coal-fired power generation

A WORLD LEADER IN POWER GENERATION AUTOMATION SOLUTIONS

Delivering automation solutions for more than 100 years

Invensys has delivered power generation automation solutions to the fossil market segment for over 100 years. Highly reliable, world class automation systems combined with intelligent power generation specific application solutions define our success in this marketplace. In particular, our commitment to coal-fired power generation is defined by our continuously innovative solutions for some of the world’s largest award winning plants.

Comprehensive solutions for coal-fired power generation

The electrical power generation industry now demands much more of its control and instrumentation suppliers — and Invensys is delivering.

Our application successes include retrofit and grassroot plants, drum, once-through (sub-critical, supercritical and ultracritical) and fluidized bed boilers, large reheat steam turbines, burner management, air quality control and monitoring, plant-wide real-time data acquisition, network information integration, measurement integration of intelligent field devices, operator training simulators, enterprise operations management... and more.

COAL-FIRED POWER GENERATION

RECEIVE BENEFITS THAT IMPROVE YOUR OPERATION AND YOUR COMPETITIVENESS

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EXPERIENCED AND DEDICATED

Benefits that improve your operation

Our well-staffed, experienced, dedicated power engineering organization ensures customer satisfaction for power projects worldwide. Get benefits that improve your operation — and your competitiveness.

• Faster load-following capability through adaptive, nonlinear, multivariable coordinated control

• Extended on-line availability resulting from our inherent hardware reliability, software quality, system security, improved turndown performance, intelligent plant interlock control, and design basis of proven control strategies

• Improved heat rate with Advanced Process Control for optimizing boiler combustion using adaptive tuning, constraint control, multivariable, neural networks, linear optimizer, and other techniques

• Increased unit operational range via more accurate multi-output loop compensation strategies

• More stable operation resulting from an integrated plant-wide control system, consistent and intuitive displays, tighter setpoint controls, and anticipatory adaptive feedforward control

• Faster, more reliable startups, with on-screen operator device permissive startup guides and automatic equipment startup

• Faster on-line commissioning enabled by our world class simulation technology that helps to validate control implementation, expedites factory and site checkout, and reduces tuning time

• Higher availability and reliability resulting from smoother operation by well-trained operators

IN-DEPTH COAL-FIRED FOSSIL POWER GENERATION EXPERIENCE

Enabling 20% of worldwide generation capacity

With over 100 years of experience and 1700 power generation units under control, enabling 20% of the worldwide generation capacity, it’s no wonder that Invensys is viewed as a premier supplier of innovative coal-fired power plant solutions. Our coal-fired power generation experience extends to boiler designs of virtually all manufacturers, burning coal of all classifications, ultimate and proximate analyses and heating values. Our breadth of experience covers all aspects of a generation facility.

Boiler Control• Drum/Once-Through/Fluidized Bed

• AGC Control

• Coordinated Control with:– Automatic mode selection (boiler follow, turbine follow, full coordinated/megawatt control)– Boiler and turbine master demand development– Load runback– Load rundown/Load block

• Combustion– Cross limited air/fuel control– Primary and secondary air control– Programmed O2 trim– Programmed boiler demand with rate of demand change biasing– Total fuel control to maintain total fuel to the boiler equal to the firing demand as mills are added or

removed from service– Mill feeder speed control– Mill air flow and temperature control

• Single and three element mode drum level control with load-based automatic mode selection

• Furnace pressure with feedforward characterized load biasing

• Steam temperature using both spray and burner tilt, as applicable

Automatic Sootblowing• Provides automatic sequencing of the blowers with the flexibility to allow on-line modifications to the

automatic sequence by selection of groups and/or individual blowers

• Automatic Sootblower operation provides the following operation modes for group start of each configured group:– Manual (Single Pass): Operator initiates Group start. Sequence stops at the end of the Group– Time of Day (Single Pass): Group sequence automatically starts at a selectable time and stops at the end of

the group– Time After Last Start: Group Sequence automatically restarts the group after the selected time delay from

the last start command– Continuous: Operator starts Group sequence; group restarts after selected operator adjustable time delay

from end of the group– Remote Auto: Supervisory program initiates group start, and sets /adjusts time delay after completion for

the next group run– Hold/Run: This mode permits halting the group and restarting where it left off

