1/16/2012*

CONTROLS & INSTRUMENTATION

FOR

660 MW SUPERCRITICAL UNIT @ Tiroda

Road Map

Instrumentation at Tiroda Power Plant

Feedwater Control

Automation technologies

IT Integration

INSTRUMENTATION @ TIRODA

Application of Technology

TechnologyApplicationSMART / HARTTransmitter / PositionersIR sensorsFlame Scanner & CHP Conveyor fire detectionPiezoelectric sensorsCompressor system3D Imaging level measBunker level MeasCCTVFlame MonitoringAcoustics SensorBTLDSWireless TransmitterRemote flow measMODBUS/OPCThird Party Interface

Boiler Tube Leakage Detection System :Available Schemes : Accoustic Conductivity Mass Balance

Accoustic Detection @ Tiroda- Enhanced Sensors for Noise signal measurement and elimination

Boiler tube leak prediction through an analysis of acoustic frequency spectrum by Quick Fourier Transformation

Location and intensity of leak identification

Operator to take measures immediately to prevent the accident from worsening thereby reduce the time and cost spent on the repair

High temperature resistant optical system consists of quartz and corundum, which can be normally operated in a certain amount of purging air.

Screen menu setting, remote control in central control room, for forward and retract movement of camera.

Horizontal mounting and large field angle probe

- System is equipped with automatic forward and backward protection device, which can automatically withdraw from furnace when no pressure in cooling air.Furnace TV :

FEEDWATER CONTROLThe key differentiator between subcritical and supercritical

008 406p

Ts-Tsat

TDeg. of Super HeatFeedwatercontrolFWTPFeed Water ControlWW

Eco

BCP

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SUBCRITICAL (DRUM)Low Load Single Element Level Control

Higher Load Three Element Level Control

SUPERCRITICAL (ONCE-THRU)Wet Mode BCP in recirculation mode for Load < 30 %

Levelling Vessel Level Control

Feedwater to Coal Flow ratio = (7 to 9) : 1

Dry Mode BCP stopped for Load > 40%

Feedwater to Coal Flow ratio = (7 to 9) : 1

Flow control based on degree of

superheat (21-35 deg)Feed Water Control

Feed Water Control

From Water Wall O/LFrom Water Wall O/LSeparator Tank ALevelling VesselTo SuperheaterTo SuperheaterTo BCPTo CondensorTo SH SprayTo SH SpraySeparator Tank - B

Main objective in Super Critical Boiler FW control system is a) To maintain Level of the Levelling Vessel at Wet Mode

b) To maintain Deg. Of Superheat at Separator Outlet

c) To maintain FW flow to Fuel Flow Ratio Feed Water Control

Levelling Vessel Level Control by-

Feed Water ControlBCP

CV to 1st stage DSH waterDrain CVs to CondensorFrom Separator-BBCP DischargeCV to Eco. I/LLevelling VesselFrom Separator-ADrain CVs to OAC/Waste

Degree of Superheat is maintained in the separator outlet in the range of 21 - 35 degC

Why Degree of Superheat ?> 35 deg C : May lead to overheating of water wall tubes.

< 21 deg C : May lead to flow of wet steam to SH coils.

Note : Bias for degree of superheat > 21 degC is in Operators controlFeed Water Control

Separator O/L Temperature ControlPIDSeparator O/L Temperature - TsSeparator O/L PressF1(x)PIDTDBFP MasterCommandFeedwater FlowFuel FlowF2(x)Temp Correctionblock

XY01201234019.5377....

XY0010366323616383202285....Deg of SH + TsatPVPVSPSPDesired FW Flow

AUTOMATION TECHNOLOGIES

AUTOMATION TECHNOLOGIESConventional

PLC

DCS with local IO & limited processing capabilities

Speed limited to backplane communication

Server Based architecture

Statement based Logic configuration

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 Thermocouples,CWPH, CT, FOPH, Compressor system

MESH NETWORK

DCS DETAILSFoxboro Invensys IA System with IACC

Controller : FCP270 with Direct 100 Mbps Ethernet fiber connection and fault tolerant configuration. Number of Controllers : 27 per Unit

IO Modules : Supports all types of measurement inputs with optical isolation integrated in applicable cases. Number of IO Modules : 1400+ per Unit

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

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

BOILER MFT TRICONEX

TRIPLE MODULAR REDUNDANT SYSTEM

HARD WIRED BACKUP RELAY PANEL

TUV SIL3 CERTIFIED

PROGRAMMING SOFTWARE :

(Tristation 1131 Standard Programming) Class (IEC61131-3 )

1. Availability of online data-a) For Operatorb) For Management at Tirodac) Corporate Office d) Other OEMs for analysis purpose of their equipments2. 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.Benefits of Latest Technology

IT INTEGRATION

IT INTEGRATION

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

Remote access/troubleshooting of vibration monitoring system

Integration with SAP

SMS alerts on Equipment Trip / Alarms

Thank You!!

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