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1/16/2012

CONTROLS & INSTRUMENTATION FOR 660 MW SUPERCRITICAL UNIT @ Tiroda. 1/16/2012. 1. Road Map. Instrumentation at Tiroda Power Plant Feedwater Control Automation technologies IT Integration. INSTRUMENTATION @ TIRODA. Application of Technology. Boiler Tube Leakage Detection System :.

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1/16/2012

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  1. CONTROLS & INSTRUMENTATION FOR 660 MWSUPERCRITICAL UNIT @ Tiroda 1/16/2012 1

  2. Road Map • Instrumentation at Tiroda Power Plant • Feedwater Control • Automation technologies • IT Integration

  3. INSTRUMENTATION @ TIRODA

  4. Application of Technology

  5. 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

  6. Furnace TV : • 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.

  7. FEEDWATER CONTROL The key differentiator between subcritical and supercritical…

  8. Natural circulation boiler Once-through boiler Steam flow • m T Level Eva Eco Feedwater control FW Feed Water Control Deg. of Super Heat T Ts-Tsat P T WW Feedwater control Eco BCP FW 008 406p

  9. Feed Water Control SUBCRITICAL (DRUM) SUPERCRITICAL (ONCE-THRU) • Low Load • Single Element Level Control • Higher Load • Three Element Level Control • 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)

  10. Feed Water Control To Superheater To Superheater Separator Tank – A Separator Tank - B From Water Wall O/L From Water Wall O/L Levelling Vessel To Condensor To SH Spray To SH Spray To BCP

  11. 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

  12. Levelling Vessel Level Control by- Feed Water Control From Separator-A From Separator-B Levelling Vessel Drain CVs to Condensor CV to 1st stage DSH water BCP Drain CVs to OAC/Waste BCP Discharge CV to Eco. I/L

  13. 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 control Feed Water Control

  14. Separator O/L Temperature Control Separator O/L Temperature - Ts Separator O/L Press PV PID Deg of SH + Tsat SP F1(x) X Y 0 120 12 340 19.5 377 . . . . Feedwater Flow PV Desired FW Flow PID Temp Correction block SP F2(x) Fuel Flow X Y 0 0 103 663 236 1638 320 2285 . . . . TDBFP Master Command

  15. AUTOMATION TECHNOLOGIES

  16. AUTOMATION TECHNOLOGIES • Conventional • 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

  17. MESH NETWORK

  18. DCS DETAILS Foxboro 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

  19. BOILER MFT • TRICONEX • TRIPLE MODULAR REDUNDANT SYSTEM • HARD WIRED BACKUP RELAY PANEL • TUV SIL3 CERTIFIED • PROGRAMMING SOFTWARE : (Tristation 1131 Standard Programming) Class (IEC61131-3 )

  20. 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.

  21. IT INTEGRATION

  22. 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

  23. Thank You…!!

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