Burner Management• Boiler Purge

• Master Fuel Trip (MFT) condition including first out

• Fuel Tripping including first out

• Safety Interlocking

• Flame Detection

• Grouped initiation of ignition and shutdown

• Supervise and control mill and burner startup/shutdown sequences

• Alarm abnormal conditions

• Optional boiler-front equipment

Air Quality Control• Mechanical precipitator

• Electrostatic precipitator

• Baghouse

• Wet/dry scrubber

• Selective Catalytic Reduction (SCR) and Selective Non-Catalytic Reduction (SNCR)

Turbine Control• Speed and Frequency governor

• Steam admission mode selection

• Master trip and backup overspeed protection

• On-line valve test

• Optional:– Auto-synchronization– Automatic startup– Digital overspeed trip system– Mechanical upgrade

• Valve actuators• Hydraulic skid system• Quad hydraulic trip block

Balance of Plant Control• Condensate

• Condenser hotwell

• Feedwater heaters

• Steam coil air heater

• Make-up water

• Turbine lube oil temp

• Generator H2 temperature

• Switch logic

• Switchyard

• And more


Optimization• Emissions reduction

• Heat rate improvement

• Tighter steam temperature control

• Improved mill performance (reduced LOI)

• Optimized Sootblowing

• Advanced embedded technology

• Multivariable Control– Constraint Management– Future Predictions

• Neural Networks

• Linear Optimizer

• Fuzzy Logic

• Non-Linear Soft Sensor Inferentials

Data Acquisition• Historian

• Periodic/Demand Logs

• Real-time and historical trends, XY plots

• System wide Sequence of Events to 1 msec resolution using GPS time synchronization technology

• Post Event Review with enhanced Transient Data Recording/Transient Data Analysis using GPS time synchronization technology. Analog and digital values collected and time stamped to 10 msec and 1 msec, respectively. Associated plotting, trending and reporting tools help analyze and resolve plant events

• Equipment Run Time

• Tag Out

• Group Measurement Display

• Performance Monitoring

• Controllable Losses

• Advanced Alarm Management

• Generator Monitoring

• And more

Operator Training• Generic Drum Off-The-Shelf Operator Training

System

• Full operator training simulators and training programs covering all boiler types including Circulating Fluidized Bed (CFB) and Integrated Gasification Combined Cycle (IGCC)

• Operator training simulators for environmental retrofits including Flue Gas Desulfurization (FGD) systems

• Control Emulations of Invensys and non-Invensys controllers for controls checkout and operator training

• EYESIM™ 3D virtual reality training platform for integrated control room and field operator training

Controls Checkout and Operator Familiarization• DYNSIM® Checkout model library for controls

checkout

• Medium Fidelity simulation for operator familiarization

• Easy-to-build, robust models, forgiving of missing information

• Transmitters with simple calibration

A FOUNDATION OF FIELD-TESTED, TIME-PROVENCOAL-FIRED POWER PLANT CONTROL STRATEGIES

Capitalizing on and reinvesting prior experience is part of our continuous improvement program. A core success strategy of this program is our ability to leverage experience on other coal-fired power generation projects. Our Global Delivery projects organization routinely captures the lessons of prior projects to reuse within our extensive Knowledge Management system. This is part of our process of continual fine-tuning that has made us one of the most reliable project services providers in the power generation industry. Consistent with this approach, we have developed a set of power generation engineering templates that capture our experience. The Engineering Excellence Template Power Library is an integrated set of libraries for field devices, Logic and Control for use on Foxboro I/A Series systems. It provides out-of-the-box field device monitoring and control:

• Power Primitive Block TemplatesSAMA type symbols used by I/A Series graphical control configurator (InFusion Engineering Environment – IEE) for the development of power generation control strategies.

