameter: power factor

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