advanced control system

7/28/2019 Advanced Control System

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ADANI POWER MAHARASHTRA LTD, TIRORAADANI POWER MAHARASHTRA LTD, TIRORA

1/16/2012 1

ADVANCED CONTROL SYSTEM

660 MWSUPERCRITICAL UNIT @ Tiroda

Mr. N. D. Prasad

Mr. Shriram Pimplikar

Mr. Rakesh Dash


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ADANI POWER MAHARASHTRA LTD, TIRORA

Road Map

Advancements in Power Plant process measurementtechnology

Field Instrumentation ( pressure, level etc )

Latest Trends in C&I

Feedwater Control

Automation technologies

IT Integration


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Advancements in ProcessMeasurement technology

Field Instrumentation ..


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TRANSMITTERS

Conventional Sensors

Strain Gauge

Potentiometer

Capacitance Type

Latest Sensors

Capsule

Piezoelectric

Magnetic type

Optical type

Silicon Resonant


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PROCESS MEASUREMENT

Conventional Protocols

One Transmitter for one type of

measurement

4-20 Ma

Local Calibration

No health monitoring

Latest Protocols

Multivariable Transmitter

HART

Fieldbus

Remote Calibration & Health

Monitoring

Multivariable transmitters

( measures, temp, press etc. )

HART Settings


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TEMPERATURE MEASUREMENT

Conventional

RTD

Thermocouple

Thermistor

Latest

RTD/Thermcouple

Wireless IR

Thermal Imaging

Head Mounted integrated

sensor/transmitter

Thermal Imaging


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LEVEL MEASUREMENT

Conventional

Capacitance Type

Inductance Type

Latest

Radar

Ultrasonic

3D Level Scanner

Radar Type

3D Type


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FLOW MEASUREMENT

Conventional

DP Type using Orifice, Venturi etc

Mechanical ( turbine ) type

Latest

Magnetic Type

Ultrasonic

Coriolis Type for Mass Flow

Positive Displacement type

Magnetic Type

DP Type


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CONTROL VALVE POSITIONER

Conventional

Separate I/P converter

Separate mechanical type

positioner with limit switches &

feedback

Mechanical zero and span setting

Latest

SMART Positioners

integrated with I/P converter

Configurable limit switches (

NO/NC ) and position feedback

Auto Calibration for zero and

span, Fail Safe condition

Configurable for valve

characteristic

SMART POSITIONERSSADC


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Boiler Tube Leakage System :

-Noise signal of the boiler tube leak is capturedby the Enhanced Sensors.

-Next a variety of noise disturbance is eliminated occurring during the boileroperation.

- Finally the boiler tube leak is predicted through an analysis of acoustic frequency

spectrum got by Quick Fourier Transformation on computer.

- Moreover, the location and intensity of leak can be identified.

In this way, the operator can take some measures immediately to prevent the

accident from worsening, reduce the time and cost spent on the repair


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Advanced Type of Oil Gun/Ignitor System

Basic Components :

- Oil Gun Assy. With Cylinder and Limit Switch

- Solenoid Valve Box

- Power pack with 20J HESI

- High Energy Cable

Swirler

Apron Flange

Junction

Box

Air

Supply

Cylinder

Limit

Switch Oil Gun

Body


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Technology Application

High Precision Digital

Pressure Indicator

C&I Lab Test Bench

Accoustic sensor Boiler Tube Leakage

Detection System

IR sensors

SMART technology

Flame Scanner & CHP

Conveyor fire detection

POSITIONERS

Piezoelectric sensors Compressor system

3D Imaging level meas CHP/AHP bunker level

CCTV

HART

MODBUS / OPC

Boiler Flame & other critical

areas

Transmitters

Third Party / IT Interface

Technology vs. Application


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008 406p

Natural circulation boiler Once-through boiler

Feedwatercontrol

Level

Feedwater

Steam flowm

EvaEco

T

T

Enthalpy

Feedwatercontrol

Feedwater

TP

Eco

Eva

CONTROLS

Sub Critical vs. Super Critical

Feedwater Control


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Feedwater ControlSUBCRITICAL (DRUM)

Three Element Drum LevelControl

SUPERCRITICAL (ONCE-THRU)

Feedwater to Coal Flow ratio = 7 to 9

BCP in recirculation mode for BMCR load < 30 %

BCP stopped for BMCR load > 40%

Flow control based on degree of

superheat (22-35 deg)


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AUTOMATION TECHNOLOGIES

Conventional

PLC

DCS with local IO & limited

processing capabilities

Speed limited to backplane

communication

Server Based architecture

Statement based Logicconfiguration

Latest

Advanced PLCs

DCS with remote IO

Capability **

TCP/IP communication upto

1Gbps

Mesh Topology for reliable

network

Graphical Drag and Drop

facility for logic configuration

** Used for Metal Temperature Thermcouples,

CWPH, CT, FOPH, Compressor system


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DCS HARDWARE ARCHITECTURE

Offsite PLC Interface

through Modbus,OPC etc


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ADANI POWER MAHARASHTRA LTD, TIRORAMESH NETWORK


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DCS DETAILS

Foxboro Invensys IA System with IACC

Controller: FCP270 with Direct 100 Mbps Ethernet fiber connectionand fault tolerant configuration

IO Modules : Supports all types of measurement inputs with opticalisolation integrated in applicable cases

Termination Assemblies : Field signal connection modules, whichprovide optional signal conditioning and circuit protection

Logic Configuration Software : Uses IA configuration componentwhich is graphical based user interface


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DCS Configuration

Number of I/Os per unit : 9000 +

Number of I/O Modules : 1400+

Number of I/O cabinets : 66


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BOILER MFT

TRICONEX TRIPLE MODULAR REDUNDANT (TMR) SYSTEM USED FORBOILER MASTER FUEL TRIP INITIATION

TUV SIL3 CERTIFIED

PROGRAMMING SOFTWARE :

Tristation 1131 Standard ProgrammingClass ( IEC61131-3 )

ADANI POWER MAHARASHTRA LTD TIRORA


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BTG/Offsite System PLC Hardware Software

ETS GE Fanuc 90-70 Invensys

Intake Water AllenBradley make

Logix L32E

RX Logic 5000

FOPH GE make PAC-Rx3i

SCADA - Cimplicity

Engineering S/W

Machine Addition 6.0

CHP GE make PAC-Rx3i

DM Plant GE make PAC-Rx3i

Ash Handling Plant GE make PAC-Rx3i

Mill Reject system GE make PAC-Rx3i

Aux. Boiler ABB make - PM590 Code-Sys


Various PLC systems used for BTG / Offsite Systems


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Total Plant Automation

Coordinated Master Control (CMC) /

Coordindated Control System (CCS)

Free Governor Mode of Operation (FGMO)


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IT INTEGRATION

Management Information System ( MIS )interface with external world and officeautomation system

Remote access/troubleshooting of vibrationmonitoring system

Integration with SAP

SMS alerts on Equipment Trip / Alarms



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Benefits of Latest Technology:-

1.Availability of online data-a) For Operator

b) For Management at Tiroda

c) Corporate Office

d) Other OEMs for analysis purpose of their equipments

2. Resulting in better analysis of problems by experts and quicker

solutions.

3. Improved efficiency due to high speed processing of various I/Os.

4. Reduction in outages due to highly automated and reliable control

system, leading to increased PLF and availability.

5. Online performance calculation of 660MW Unit.

6. Latest technology enables predictive maintenance.

7. Reduction in Man/Megawatt Ratio.



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Thank You!!

advanced control system

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