• Custom Engineering FunctionsPredefined (SAMA like) blocks and strategies with custom appearance objects for:– Motor run time– Timers– Dual and triple transmitter selection

• Block and Macro TemplatesPreconfigured motor, breaker, valve and analog control

• Boiler Control Strategy TemplatesPreconfigured control strategies– Automatic Gain Changing (MOCS)– Performance Plus™ Coordinated Controls– Total Fuel Control for Coal-fired Boilers– Aux Boiler with Automatic Ratio Control Between Oil & Gas Firing– CE/B&W Coal-fired Mills (2 Dampers)– B&W Coal-fired Mills (3 Dampers)– Secondary Air Flow Control– Forced Draft 2 Speed Fans– Forced Draft Axial Fans– Typical Forced Draft Damper Logic with Clean

Air Path Input– Typical Furnace Draft Control– Induced Draft 2 Speed Fans– Induced Draft Axial Fans– Typical Induced Draft Damper Logic with Clean

Air Path Input


Datasheet describing all control strategies

Example of control strategy using SAMA notation

– Primary Air Flow– Primary Air 2 Speed Fans– Primary Air Axial Fans– Typical Primary Air Damper Logic– Oxygen Control for a Single Fuel– Measurements for Total Air– Auxiliary Air Dampers– Fuel/Air Damper– Separated Over-Fire Air Dampers (SOFA)– NOx Dampers– Three-Element Drum Level Control (Constant

Speed Pumps or Valves)– Pump Recirculation Flow Control– Variable Speed Feed Pumps, 2 Pump, and

Pump vs. Valve Feedwater Controls– Final Superheat Temperature Control– Final Reheat Temperature Control– Reheat Temperature Control RH & SH Pass Dampers– Typical Lead/Lag Pump Control– Automatic Oil & Coal Firing Ratio Control– Pegging Steam to Deaerator– Hotwell Level Control– Three-Element Deaerator Level Control– And more

• FoxDraw GraphicsStandardized Graphics Library including symbols and overlays.

• DocumentationDetailed documentation of all blocks, strategies and graphics including User Guides and Data Sheets.

• TestingAll templates have been pre-tested and independently verified.

• Key Benefits of Invensys Engineering Excellence Templates– Consistent control implementation across the plant for easier

maintenance– Reduced project schedule for earlier product production– Lower risk project execution– Reduced engineering– Improved quality

Standardized display symbols and overlays

Example of control strategy


PROJECT EXECUTION APPROACH

Focused on meeting overall objectives

Our project delivery strategy is focused on meeting the overall objectives of the project while minimizing execution risk and ensuring predictability and control of costs, on-time delivery, optimum choice of the most robust technology and the most effective post-commissioning support and service.

Our approach• Capitalize on and reinvest prior experience - A key success factor is our ability to leverage prior experience

on projects of similar size and scope from around the globe.

• Integrated Core Execution Team - As a single supplier of all control and safety systems, we are able to provide a highly experienced and completely integrated core execution team in either single or multiple locations under common leadership.

• Ensure compliance and consistency - Core execution teams provide design guidance and consistency across all elements and phases of the project from pre-award to handover.

• Knowledge transfer and local support - Resources from the local Invensys operation interface with the wider Invensys community to facilitate knowledge transfer and long term site support.

• Remove control and safety systems from the critical path - Capture best practice and implementation knowledge in rules for use in automated engineering tools.

• Reduced system testing time - Inclusion of fully integrated plant simulation tools provides a unique opportunity to both reduce testing time and verify overall process and control design. Through such rigorous testing, the duration required for commissioning and start up is significantly reduced. In addition, any critical process or design flaws can be uncovered early in the project lifecycle before the plant is live.

Strategy for engineering and testing

Invensys has developed a unique suite of automated design, engineering and configuration tools and practices that automate previously manual processes:

• Generate the control module layer

• Generate the safety device logic

• Generate a plant simulation model, as required

• Generate dynamic symbols for use in the human-machine interface (HMI)

As part of our engineering execution strategy, we can apply our suite of standard control, safety logic and HMI templates to work directly with many industry recognized database tools.


BEYOND APPLICATIONS…THE NEED TO DELIVER INTEGRATED SOLUTIONS

InFusion software provides the world’s first Enterprise Control System

Application experience and expertise with grassroot, retrofit and expansion coal-fired power automation projects is fundamental to success in the power generation market. The Invensys way, however, goes beyond application delivery to encompass a total integrated solution.

Invensys’ I/A Series® Distributed Control System (DCS) running Invensys InFusion software provides the world’s first Enterprise Control System (ECS). The InFusion ECS encompasses all of the products offered by Invensys. InFusion gives Invensys’ customers best of breed capabilities in an open, flexible system with capabilities beyond other vendors.

We offer more than any single product or discipline – consulting, services, and a proven portfolio of specialized offerings from our well-known legacy brands of Foxboro®, Triconex®, SimSci-Esscor™, Eurotherm®, Avantis® and Wonderware®. With these brands, we are able to deliver the most consistent integrated solution from a single automation supplier.

Compliance with industry standards and guidelines (such as NFPA, TUV, TSSA, KKS, VGB, etc.), and seamless integra-tion of redundant, fault-tolerant and triple modular redundant (TMR) technologies is routine with Invensys systems.

Power companies around the world are either being mandated to implement or are voluntarily implementing additional security procedures to heighten their protection of critical infrastructure. Invensys has taken a proactive approach to this need by working closely with regulating agencies such as NERC, CFATS, ISA SP99, NIST SP800, etc. to comply with these evolving regulations. In fact, Wurldtech certification has been achieved for the Foxboro I/A Series FCP270 and ZCP270 Fault-Tolerant Controllers and Triconex Trident and Tricon Controllers. Foxboro I/A Series ECS with Security Enhancements meets the latest NERC CIP (Critical Infrastructure Protection) standards. Choosing to install the security enhancements allows users to take advantage of Microsoft Active Directory® network services on a domain-based network topology.

Security features• Hardened workstation BIOS settings

• Hardened workstation O/S images

• Invensys customized Active Directory Group Policies

• Unique user or machine login/passwords

• Virus scan, spyware malware detection

• Station Assessment Tool (SAT) for workstation audits/assessments

Rules-based tools support the engineering process

Optional McAfee ePO (ePolicy Orchestrator) security tools• Host intrusion prevention

• Powerful and configurable firewall

• Application blocking

• Hardware port (device) control

• Rogue machine detection

High fidelity, full stimulation simulator for training and control development and checkout is a core delivery solution of Invensys. It includes specialized FSIM Plus® and TRISIM Plus® control software which is a perfect representation of Foxboro I/A Series and Triconex controllers, eliminating the need for controller hardware and a system translator/emulator. IM Plus and TRISIM Plus include the ability to freeze, slow, or speed up simulation time, save and load snapshots of the system state at different points in time, and provide full I/O stimulation. Medium and low fidelity simulation solutions are also available for control testing and operator familiarization.

Third-party system integration is easily accommodated with the Foxboro I/A Series Field Device System Integrator (FDSI) IO modules for simplex and redundant, serial and Ethernet connections with the most popular protocols, including: Modbus slave, OPC DA 2.x, Triconex TSSA, DNP3, and Allen-Bradley ControlLogix, CSP and DHplus. In addition, Invensys offers a number of custom gateways including GE GSM for GE gas and steam turbine interfaces.

Invensys InFusion™ Enterprise Control System offers the most robust, fully functional interface to smart field devices such as HART, Profibus, and Foundation Fieldbus including Control in the Field (CIF). Our fieldbus approach is based on Field Device Tool (FDT) Open System standards to simplify configuration, commissioning and maintenance (including advanced diagnostics). The Invensys fieldbus approach accommodates qualified field devices from all vendors, with no “hidden” capabilities.

Integrated Fossil Power Solutions

Invensys Operations Management5601 Granite Parkway III, Suite 1000Plano, Texas 75024 U.S.A.1.469.365.6400iom.invensys.com

Invensys, the Invensys logo, ArchestrA, Avantis, Eurotherm, Foxboro, IMServ, InFusion, SimSci-Esscor, Skelta, Triconex, and Wonderware are trademarks of Invensys plc, its subsidiaries or affiliates. All other brands and product names may be the trademarks or service marks of their representative owners.

© 2011 Invensys Systems, Inc. All rights reserved. No part of the material protected by this copyright may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording, broadcasting, or by any information storage and retrieval system, without permission in writing from Invensys Systems, Inc.

PN I-PW-0109 Rev. 04/15

http://iom.invensys.com

coal-fired power generation

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